Lean, green, and smart manufacturing: An ingenious framework for enhancing the sustainability of operations management on the shop floor in industry 4.0

Abstract

In the present competitive landscape industry, individuals have emphasized fulfilling the consumer needs in available resources and limited constraints. However, the industry individuals face several problems in achieving operational efficiency. These problems include ergonomics issues, environmental waste, work processes waste, inobservance on the shop floor, and workers’ apathy. The operations management teams use various approaches to improve operational excellence on the shop floor, including lean manufacturing, smart manufacturing, green manufacturing, and artificial neural network. These approaches are used to enhance productivity by eliminating problems in the operations management on the shop floor. The present research aims to develop a framework for improvement in operational excellence and sustainability in operations management on the shop floor in an industry 4.0 environment using lean, green, and smart manufacturing concepts. In the study, a strategic ergonomics assessment and environmental assessment have been used to assess working and operational performance on the shop floor. The adaptability of the developed framework has been investigated by implementing it in mining machinery manufacturing industry. The framework has been developed with insights gained from previous research, industry individuals, and brainstorming analysis on problems faced in operations management on the shop floor in industry 4.0 working environment. The novelty of the present study lies in the fact that no model has been developed for achieving operational excellence on the shop floor in industry 4.0 using the smart, lean green manufacturing concept. The developed framework significantly improved productivity by 85%, improved machinery utilization by 21%, reduced production time by 65%, reduced manufacturing defects by 96%, and production cost by 75%. The present research work strongly believe that the developed model would benefit industry individuals in enhancing sustainability in operational excellence on the shop floor in industry 4.0 environment by establishing a more competent and cleaner working environment with available resources.