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Green manufacturing is a method to minimize waste and pollution caused by manufacturing processes through the management of raw materials, energy use, production processes and health and safety issues.The implementation of Green Manufacturing can be more efficient if it is implemented simultaneously with lean manufacturing.Lean production techniques often create a culture of continuous improvement, employee empowerment, and waste minimization, which is very compatible with organizational characteristics encouraged under environmental management systems (EMS) and pollution prevention (P2).
As a result, the company’s chemical inventory was reduced by 70% with estimated saving of $5,000 per year.
The company also reduced its air conditioning needs, which cut electricity costs by $2,000/month (40%) and reduced its wasted ink by training employees to mix specialty colors from existing ink stocks.
Besam followed several recommendations from the energy management survey, including replacement of metal halide lighting with fluorescent fixtures with occupancy sensors, installation of high efficiency lamps and electronic ballasts with occupancy sensors, reduction of compressor air pressure, and repair of compressed air leaks. Department of the Interior Bureau of Land Management (BLM) successfully implemented an energy savings performance contract (ESPC) with Johnson Controls, Inc.
Total annual savings from these efforts was 233,555 k Wh/$25,776. (JCI) to implement energy efficiency improvements at remote BLM sites.
Kennecott Utah improved the energy efficiency of its refinery through installation of combined heat and power system in 2010.
The 6-megawatt system produces more than half of the refinery’s total electricity needs and waste heat from the CHP is recycled to produce process steam.
As a result, the company’s Oak Hill Fabrication plant in Austin, Texas reduced its annual energy consumption by 28 million k Wh of electricity and 26,000 million Btu of natural gas between 20, with more than million in annual savings.
Guardian Automotive’s Ligonier Plant implemented a waste reduction program to continuously search for ways to reuse and recycle materials.
The purchase of two chillers and implementation of a closed loop system to cool heated components resulted in an 85% reduction in water use.
An examination of the company’s inventory and purchasing records demonstrated over 80 different chemicals on-site.