- Email: [email protected]
Environmental management inside production systems
Journal of Materials Processing Technology 162–163 (2005) 759–765
Environmental management inside production systems K. Mijanovic a , J. Kopac b,∗ b
a International Forum “Bosnia”, Ferhadija 30 Sarajevo, Bosnia and Herzegovina University of Ljubljana, Faculty of Mechanical Engineering, Aˇskerˇceva 6, 1000 Ljubljana, Slovenia
Abstract This paper deals with management of quality and environment problems of transition countries like Bosnia and Herzegovina. It is true if we say that without acceptable quality our products we can not sale it at EU markets. Many of us insisted on quality management system (QMS) but we must use and calculate with environmental management system (EMS), which means all environmental activities such as environmental audit, assessment of environmental performances, environmental labelling, life cycles of products and the other environmental aspects of products. The consumer in most developed country looks on quality of products trough the life style as they have. Sense of personal responsibility is one of most important elements of structure of mankind behaviour. From that, we can derivate characteristics of quality system (QS) and its efficiency. It is especially applicable for complex science such as ecology. Being that management of factories in Bosnia and Herzegovina during the period of non-finishing transition (it is not separated ownership and managing of factories) has significant influence in specific and general decision processes. That gave special significance in the scope of researching of applicable eco-management. In this paper we will try to show how our factories could make technological acceptance of international standards, so that production factors are in useful function in restriction and transition period in Bosnia and Herzegovina, and implemented of reengineering management of quality and environment. © 2005 Elsevier B.V. All rights reserved. Keywords: QMS; EMS; Environmental performances; Reengineering; Synthetic cutting oils; Production systems; Drilling processes
1. Introduction For machining processes is necessary to implement requirement of quality management system (QMS) and environmental management system (EMS). QMS need for continue analysed measurable parameters and its compare during production processes and to correct it if necessary with intention to satisfied consumer and standard operative procedures. EMS need necessity of reengineering of production processes corrected input data parameters on specific working places where organised machining process is. There are more requests which are in front of products with intention to satisfy next functions as: physical quality, machining quality, assurance of its function, serviceable, price, design, etc., to aim successful posts life cycles control. Environmental friendly production as a part of completed production processes is condition No. 1 to show us as a serious economic ∗
Corresponding author. Tel.: +386 1477 1200; fax: +386 1251 8567. E-mail address: [email protected] (J. Kopac).
0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2005.02.228
partner [1]. Partnership is precondition for survival of factory especially when we must answer on request ions in restitution processes. For good mongering technologists must gave “new solutions” as answer for “new request”. Technologists are ones who carrying production changes and there are many questions in front of them.
2. From postulates of development to the excellencies When we talk about development we must think about modern factors of developments, and who are the development factors? There are the postulates in function of market and the only ones judge of validity of realisation of development projects. Market is personification of consumer, and all of the other attributes it leading to the excellencies in production processes. It is manifested through the completed its quality and environmental management systems to the TQM, with unavoidable reengineering processes. The reengineering and quality are postulates of modern development, so
760
K. Mijanovic, J. Kopac / Journal of Materials Processing Technology 162–163 (2005) 759–765
we can say that basic elements of sustainable development are:
• improving of improvement of jobs; • improving of improve of improvement of jobs.
• • • •
requestion of the ISO 9000/2000 standards; requestion of the ISO 14000 standards; quality to the level of TQM; reengineering and design all of the management processes as a function of TQM; • excellencies as a function of satisfaction of consumer; • validation to the self-evaluation.
Reengineering is a big project of business organisation which goal is to improve significant characteristics of main processes using simple opportunities to accomplish exception of consumers. Process is flow of jobs in addition of validity that enable transform whish of consumer as input to the real value as output. That value is changing (from “+” to “−”) through the many of functions of business organisation.
3. Requestion of the ISO 9000/2000 standards
6. Reengineering of management as a function of TQM
The requstion of the ISO 9000/2000 standard define base and process model with the thigh relation between consumer request and his satisfaction through the four moduls: • • • •
responsibility of top management; correct resource management; products realisation; and measuring, analyses and promotion.
4. Requestion of the ISO 14000 standards • satisfied all requests for environmental protection; • achievement more electivity for environmental protection; and • validation of their activities, operations and services.
5. Quality to the TQM level One of possible used definition of Total Quality Management is “TQM is management approach to the continually improvement of processes in the organization which are realized on the basis defined strategy, vision and mission directed to fulfil satisfaction of consumer, with the goal of achievement of world class quality of products and services”. Complex definition of the TQM is directed to the key worlds: leadership of top management, product excellencies, world class of quality. Performances of system, with confirmation of producers excellencies (that means leadership at all level of management, continually education of employees, improvement of production processes, flexibility against the request of environment and interesting groups, efficiency to the market requestions, design and disposal of goods) show us that we can reach TQM, using reengineering. That means the consumer take central place in that mosaic and form (TQM, reengineering, product excellencies) as a promoter, assessor and user. There are four limited working levels toward the reach, maintain and improvement of TQM: • doing the jobs; • improving of jobs;
At the last time appeared necessity to define best way of organisation of management. Field of action is between two extreme variants of organize of management: classic type or hierarchy and network type or team approach. Hierarchy and network type showed significant differences and using one or the other type and in various business organisation there was successful or unsuccessful results. Specific of it is that in any variants, even and in the transition variants manager do not loose his position but he change his managing of business organisation. According to mention, management stopped to be effectively giving tasks to lower level in the business organisations. That means the manager must be open for new ideas, suggestions and initiatives of his colleagues.
7. Eco-management as modern approach for environmental management Eco-management could be defined as part of EMS which should help industry in order to systematically organize approach to the environment and to build its concern about environment in its own production and business strategy [2]. This definition is not mean only control pollutant emissions of waste material or waste management; it is more sophisticated concept which represented answer on crucial question: how could we find optimum between production and environment? That means that we must take carry on each phase of production processes on environmental characteristics products and production processes and packing of products, transportation activities and other effects of products to the environment. Developed country industry is under the permanent pressure to improve environmental efficiency of production processes, distributions and services and its ecological characteristics. There are many influences of different factors toward these requestions for industry and some of this are: • Implementation of market directed instruments in to the environmental laws and in connection with those very strict standards. Market subjects should change its behaviour in accordance with principle “polluter pay”. That means it
K. Mijanovic, J. Kopac / Journal of Materials Processing Technology 162–163 (2005) 759–765
will cost for using of natural resources and pollution of it must be calculated as one of production cost. • It is evident interest of customer which is well educated and they take tension on the ecological cleaner products. On the other side company that produce and sale “Eco friendly” products are very successful because of it. Environmental management policy is defined at the international level through the international agreements and conventions. To accept a principles, instruments and standards are one of the key prerequisite for our approaching processes to the develop countries. Harmonizing our standards with the EU standards is crucial for Bosnia and Herzegovina. If we do not accept EMS as a part of company strategy and business opportunity it could influent significantly bad to our manage affairs.
8. Evaluation of life environment and sustainable development Successful realization of sustainable development, as one of the basic goals of harmonization of economic system relation and natural environment, implicates correct understanding of possible evaluative contribution of non-market goods to sustainable development. An economy will not go into direction of sustainable development if all goods of life environment are correctly evaluated and if those values are included into decision-making system of individuals, firms, and State. Although the correct evaluation of non-market goods of natural environment is a crucial question, for specific economy for being successful in using it resources cannot be guaranty for successful development. If evaluation of life environment would be right it would have been necessary resulted in sustainable development, which is presented below on Fig. 1.
Fig. 1. Sustainability vs. efficiency [3].
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On picture 1 it is shown the border of possible usefulness, defined for given tastes, technology and disposable recourse for two generation. If the goods of natural environment are correctly evaluated, an economy has to be on certain point inside the space of border line of usefulness, or on line of maximal possible usefulness and has to be closed with a vertical or horizontal axis, for example in point A. The correct evaluation of goods and services of life environment makes economy more efficient and may move it to the point B. But, if displacement toward point B is not consistent to sustainable development, the usefulness of generation “2” was decreased below generation “1” level of welfare. The correct evaluation of goods and services of natural environment could result inside sustainable development only if low cost of transfer mechanism, which enables re-distribution of welfare between generations from B to B . The points across the line of possible usefulness inside segment C to B could have been chosen like a sustainable solutions only if we had knew the look of inter-generational function of social welfare.
9. The cleaner production—an approach aspect of environmentally acceptable technologies The environmental problems are direct consequences of human activities, or simply said “social metabolism”. From an economic point of view, the environmental problems are basically the results of market failure. Inventive, investment and productive capacities of market supplied us with goods to which consumer’s wants and need so they could be functional inside modern, technically independent society. After certain time period, the worn out material goods need to be factually taken off as well as the by-product, which are created from the production of material goods itself. The correct deferment and recycling process need sophisticated and integrative systems. Inside western countries it is in use sophisticated financial mechanism for resolving the environmental problematic. But, in many societies these costs are not efficiently eternalised, so the costs of rejected products are being paid by whole society. These costs represent economic discrepancy inside life product cycle. In fact it is happened that whole society pays for something that is only used by few. Because of these reasons, we have government interventions over certain acts of law or regulations, so the influence on decreasing level of prices of certain components and products of waste disposal and recycling. By the set of law acts, authorities are starting to punish economic subjects, who disrespect standards, but on another way there is a question what shall we do with a firms, which are filling out law regulations. The last 10–15 years it became clear an idea that decreased emission of injurious materials is being performed at the place of its beginning. The strategy of pollution prevention and minimizing the level of waste has been necessary to established, so the costs of purification becomes decreased, especially
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from the moment when principle of “Polluter pays” has been presented. This new approach, called “Cleaner production” is promising, because it unites environmental and business sides of problem. Widely accepted definition of sustainable development is the one, which was developed by Brutlands commission and says: “Sustainable development is a development which satisfies the needs of presence, but without jeopardizing opportunities of future generations for satisfaction of their needs”. One of the key questions of sustainability is the question about consciousness that natural and material resources are limited. The cleaner production represents a goal which is perfectly fit into efforts, which lead to sustainable development. In its essence the cleaner production can be presented as: • reduction of produced waste quantity, or avoidment of selfproduction; • efficiency of energy and resources usement; • production of environmentally accepted products and services; • to achieve the less quantity of waste production, lower prices and higher profit.
Table 1 Chemical composition of Al-alloy (AlMgSi) (%) Mg Fe Si Ti Cu Zn V Cr Mn
2.1 0.27 0.3 0.045 3.5 0.04 0.005 0.001 0.83
Table 2 Chemical composition of steel Ck45 (%) C Si Mn P S Cu Cr Ni Mo
0.46 0.18 0.52 0.03 0.04 0.29 0.32 0.12 0.02
Installing the cleaner production inside firms, the advantages are visible from two aspects: Eternal (the aspect of economic usefulness), and external (the aspects of environmental protection and preservation).
(easy biodegradable oil) in conditions of drilling two different materials (aluminium alloy and steel with characteristics showed in the Tables 1 and 2) [7]. Mathematical modelling of the drilling process is founded on design of experiments and multifactorial analysis. Numerical dependences between quality parameters processes metal and drilling processes for Al-alloy and steel is calculated by Eq. (1):
10. Practical example
Ra = Cvx sy (m)
Bosnia and Herzegovina has a good metal industry companies. With the excellent human resources, images and tendencies in the development opportunities it has a good chances to restructuration and continue cooperation with the European and world companies. Tools industry Trebinje, from SE part of Bosnia and Herzegovina is one of it, with the 50 year tradition in tools production. That part of B&H is rich with the clean water resources and it is suitable for agriculture and eco tourism. Tools industry use about 60 t per year of heavy biodegradable cooling and lubrication oil for machining processes, and 1/3 of it is uncontrolled dispersed out of system on the different ways:
where Ra is the average deviation of roughness; C, the constant depends of material; v, the drilling speed (m/min); s, the feed (mm/revolution); x, y exponents depends on the condition of machining process. Area of drilling speed variation (Al-alloy) [vmin = 60 (m/ min); vmax = 90 (m/ min)].
• • • •
burning and evaporating; with the chip; with the products; technical incorrectness of equipment.
Finding better solution for this problem is necessity. This practical example is talking about one solution for this problem by using synthetic easy biodegradable oils, which are friendly for environment [4–6]. Old oil are unacceptable for environment management system and it could not justify requirements of ISO 14041 standard. Research is conducted on the two series of experiments: with the old classic lubricant oil (heavy biodegradable oil) with the new synthetic lubricant oil
(1)
Table 3 Standard characteristics of cutting edge Bright bore γ α ϕ ψ S t
s
27◦ 12◦ 128◦ 50◦ 1.5 0.25 0.19 0.60
TiN e1 d
d p1 p2 z l l1
0.03 8.0 0.02 4.28 4.31 4.5 116.5 77
K. Mijanovic, J. Kopac / Journal of Materials Processing Technology 162–163 (2005) 759–765
763
Table 4 Results of drilling experiments by drilling steel Ck45 with HSS drill and mineral oil ISO VG 22 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
1.49 1.42 3.45 1.19 3.77 4.05 3.47 2.64
0.3988 0.3507 1.2384 0.1740 1.3271 1.3987 1.2442 0.9708
8.88 6.68 17.29 6.93 16.64 22.30 16.10 8.94
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
2.1838 1.8991 2.8501 1.9359 2.8118 3.1046 2.7788 2.1905
1.5102 0.0193 0.1138 0.9633 1.6580 2.4575 0.9755 0.0249
20.1949 0.4403 2.9501 12.2994 20.7445 104.3383 16.1171 9.8935
0.3617 0.0087 0.0087 0.3617 0.1746 0.2396 0.1122 0.0038
0.1677 0.0090 0.0090 0.1677 0.1023 0.3753 0.0823 0.0909
Area of feed variation (Al-alloy) [smin = 0.09; smax = 0.20 (mm/o)]. Area of drilling speed variation (steel) [vmin = 20 (m/ min); vmax = 30 (m/ min)]. Area of feed variation (steel) [smin = 0.04 (mm/o), smax = 0.12 (mm/o)]. Choose of cutting edge is type N with characteristics showed in the Table 3. Inside the experiment with TiN bore has been taken 1/2 of oil quantity. Experiment is conducted at the drilling machine type ASIERA PA22 and quality parameters of processes metal is measured at PERTHOMETER S6P by using one-axis indicator. Results of research and calculate are showed at diagrams. Analysis of results and diagrams are given partially in next tables and correlation equations (see Tables 4–7).
Equation Ra depends on parameters in code shape: Y1 = 0.8878 + 0.2781X1 − 0.1657X2
(2)
Equation Ra depends on parameters in technical shape: Ra = 0.0035v1.3719 s−0.2059 [m]
(3)
Equation Ra depends on parameters in code shape: Y2 = 2.4693 + 0.2997X1 − 0.1758X2
(4)
Equation Ra depends on parameters in technical shape: Rz = 0.0104v1.4785 s−0.2184 [m]
(5)
Equation Ra depends on parameters in code shape: Y1 = −0.6424 + 0.1696X1 − 0.4924X2
(6)
Table 5 Results of drilling experiments by drilling AlMg alloy with HSS drill and cutting bio oil VG 15 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
0.54 0.29 1.09 1.03 0.41 0.44 0.44 0.42
−0.6162 −1.2379 0.0862 0.0296 −0.8916 −0.8210 −0.8210 −0.8675
2.76 1.60 4.77 5.09 2.19 2.76 2.42 2.24
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
1.0152 0.4700 1.5623 1.6273 0.7839 1.0152 0.8838 0.8065
0.0253 0.0003 0.0049 0.0921 0.0233 0.0150 0.0150 0.0203
0.5138 0.0000 0.0004 1.7476 0.5648 0.0329 0.2720 0.4921
0.1219 0.0044 0.0044 0.1219 0.1002 0.0605 0.0605 0.0855
0.0904 0.0000 0.0000 0.0904 0.0870 0.0041 0.0381 0.0742
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Table 6 Results of drilling experiments by drilling AlMg alloy with HSS + Ti drill and mineral oil ISO VG 22 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
0.29 0.48 0.85 0.70 0.61 0.81 0.64 0.74
−1.2379 −0.7340 −0.1625 −0.3567 −0.4943 −0.2107 −0.4463 −0.3011
2.10 2.99 4.38 4.01 4.17 5.64 3.16 4.48
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
0.7419 1.0953 1.4770 1.3888 1.4279 1.7299 1.1506 1.4996
0.0106 0.0004 0.0014 0.0620 0.0011 0.0280 0.0000 0.0095
0.3510 0.0071 0.0152 1.2799 0.0979 3.1788 0.4859 0.3880
0.0926 0.0020 0.0020 0.0926 0.0027 0.0536 0.0000 0.0199
0.0618 0.0008 0.0008 0.0618 0.0061 0.1444 0.0397 0.0224
Table 7 Legend for Figs. 1–4 ×
Synthetic biodegradable oil ISO VG 15 Mineral oil ISO VG-22 Semi synthetic oil ISO 3170 (5% emulsion) Synthetic oil ISO 3170 (7% emulsion)
Equation Ra depends on parameters in technical shape: Ra = 0.5626v0.8365 s−0.6120 [m]
(7)
Equation Ra depends on parameters in code shape: Y2 = 1.0205 + 0.1201X1 − 0.4261X2
(8)
Equation Ra depends on parameters in technical shape: Rz = 0.042010v0.5923 s−0.5295 [m]
(9)
Equation Ra depends on parameters in code shape: Y1 = −0.4929 − 0.0774X1 − 0.3632X2
(10)
Fig. 2. Diagram Ra/v; Al-alloy/HSS drill.
for drilling processes is satisfied for quality of metal surface, and avoiding the sediments. Utilization of synthetic biodegradable substances in processing steel Ck45 and AlMg alloy resulted in the increase in the treat ability parameter by 5, up to 15%, from the aspect of the treated area quality as
Equation Ra depends on parameters in technical shape: Ra = 0.7758v−0.3820 s−0.4513 [m]
(11)
Equation Ra depends on parameters in code shape: Y2 = 1.3139 − 0.0663X1 − 0.2572X2
(12)
Equation Ra depends on parameters in technical shape: Rz = 5.6156v−0.3269 s−0.3196 [m]
(13)
11. Conclusions In this paper we have tried to give contribution to the methodological approach for searching systematic answer from company concerning to the QMS and EMS. After conducting experiment we can conclude that using synthetic oil
Fig. 3. Diagram Ra/v; steel Ck45/HSS drill.
K. Mijanovic, J. Kopac / Journal of Materials Processing Technology 162–163 (2005) 759–765
Fig. 4. Diagram Ra/v; Al-alloy/HSS + TiN drill.
765
compared to the utilization of classic mineral substances. The use of titanium nitride coating on tool blade resulted in a 50% lower amount of refrigerant and lubricant used while cutting, under the same conditions of treatment and approximately same treat ability parameters (see Figs. 2–5). Synthetic oils are in some results same as mineral oils, and that results push us toward future research especially in the field of better machining condition and synthetic oils which should satisfied more demand technological systems which must suitable to the principle of excellencies. It is important to have a good cooperation between oil producers and company especially in the testing phase of lubricants which can provide good oil layer in condition of higher pressure and temperature. Taking a care about QMS and EMS producers of synthetic oil and consumer become strategic partners in the machining processes. References
Fig. 5. Diagram Ra/v; steel Ck45/HSS + TiN drill.
[1] K. Mijanovi´c, S. Opraˇsi´c, M. Omanovi´c, I. Paˇsali´c:, Machining processes and Environmental Management, International Conference RIM, Biha´c, 2003. [2] M. Omanovi´c, Contribution to the strategy of sustainable development of Bosnia and Herzegovina, Zenica (2000). [3] R. Howarth, R. Norgaard, Environmental valuation under sustainable development, Am. Econ. Rev. 82 (2) (1992) 473–477. [4] J. Kopaˇc, M. Sokovi´c, K. Mijanovi´c, Influence of new cutting fluids on the tapping process CIMS Courses and Lectures, vol. 372, Springer, Wien, 1996. [5] J. Kopaˇc, M. Sokovi´c, K. Mijanovi´c, Ecological parameters of cutting fluids and their influence on machining process, in: Proceedings of the 26th International Conference of Production Engineering, SMPJ, Zagreb, 1996. [6] M. Sokovi´c, K. Mijanovi´c, Influence of new cutting fluids and its influence on quantifiable parameters of the cutting processes, J. Mater. Process. Technol. 109 (2001). [7] K. Mijanovi´c, Influence of Environmental Parameters on Production systems, Ph.D. dissertation, Mechanical Faculty Sarajevo, University of Sarajevo, 2004.
Environmental management inside production systems K. Mijanovic a , J. Kopac b,∗ b
a International Forum “Bosnia”, Ferhadija 30 Sarajevo, Bosnia and Herzegovina University of Ljubljana, Faculty of Mechanical Engineering, Aˇskerˇceva 6, 1000 Ljubljana, Slovenia
Abstract This paper deals with management of quality and environment problems of transition countries like Bosnia and Herzegovina. It is true if we say that without acceptable quality our products we can not sale it at EU markets. Many of us insisted on quality management system (QMS) but we must use and calculate with environmental management system (EMS), which means all environmental activities such as environmental audit, assessment of environmental performances, environmental labelling, life cycles of products and the other environmental aspects of products. The consumer in most developed country looks on quality of products trough the life style as they have. Sense of personal responsibility is one of most important elements of structure of mankind behaviour. From that, we can derivate characteristics of quality system (QS) and its efficiency. It is especially applicable for complex science such as ecology. Being that management of factories in Bosnia and Herzegovina during the period of non-finishing transition (it is not separated ownership and managing of factories) has significant influence in specific and general decision processes. That gave special significance in the scope of researching of applicable eco-management. In this paper we will try to show how our factories could make technological acceptance of international standards, so that production factors are in useful function in restriction and transition period in Bosnia and Herzegovina, and implemented of reengineering management of quality and environment. © 2005 Elsevier B.V. All rights reserved. Keywords: QMS; EMS; Environmental performances; Reengineering; Synthetic cutting oils; Production systems; Drilling processes
1. Introduction For machining processes is necessary to implement requirement of quality management system (QMS) and environmental management system (EMS). QMS need for continue analysed measurable parameters and its compare during production processes and to correct it if necessary with intention to satisfied consumer and standard operative procedures. EMS need necessity of reengineering of production processes corrected input data parameters on specific working places where organised machining process is. There are more requests which are in front of products with intention to satisfy next functions as: physical quality, machining quality, assurance of its function, serviceable, price, design, etc., to aim successful posts life cycles control. Environmental friendly production as a part of completed production processes is condition No. 1 to show us as a serious economic ∗
Corresponding author. Tel.: +386 1477 1200; fax: +386 1251 8567. E-mail address: [email protected] (J. Kopac).
0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2005.02.228
partner [1]. Partnership is precondition for survival of factory especially when we must answer on request ions in restitution processes. For good mongering technologists must gave “new solutions” as answer for “new request”. Technologists are ones who carrying production changes and there are many questions in front of them.
2. From postulates of development to the excellencies When we talk about development we must think about modern factors of developments, and who are the development factors? There are the postulates in function of market and the only ones judge of validity of realisation of development projects. Market is personification of consumer, and all of the other attributes it leading to the excellencies in production processes. It is manifested through the completed its quality and environmental management systems to the TQM, with unavoidable reengineering processes. The reengineering and quality are postulates of modern development, so
760
K. Mijanovic, J. Kopac / Journal of Materials Processing Technology 162–163 (2005) 759–765
we can say that basic elements of sustainable development are:
• improving of improvement of jobs; • improving of improve of improvement of jobs.
• • • •
requestion of the ISO 9000/2000 standards; requestion of the ISO 14000 standards; quality to the level of TQM; reengineering and design all of the management processes as a function of TQM; • excellencies as a function of satisfaction of consumer; • validation to the self-evaluation.
Reengineering is a big project of business organisation which goal is to improve significant characteristics of main processes using simple opportunities to accomplish exception of consumers. Process is flow of jobs in addition of validity that enable transform whish of consumer as input to the real value as output. That value is changing (from “+” to “−”) through the many of functions of business organisation.
3. Requestion of the ISO 9000/2000 standards
6. Reengineering of management as a function of TQM
The requstion of the ISO 9000/2000 standard define base and process model with the thigh relation between consumer request and his satisfaction through the four moduls: • • • •
responsibility of top management; correct resource management; products realisation; and measuring, analyses and promotion.
4. Requestion of the ISO 14000 standards • satisfied all requests for environmental protection; • achievement more electivity for environmental protection; and • validation of their activities, operations and services.
5. Quality to the TQM level One of possible used definition of Total Quality Management is “TQM is management approach to the continually improvement of processes in the organization which are realized on the basis defined strategy, vision and mission directed to fulfil satisfaction of consumer, with the goal of achievement of world class quality of products and services”. Complex definition of the TQM is directed to the key worlds: leadership of top management, product excellencies, world class of quality. Performances of system, with confirmation of producers excellencies (that means leadership at all level of management, continually education of employees, improvement of production processes, flexibility against the request of environment and interesting groups, efficiency to the market requestions, design and disposal of goods) show us that we can reach TQM, using reengineering. That means the consumer take central place in that mosaic and form (TQM, reengineering, product excellencies) as a promoter, assessor and user. There are four limited working levels toward the reach, maintain and improvement of TQM: • doing the jobs; • improving of jobs;
At the last time appeared necessity to define best way of organisation of management. Field of action is between two extreme variants of organize of management: classic type or hierarchy and network type or team approach. Hierarchy and network type showed significant differences and using one or the other type and in various business organisation there was successful or unsuccessful results. Specific of it is that in any variants, even and in the transition variants manager do not loose his position but he change his managing of business organisation. According to mention, management stopped to be effectively giving tasks to lower level in the business organisations. That means the manager must be open for new ideas, suggestions and initiatives of his colleagues.
7. Eco-management as modern approach for environmental management Eco-management could be defined as part of EMS which should help industry in order to systematically organize approach to the environment and to build its concern about environment in its own production and business strategy [2]. This definition is not mean only control pollutant emissions of waste material or waste management; it is more sophisticated concept which represented answer on crucial question: how could we find optimum between production and environment? That means that we must take carry on each phase of production processes on environmental characteristics products and production processes and packing of products, transportation activities and other effects of products to the environment. Developed country industry is under the permanent pressure to improve environmental efficiency of production processes, distributions and services and its ecological characteristics. There are many influences of different factors toward these requestions for industry and some of this are: • Implementation of market directed instruments in to the environmental laws and in connection with those very strict standards. Market subjects should change its behaviour in accordance with principle “polluter pay”. That means it
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will cost for using of natural resources and pollution of it must be calculated as one of production cost. • It is evident interest of customer which is well educated and they take tension on the ecological cleaner products. On the other side company that produce and sale “Eco friendly” products are very successful because of it. Environmental management policy is defined at the international level through the international agreements and conventions. To accept a principles, instruments and standards are one of the key prerequisite for our approaching processes to the develop countries. Harmonizing our standards with the EU standards is crucial for Bosnia and Herzegovina. If we do not accept EMS as a part of company strategy and business opportunity it could influent significantly bad to our manage affairs.
8. Evaluation of life environment and sustainable development Successful realization of sustainable development, as one of the basic goals of harmonization of economic system relation and natural environment, implicates correct understanding of possible evaluative contribution of non-market goods to sustainable development. An economy will not go into direction of sustainable development if all goods of life environment are correctly evaluated and if those values are included into decision-making system of individuals, firms, and State. Although the correct evaluation of non-market goods of natural environment is a crucial question, for specific economy for being successful in using it resources cannot be guaranty for successful development. If evaluation of life environment would be right it would have been necessary resulted in sustainable development, which is presented below on Fig. 1.
Fig. 1. Sustainability vs. efficiency [3].
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On picture 1 it is shown the border of possible usefulness, defined for given tastes, technology and disposable recourse for two generation. If the goods of natural environment are correctly evaluated, an economy has to be on certain point inside the space of border line of usefulness, or on line of maximal possible usefulness and has to be closed with a vertical or horizontal axis, for example in point A. The correct evaluation of goods and services of life environment makes economy more efficient and may move it to the point B. But, if displacement toward point B is not consistent to sustainable development, the usefulness of generation “2” was decreased below generation “1” level of welfare. The correct evaluation of goods and services of natural environment could result inside sustainable development only if low cost of transfer mechanism, which enables re-distribution of welfare between generations from B to B . The points across the line of possible usefulness inside segment C to B could have been chosen like a sustainable solutions only if we had knew the look of inter-generational function of social welfare.
9. The cleaner production—an approach aspect of environmentally acceptable technologies The environmental problems are direct consequences of human activities, or simply said “social metabolism”. From an economic point of view, the environmental problems are basically the results of market failure. Inventive, investment and productive capacities of market supplied us with goods to which consumer’s wants and need so they could be functional inside modern, technically independent society. After certain time period, the worn out material goods need to be factually taken off as well as the by-product, which are created from the production of material goods itself. The correct deferment and recycling process need sophisticated and integrative systems. Inside western countries it is in use sophisticated financial mechanism for resolving the environmental problematic. But, in many societies these costs are not efficiently eternalised, so the costs of rejected products are being paid by whole society. These costs represent economic discrepancy inside life product cycle. In fact it is happened that whole society pays for something that is only used by few. Because of these reasons, we have government interventions over certain acts of law or regulations, so the influence on decreasing level of prices of certain components and products of waste disposal and recycling. By the set of law acts, authorities are starting to punish economic subjects, who disrespect standards, but on another way there is a question what shall we do with a firms, which are filling out law regulations. The last 10–15 years it became clear an idea that decreased emission of injurious materials is being performed at the place of its beginning. The strategy of pollution prevention and minimizing the level of waste has been necessary to established, so the costs of purification becomes decreased, especially
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from the moment when principle of “Polluter pays” has been presented. This new approach, called “Cleaner production” is promising, because it unites environmental and business sides of problem. Widely accepted definition of sustainable development is the one, which was developed by Brutlands commission and says: “Sustainable development is a development which satisfies the needs of presence, but without jeopardizing opportunities of future generations for satisfaction of their needs”. One of the key questions of sustainability is the question about consciousness that natural and material resources are limited. The cleaner production represents a goal which is perfectly fit into efforts, which lead to sustainable development. In its essence the cleaner production can be presented as: • reduction of produced waste quantity, or avoidment of selfproduction; • efficiency of energy and resources usement; • production of environmentally accepted products and services; • to achieve the less quantity of waste production, lower prices and higher profit.
Table 1 Chemical composition of Al-alloy (AlMgSi) (%) Mg Fe Si Ti Cu Zn V Cr Mn
2.1 0.27 0.3 0.045 3.5 0.04 0.005 0.001 0.83
Table 2 Chemical composition of steel Ck45 (%) C Si Mn P S Cu Cr Ni Mo
0.46 0.18 0.52 0.03 0.04 0.29 0.32 0.12 0.02
Installing the cleaner production inside firms, the advantages are visible from two aspects: Eternal (the aspect of economic usefulness), and external (the aspects of environmental protection and preservation).
(easy biodegradable oil) in conditions of drilling two different materials (aluminium alloy and steel with characteristics showed in the Tables 1 and 2) [7]. Mathematical modelling of the drilling process is founded on design of experiments and multifactorial analysis. Numerical dependences between quality parameters processes metal and drilling processes for Al-alloy and steel is calculated by Eq. (1):
10. Practical example
Ra = Cvx sy (m)
Bosnia and Herzegovina has a good metal industry companies. With the excellent human resources, images and tendencies in the development opportunities it has a good chances to restructuration and continue cooperation with the European and world companies. Tools industry Trebinje, from SE part of Bosnia and Herzegovina is one of it, with the 50 year tradition in tools production. That part of B&H is rich with the clean water resources and it is suitable for agriculture and eco tourism. Tools industry use about 60 t per year of heavy biodegradable cooling and lubrication oil for machining processes, and 1/3 of it is uncontrolled dispersed out of system on the different ways:
where Ra is the average deviation of roughness; C, the constant depends of material; v, the drilling speed (m/min); s, the feed (mm/revolution); x, y exponents depends on the condition of machining process. Area of drilling speed variation (Al-alloy) [vmin = 60 (m/ min); vmax = 90 (m/ min)].
• • • •
burning and evaporating; with the chip; with the products; technical incorrectness of equipment.
Finding better solution for this problem is necessity. This practical example is talking about one solution for this problem by using synthetic easy biodegradable oils, which are friendly for environment [4–6]. Old oil are unacceptable for environment management system and it could not justify requirements of ISO 14041 standard. Research is conducted on the two series of experiments: with the old classic lubricant oil (heavy biodegradable oil) with the new synthetic lubricant oil
(1)
Table 3 Standard characteristics of cutting edge Bright bore γ α ϕ ψ S t
s
27◦ 12◦ 128◦ 50◦ 1.5 0.25 0.19 0.60
TiN e1 d
d p1 p2 z l l1
0.03 8.0 0.02 4.28 4.31 4.5 116.5 77
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Table 4 Results of drilling experiments by drilling steel Ck45 with HSS drill and mineral oil ISO VG 22 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
1.49 1.42 3.45 1.19 3.77 4.05 3.47 2.64
0.3988 0.3507 1.2384 0.1740 1.3271 1.3987 1.2442 0.9708
8.88 6.68 17.29 6.93 16.64 22.30 16.10 8.94
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
2.1838 1.8991 2.8501 1.9359 2.8118 3.1046 2.7788 2.1905
1.5102 0.0193 0.1138 0.9633 1.6580 2.4575 0.9755 0.0249
20.1949 0.4403 2.9501 12.2994 20.7445 104.3383 16.1171 9.8935
0.3617 0.0087 0.0087 0.3617 0.1746 0.2396 0.1122 0.0038
0.1677 0.0090 0.0090 0.1677 0.1023 0.3753 0.0823 0.0909
Area of feed variation (Al-alloy) [smin = 0.09; smax = 0.20 (mm/o)]. Area of drilling speed variation (steel) [vmin = 20 (m/ min); vmax = 30 (m/ min)]. Area of feed variation (steel) [smin = 0.04 (mm/o), smax = 0.12 (mm/o)]. Choose of cutting edge is type N with characteristics showed in the Table 3. Inside the experiment with TiN bore has been taken 1/2 of oil quantity. Experiment is conducted at the drilling machine type ASIERA PA22 and quality parameters of processes metal is measured at PERTHOMETER S6P by using one-axis indicator. Results of research and calculate are showed at diagrams. Analysis of results and diagrams are given partially in next tables and correlation equations (see Tables 4–7).
Equation Ra depends on parameters in code shape: Y1 = 0.8878 + 0.2781X1 − 0.1657X2
(2)
Equation Ra depends on parameters in technical shape: Ra = 0.0035v1.3719 s−0.2059 [m]
(3)
Equation Ra depends on parameters in code shape: Y2 = 2.4693 + 0.2997X1 − 0.1758X2
(4)
Equation Ra depends on parameters in technical shape: Rz = 0.0104v1.4785 s−0.2184 [m]
(5)
Equation Ra depends on parameters in code shape: Y1 = −0.6424 + 0.1696X1 − 0.4924X2
(6)
Table 5 Results of drilling experiments by drilling AlMg alloy with HSS drill and cutting bio oil VG 15 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
0.54 0.29 1.09 1.03 0.41 0.44 0.44 0.42
−0.6162 −1.2379 0.0862 0.0296 −0.8916 −0.8210 −0.8210 −0.8675
2.76 1.60 4.77 5.09 2.19 2.76 2.42 2.24
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
1.0152 0.4700 1.5623 1.6273 0.7839 1.0152 0.8838 0.8065
0.0253 0.0003 0.0049 0.0921 0.0233 0.0150 0.0150 0.0203
0.5138 0.0000 0.0004 1.7476 0.5648 0.0329 0.2720 0.4921
0.1219 0.0044 0.0044 0.1219 0.1002 0.0605 0.0605 0.0855
0.0904 0.0000 0.0000 0.0904 0.0870 0.0041 0.0381 0.0742
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Table 6 Results of drilling experiments by drilling AlMg alloy with HSS + Ti drill and mineral oil ISO VG 22 Nr.
x0
x1
x2
V
s
Ra
Y = ln Ra
Rz
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
90.00 60.00 90.00 60.00 73.40 73.40 73.40 73.40
0.10 0.10 0.02 0.02 0.04 0.04 0.04 0.04
0.29 0.48 0.85 0.70 0.61 0.81 0.64 0.74
−1.2379 −0.7340 −0.1625 −0.3567 −0.4943 −0.2107 −0.4463 −0.3011
2.10 2.99 4.38 4.01 4.17 5.64 3.16 4.48
Nr.
x0
x1
x2
Y = ln Rz
(Ralz − Ra)2
(Rzlz − Rz)2
(ln Ralz − ln Ra)2
(ln Rzlz − ln Rz)2
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
1 −1 1 −1 0 0 0 0
1 1 −1 −1 0 0 0 0
0.7419 1.0953 1.4770 1.3888 1.4279 1.7299 1.1506 1.4996
0.0106 0.0004 0.0014 0.0620 0.0011 0.0280 0.0000 0.0095
0.3510 0.0071 0.0152 1.2799 0.0979 3.1788 0.4859 0.3880
0.0926 0.0020 0.0020 0.0926 0.0027 0.0536 0.0000 0.0199
0.0618 0.0008 0.0008 0.0618 0.0061 0.1444 0.0397 0.0224
Table 7 Legend for Figs. 1–4 ×
Synthetic biodegradable oil ISO VG 15 Mineral oil ISO VG-22 Semi synthetic oil ISO 3170 (5% emulsion) Synthetic oil ISO 3170 (7% emulsion)
Equation Ra depends on parameters in technical shape: Ra = 0.5626v0.8365 s−0.6120 [m]
(7)
Equation Ra depends on parameters in code shape: Y2 = 1.0205 + 0.1201X1 − 0.4261X2
(8)
Equation Ra depends on parameters in technical shape: Rz = 0.042010v0.5923 s−0.5295 [m]
(9)
Equation Ra depends on parameters in code shape: Y1 = −0.4929 − 0.0774X1 − 0.3632X2
(10)
Fig. 2. Diagram Ra/v; Al-alloy/HSS drill.
for drilling processes is satisfied for quality of metal surface, and avoiding the sediments. Utilization of synthetic biodegradable substances in processing steel Ck45 and AlMg alloy resulted in the increase in the treat ability parameter by 5, up to 15%, from the aspect of the treated area quality as
Equation Ra depends on parameters in technical shape: Ra = 0.7758v−0.3820 s−0.4513 [m]
(11)
Equation Ra depends on parameters in code shape: Y2 = 1.3139 − 0.0663X1 − 0.2572X2
(12)
Equation Ra depends on parameters in technical shape: Rz = 5.6156v−0.3269 s−0.3196 [m]
(13)
11. Conclusions In this paper we have tried to give contribution to the methodological approach for searching systematic answer from company concerning to the QMS and EMS. After conducting experiment we can conclude that using synthetic oil
Fig. 3. Diagram Ra/v; steel Ck45/HSS drill.
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Fig. 4. Diagram Ra/v; Al-alloy/HSS + TiN drill.
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compared to the utilization of classic mineral substances. The use of titanium nitride coating on tool blade resulted in a 50% lower amount of refrigerant and lubricant used while cutting, under the same conditions of treatment and approximately same treat ability parameters (see Figs. 2–5). Synthetic oils are in some results same as mineral oils, and that results push us toward future research especially in the field of better machining condition and synthetic oils which should satisfied more demand technological systems which must suitable to the principle of excellencies. It is important to have a good cooperation between oil producers and company especially in the testing phase of lubricants which can provide good oil layer in condition of higher pressure and temperature. Taking a care about QMS and EMS producers of synthetic oil and consumer become strategic partners in the machining processes. References
Fig. 5. Diagram Ra/v; steel Ck45/HSS + TiN drill.
[1] K. Mijanovi´c, S. Opraˇsi´c, M. Omanovi´c, I. Paˇsali´c:, Machining processes and Environmental Management, International Conference RIM, Biha´c, 2003. [2] M. Omanovi´c, Contribution to the strategy of sustainable development of Bosnia and Herzegovina, Zenica (2000). [3] R. Howarth, R. Norgaard, Environmental valuation under sustainable development, Am. Econ. Rev. 82 (2) (1992) 473–477. [4] J. Kopaˇc, M. Sokovi´c, K. Mijanovi´c, Influence of new cutting fluids on the tapping process CIMS Courses and Lectures, vol. 372, Springer, Wien, 1996. [5] J. Kopaˇc, M. Sokovi´c, K. Mijanovi´c, Ecological parameters of cutting fluids and their influence on machining process, in: Proceedings of the 26th International Conference of Production Engineering, SMPJ, Zagreb, 1996. [6] M. Sokovi´c, K. Mijanovi´c, Influence of new cutting fluids and its influence on quantifiable parameters of the cutting processes, J. Mater. Process. Technol. 109 (2001). [7] K. Mijanovi´c, Influence of Environmental Parameters on Production systems, Ph.D. dissertation, Mechanical Faculty Sarajevo, University of Sarajevo, 2004.