In the past decade, there has been an increasing awareness in development of sustainable manufacturing systems as governments in many countries have been enforcing ever-stricter environmental policies and regulations in industry by promoting energy saving and low emissions manufacturing activities. Lean manufacturing can be helpful for achieving a sustainable manufacturing system as it can reduce production wastes and increase manufacturing efficiency. Nevertheless, this lean approach does not include a consideration in energy consumption and carbon dioxide (CO2) emissions when designing a lean manufacturing system. This paper presents a methodology which can be useful for measuring energy consumption and CO2 emissions for a typical manufacturing system design at an early stage. A case study was carried out for obtaining computational results using the developed methodology based on data collected from a real production line

Bennett, Nick

Nujoom, Reda

Wang, Qian

MATEC Web of Conferences

Reda Nujoom

Qian Wang

Nick Bennett

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An Integrated Method for Sustainable Manufacturing Systems Design

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An Integrated Method for Sustainable Manufacturing Systems Design 
Reda Nujoom,  Qian Wang and Nick Bennett 
School of Engineering, Faculty of Technology, University of Portsmouth, Portsmouth, UK 
Abstract. In the past decade, there has been an increasing awareness in development of sustainable manufacturing 
systems as governments in many countries have been enforcing ever-stricter environmental policies and regulations in 
industry by promoting energy saving and low emissions manufacturing activities. Lean manufacturing can be helpful 
for achieving a sustainable manufacturing system as it can reduce production wastes and increase manufacturing 
efficiency. Nevertheless, this lean approach does not include a consideration in energy consumption and carbon 
dioxide (CO2) emissions when designing a lean manufacturing system. This paper presents a methodology which can 
be useful for measuring energy consumption and CO2 emissions for a typical manufacturing system design at an early 
stage. A case study was carried out for obtaining computational results using the developed methodology based on 
data collected from a real production line. 
1 Introduction 
To develop a sustainable manufacturing system, system 
designers need not merely to apply traditional methods to 
improve system efficiency and productivity but also to 
examine the environmental impact on the developed 
system. This is because governments in many countries 
have been enforcing ever-stricter environmental policies 
and regulations by promoting energy saving and low-
emission manufacturing activities in industry. A 
manufacturing system can be defined as a process or 
system of transforming raw materials, components or 
parts into final products that meet customer's needs and 
specifications [1]. The traditional manufacturing system 
design is involved in determination and analysis of such 
as material-handling methods, system capacities, 
production methods, material flow, shop-floor layouts, 
system flexibilities and operations. Nevertheless, there is 
an environmental consideration that needs also to be 
addressed today; this leads to a new challenge for 
manufacturing system designers to develop an effective 
approach by incorporating environmental parameters or 
constraints [2]. 
The concept of manufacturing sustainability may be 
defined as the creation of manufactured products by 
minimizing negative environmental impacts on usage of 
energy or natural resources. The environmental issues in 
manufacturing activities focus on energy consumption 
and CO2 emissions. Koc and Kaplan presented an 
investigation on energy consumption for a particular ring 
type yarn manufacturing system [3]. Lind et al. 
developed a production simulation tool that was used for 
making a trade-off decision based on considerations of 
ergonomic constraints, levels of automation and 
environmental impacts [1]. Wang et al. proposed the 
process integration (PI) method that was used for 
evaluating CO2 emissions for a steel industry [4]. 
Gutowski et al. conducted a thermodynamic analysis by 
examining the resources used in manufacturing processes 
[5]. Branham et al. used the quantitative thermodynamic 
analysis for quantifying energy in different categories 
applied into manufacturing processes or systems [6]. 
Lean concepts are widely adopted by many 
manufacturing plants as a popular model for improving 
system efficiency and productivity without additional 
investments. Lean manufacturing is a systematic 
approach to eliminate non-value added wastes in various 
forms and it enables continuous improvement [7]. These 
wastes are overproduction, waiting for parts to arrive, 
unnecessary movement of materials, the waste in 
processing, unnecessary inventory, excess motion and the 
waste of rework [8]. However, traditional lean 
manufacturing does not consider environmental wastes 
which also need to be identified as these wastes add no 
values on manufactured products. This paper presents an 
integrated method by incorporating parameters of energy 
consumption and CO2 emissions into a manufacturing 
system design at an early stage. A case study was used 
for obtaining computational results based on data 
collected from a real production line. 
2 Energy consumption and CO2 
emissions of a typical manufacturing 
system  
In a manufacturing system, energy is used for operating 
machines, air conditioning systems, illumination systems 
and other supportive equipment such as compressors 
which supply compressed air to some machines [3]. 
    
  
 
DOI: 10.1051/05005 (2016), matecconf/2016MATEC Web of Conferences 70050057
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 © The Authors,  published  by EDP Sciences.  This  is  an  open  access  article  distributed  under  the  terms  of  the Creative  Commons Attribution
 License 4.0 (http://creativecommons.org/licenses/by/4.0/). 
Energy and CO2 emissions are generated by either 
combusting fossil fuels directly or using electricity which 
is generated indirectly by using fossil fuels or renewable 
resources. To describe amounts of energy consumption 
and CO2 emissions, the following notations are used: 
Notations: 
m: number of processes in a manufacturing system 
ni: number of machines involved in process i, where 
{1, 2,...., m}i 
Ei (kWh): energy consumption for a machine involved 
in process i
Ei
cond
(kWh): energy consumption of an air 
conditioning system  
Ei
illum (kWh): energy consumption of an illumination 
system  
Ei
air comp (kWh): energy consumption of a compressed 
air needed for a machine involved in process i
TE (kWh): total energy consumption of a 
manufacturing system  
Ni (kw): installed power for a machine involved in 
process i
Ri (kg/h): manufacturing rate for a machine involved 
in process i
i
 (hr): operating time for a machine involved in 
process i  
µi (%): efficiency for a machine involved in process i
i
 (kg): mass of materials transferred from a machine 
involved in process i  
Gi(kg): mass production per month ¥i (%): total waste 
ratio for a machine involved in process i  
Ęi (kWh): energy consumption of air conditioning per 
month  
Ěi (kWh): energy consumption of illumination per 
month 
ζair comp
i
 (kWh/m3): energy consumption per cubic 
meter of a compressor
i
(m3/h): compressed air used for a machine 
involved in process i per hour
 compair
i
 (m3/h): capacity of compressed air in cubic 
meter per hour of a compressor  
 compair
i
N (kWh): installed power for a compressor 
ei (kg/kWh): amount of CO2 emissions per kWh 
released from a machine involved in process i
Tei (kg/kWh): amount of CO2 emissions per KWh 
released from a machine, an air conditioning system and 
an illumination system, which involved in process i
 : CO2 emission factor using different energy 
sources 
Te (kg/kWh): total amount of CO2 emissions released 
from the manufacturing system  
qi (kg): mass of materials involved in process i  
2.1 Energy consumption  
The energy consumption Ei for a machine involved in 
process i is given by
      
i i i i
E N n 	 	                            (1) 
The operating time 
i
  for a machine involved in 
process i is calculated by: 
i
i
i i
q
R




	
                                  (2) 
Mass of materials qi transferred from a machine 
involved in process i is obtained by:
   (1  )¥
i i i
q   	                      (3) 
The energy consumption of an air conditioning 
system Eicond in a manufacturing system is given by:  
 =   cond
i i
i
i
E Ę
G

	
                     (4) 
The energy consumption of an illumination system
Ei
illum is calculated by: 
illum
i i
i
i
G
E Ě

 	
                     (5) 
The energy consumption of a compressed air needed 
for a machine involved in process i air comp
i
E  is 
calculated by: 
        air comp air comp
i i i ii
E n 

 	 	 	
     (6) 
where air comp
i
  can be determined by:  
 comp
 comp
ai
i
i
r
air comp
i air
N



                       (7) 
The total energy consumption TE for a manufacturing 
system is given below:  
1
  (      )
m
air comp cond illum
i i i i
i
TE E E E E

   

  (8)
where {1,2,...., m}i        
Hence, equation (8) will be as follows: 
1
 (1 )  [     
     
     ] 
¥m
i
i i
i i
air com
i
i
i i
p
i i ii
i i
i i
µ
Ę
TE n
R
n
G G
Ě
 


 	 
 	  	
	
 	 	 	
 
 	  	

2.2 CO2 emissions
The amount of CO2 emissions ei released from a machine 
involved in process i is calculated by:
   
i i
e E 	                       (9) 
 
  
 
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where, the CO2 emission factor  can be defined as 
shown in table 1 [9].
Table 1. Amount of CO2 emission factor per kWh using 
deferent energy sources. 
Energy source Emission factor kg/kWh 
Oil as direct energy source when 
oil is combusted to generate 
thermal energy                            
0.5 
Oil as indirect energy source to 
generate electricity 0.6895
Solar as indirect energy source to 
generate electricity 0.05
The total amount of CO2 emissions Te can be 
calculated as follows [10]. 
1
0.6895  
(   
  [   
) ]cond illum
i
m
i i
i
air comp
i i
E E
e q
E
Te

 	  	
 

(10)
where {1, 2,...., m}i 
Hence, equation (10) will be as follows: 
1
¥    {       (1 ) 
 0.6895 [    
    } ]
i
i i
m
i i i i
i
air comp
i i
i i
i
i i
i
Te N n
G
n
G
Ę Ě

 



	
 	 	 	 	  	 

 
 	
	 	 	
 	

3 A case study 
Figure 1 illustrates a process flow chart or precedence 
diagram for producing plastic and woven sacks at a 
company. The study was carried out for analysing the 
energy consumption and CO2 emissions for a 
manufacturing system consisting of machines for 
carrying out process tasks, an air conditioning system, an 
illumination system and a compressor system. Air 
conditioning is necessitated to maintain reasonable 
temperatures required for operators, effective machining 
operations and quality of products. The production line 
comprises 10 different processes tasks, each process task 
involves a number of machines and each machine has 
energy, mass inputs and different specifications. Table 2 
shows the symbols representing the manufacturing 
processes used by the factory. 
Figure 1. The process flow of plastic and woven sacks. 
Table 2. Manufacturing processes tasks for producing plastic 
and woven sacks. 
Tasks Description Predecessors
R.M1
R.M2
G 
W 
L 
P 
A 
F 
C
K 
S 
B
Raw material (Polypropylene)
Raw material (Polyethylene)
Extruding the Polypropylene to 
make stands
Weaving the strands into rolls of 
sacks 
Laminating the rolls 
Printing and branding 
Cutting the rolls into bags 
blowing the polyethylene into 
Inner-film bags
Cutting blown inner-film in to 
bags 
Liner stick, inserts and smoothes 
out blown film 
Film sewn into bag  
End product compressed using 
baling machines
None 
None 
R.M1 
G 
W 
L 
P 
R.M2 
F 
F,C
K 
S 
Table 3 shows collected data from the company. 
These include the mass of materials involved in process i
per month, number of machines involved in process i, 
waste ratio, manufacturing rate and installed power. 
Table 3. Data collected from a plastic and woven sacks 
company. 
Tasks i
(kg/month) 
ni ¥t (%) Ri(kg/h)
Ni
(kW)
G 254800 4 0.02 408 200
W 244608 40 0.04 392 14
L 300309 3 0.015 481 70
P 297306 5 0.01 476 20
A 291360 13 0.02 467 7
F 11050 3 0.002 18 40
C 11028 2 0.002 18 7
K 301536 13 0.003 483 0
S 298521 54 0.01 478 0.8
B 298521 4 0 478 4
4 Comparative results  
Table 4 shows computational results in energy 
consumption and CO2 emissions of machines involved in 
a process task and Figure 2 illustrates these results. 
Energy consumption of the machines involved in a
process task of a manufacturing system depends on the 
installed power Ni and the operating time
i

. As shown in 
Figure 2, the machines for completing process task G
have the largest energy consumption and the machines 
for completing process task K have the least energy 
consumption. This is because the machines involved in 
process task G have the highest installed power Ni (200 
kw) and the highest operating time
i

(646 h), while the 
machines involved in process task K have the lowest 
installed power Ni (zero kw) as this process is a manual  
task.  
CO2 emissions released from the machines involved in 
a process task of a manufacturing system depends on the 
 
  
 
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energy consumption used by the machines, the emission 
factor and the energy source. Table 4 alos shows the 
amount of CO2 emissions which are subject to the CO2
emission factor  using different energy sources and 
Figure 3 illustrates these results. As shown in Figure 3, 
the machines in completing process task G have the 
highest amount of CO2 emissions Tei (91244910178 
kg/kWh using oil as indirect energy to generate electricity, 
66167449497 kg/kWh using oil as direct thermal energy 
and 6616751966 kg/kWh using solar as indirect energy to 
generate electricity), respectively.This is because the 
machines involved in process task G have the highest 
amount of energy consumption. By contrast, the 
machines involved in process task K generate zero CO2
emissions as this process is a manual task. The amount of 
CO2 emissions that released from this task is released 
from the air conditioning and illumination system only 
which is 4431 kg/kWh. The results in Table 4 also show 
that using the solar source of energy has the lowest total 
of CO2 emissions Te of 15679203081 kg/kWh, followed 
by oil as a direct energy source to generate thermal 
energy of 1.6×1011 kg/kWh and oil as indirect energy 
source to generate electricity of 2.2×1011 kg/kWh, 
because solar energy has the least emission factor  (0.05 
kg/kWh) followed by oil as direct energy source (0.5 
kg/kWh) and oil as indirect energy source (0.6895 
kg/kWh). The amount of total CO2 emissions Te using oil 
as indirect energy source is higher than using oil as direct 
energy source because electricity is already generated 
through oil and the emission factor  for using oil as 
indirect energy source is higher than the emission factor 
for using oil as direct energy source. 
Table 4. Calculated results for energy consumption and CO2 emissions
Source of energy 
Oil Solar 
Indirect energy to 
generate electricity 
Direct energy when oil is 
combusted to generate 
thermal energy
Indirect energy to 
generate electricity
Tasks
Ei 
(kWh) iτ
(h) 
Amount of CO2 emissions (kg/kWh) 
                Tei                                         Tei                                        Tei
G 509184 646 91244910178 66167449497 6616751308
W 363417 640 63744725119 46225327628 4622536751
L 133005 636 27953731584 20271018351 2027108300
P 63024 633 13048677512 9462422354 946249157
A 57919 625 11868414917 8606547911 860689587
F 75029 630 572799149 415374486 41542833
C 8753 625 66700011 48370533 4844068
K 0 624 4431 0 0
S 27226 623 5660055586 4104465022 410450490
B 9984 620 2055013982 1490221654 149026153
Eiair comp 69309
Eicond 41184
Eiillum 23088
(TE) 1381125
(Te) 2.2×1011 1.6×1011 15679203081
Figure 2. Energy consumption calculated results. Figure 3. The amount of CO2 emissions using oil as direct 
energy source and indirect energy source and solar as indirect 
energy source to generate electricity.
 
  
 
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5 Conclusions and discussions  
When designing a manufacturing system, engineers used 
to focus on key performance indicators in terms of 
system productivity and capacity; environmental 
considerations are often overlooked. This paper presents 
an integrated method which addresses environmental 
sustainability relating to manufacturing activities. The 
developed method was aimed at helping decision-makers 
to design a manufacturing system incorporating a number 
of environmental parameters in terms of energy
consumption and CO2 emissions. The computational 
results were validated based on data collected from a real 
case in industrial case. In addition, the developed method 
allows a joint analysis of the system performance using 
environmental constraints.
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An integrated method for sustainable manufacturing systems design

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