Manufacturing Process Level Framework for Green Strategies KPIs: The Welding Process Case

Abstract

Increased global temperature has dictated the need to reduce carbon emissions in the manufacturing sector, while it is expected to both improve sustainability and maintain the quality of manufacturing processes. Green strategies, such as Zero Defect Manufacturing, Circular Economy and Sustainability have been proposed, with different key performance indicators (KPIs) with unidentified relationship between those KPIs and process parameters. Up to now, no study has identified this relationship, or tried to combine different green strategies and KPIs. This study aims to investigate the impact of specific process parameters (process power & speed) for the case of welding on KPIs for Zero Defect Manufacturing (defect rate), Circular Economy (energy consumption) and Sustainability (carbon footprint). The methodological approach was based on previously published framework, while a specific case study was used to showcase the complexity of relationship between the process parameters and the relevant KPIs. The main outcome of this study is the non-linear relationship shown in most cases, such as in the case of the impact of power and speed on the defect rate and on the carbon footprint. In addition, KPIs from one green strategy could be applicable to the other, via defining the link between quality of welding, energy consumption and carbon emissions. The latter could be used to define a holistic strategy incorporating different strategies and KPIs for improving sustainability in manufacturing.