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16th Global Conference on Sustainable Manufacturing - Sustainable Manufacturing for Global Circular Economy
16th Global Conference on Sustainable Manufacturing - Sustainable Manufacturing for Global Circular Economy
Conceptual model of Life Cycle Assessment based generic
Conceptual model of Life Cycle Assessment based generic
computer tool towards Eco-Design in manufacturing sector
computer
Manufacturing tool towards
Engineering Eco-Design
Society International in manufacturing
Conference
2017, Vigo (Pontevedra), Spain
sector
2017, MESIC 2017, 28-30 June
R.L. Peiris *, A.K. Kulatunga, K.B.S.N. Jinadasa
R.L. Peiris *, A.K. Kulatunga, K.B.S.N. Jinadasa
Costing
Department ofmodels
a
Manufacturing &for capacity
Industrial optimization
Engineering, Faculty in Industry
of Engineering, University 4.0: Trade-off
of Peradeniya, Peradeniya 20400, Sri Lanka
DepartmentDepartment of Civil&Engineering, Faculty of Engineering, University of Peradeniya, Peradeniya Peradeniya
20400, Sri Lanka
b
a
of Manufacturing Industrial Engineering, Faculty of Engineering, University of Peradeniya, 20400, Sri Lanka
between
Department
b
used Faculty
of Civil Engineering, capacity andUniversity
of Engineering, operational efficiency
of Peradeniya, Peradeniya 20400, Sri Lanka

Abstract A. Santana , P. Afonso , A. Zanin , R. Wernke

a a,* b b

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Even though life cycle assessments (LCA) provide a complete environmental performance analysis and guide to eco-designs,
b
Unochapecó, 89809-000 Chapecó, SC, Brazil
complexities
Even though have slowedassessments
life cycle down the distribution
(LCA) provide of LCA methodology
a complete in manufacturing
environmental sector. Even
performance though
analysis and bottom
guide tolevel advanced
eco-designs,
LCA computer
complexities haveapplications
slowed downlike the
SimaPro and Gabi
distribution are available,
of LCA methodology it hasinnot become popular
manufacturing in industry.
sector. A comprehensive
Even though research
bottom level advanced
work is needed to
LCA computer develop life
applications likecycle inventory
SimaPro (LCI)are
and Gabi under complexities
available, it has notsuch as datapopular
become collection, scenarioAidentification,
in industry. comprehensive allocation,
research
aggregation
work is neededandtodata quality
develop lifemeasurements.
cycle inventory During
(LCI)life cycle
under impact assessment
complexities (LCIA)
such as data with advanced
collection, scenarioLCA software, the
identification, linking
allocation,
Abstract
of international
aggregation and databases makes
data quality severe challenges
measurements. During lifesuchcycle
as clear
impactidentification
assessment of secondary
(LCIA) life cycles,
with advanced selection
LCA of appropriate
software, the linking
datasets and dataset
of international modifications.
databases An analytical
makes severe challengesinterpretation
such as clearof impact categories
identification can be usedlife
of secondary to identify environmental
cycles, selection hotspots
of appropriate
Under
and
datasets the
provide conceptmodifications.
and eco-design
dataset ofcapabilities.
"Industry 4.0",
AnThis production
conceptual
analytical processes
computer
interpretation model
of impact will
is be pushed
proposed
categories tocan beto
overcome
usedbeto increasingly
the long barrier
identify interconnected,
between
environmental raw data
hotspots
information
feeding
and provide based on assistance.
and eco-design a real timeAThis
capabilities. basis
strong and,
LCAnecessarily,
conceptual based,
computer much
industry more
specific,
model efficient.
Industrially
is proposed In this context,
Generic,
to overcome capacity
eco-design
the guided,
long barrier optimization
userraw
between friendly
data
goes
and beyond
real
feeding and the traditional
timeeco-design
DSS tool motivates aimindustrialists
assistance. of capacity
A strong tomaximization,
LCA move
based,towards contributing
sustainable
industry also for organization’s
manufacturing.
specific, Industrially profitability
Generic, eco-design andfriendly
guided, user value.
and real time
Indeed, leanDSS tool motivates
management industrialists
and continuous to move towards sustainable
improvement approaches manufacturing.
suggest capacity optimization instead of
© 2018 The Authors.
maximization. The Published
study of by Elsevier
capacity Ltd.
optimization and costing models is an important research topic that deserves
©© 2018
2019
This is anThe
The Authors.
open
Authors. Published
accessboth
article
Published by
under Elsevier
the CC
by Elsevier B.V.
BY-NC-ND
Ltd. license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
contributions from the practical and theoretical perspectives. This paper presents and discusses a mathematical
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
This is an openunder responsibility
access article underof the scientific
CC BY-NC-ND committee of the
license 16th Global Conference on Sustainable Manufacturing
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
model
Selectionfor and
capacity management
peer-review based on different
under responsibility of the costing
scientificmodels
committee (ABC of and TDABC).
the 16th GlobalAConference
generic model has been
on Sustainable
(GCSM)
Peer-review
Manufacturing under responsibility of the scientific committee of the 16th Global Conference on Sustainable Manufacturing
(GCSM).
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
(GCSM)
value. The
Keywords: trade-off
Sustainable capacity maximization
Manufacturing, vs operational
Life Cycle Assesment, efficiency
Decision Support System, is highlighted
Eco-Design, and
Design for it is shown that capacity
Sustainability
optimization might hide operational inefficiency.
Keywords: Sustainable Manufacturing, Life Cycle Assesment, Decision Support System, Eco-Design, Design for Sustainability
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
2017.

Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

1. Introduction
* Corresponding author. Tel.: +94775401626.
E-mail
* The address:
cost rajithalakshanpeiris@gmail.com
of idle
Corresponding capacity
author. is a fundamental information for companies and their management of extreme importance
Tel.: +94775401626.
E-mail address:
in modern rajithalakshanpeiris@gmail.com
production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789 © 2018 The Authors. Published by Elsevier Ltd.
in several ways:
This is an open access
tons ofunder production, available hours of manufacturing, etc. The management of the idle capacity
2351-9789 © 2018 Thearticle the CC BY-NC-ND
Authors. Published license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
by Elsevier Ltd.
* Paulo Afonso.
Peer-review underTel.: +351 253
responsibility 510 761; fax: +351
of the scientific 253 604
committee of741
the 16th Global Conference on Sustainable Manufacturing (GCSM)
This is an open access article under CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
E-mail address: psafonso@dps.uminho.pt
Peer-review under responsibility of the scientific committee of the 16th Global Conference on Sustainable Manufacturing (GCSM)

2351-9789
2351-9789©©2017
2019The
TheAuthors.
Authors.Published by Elsevier
Published B.V. B.V.
by Elsevier
Peer-review underaccess
This is an open responsibility
article of the scientific
under committee oflicense
the CC BY-NC-ND the Manufacturing Engineering Society International Conference 2017.
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the scientific committee of the 16th Global Conference on Sustainable Manufacturing (GCSM).
10.1016/j.promfg.2019.04.012
84 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90
2 Author name / Procedia Manufacturing 00 (2018) 000–000

1. Introduction

Due to high input-output exchange flows corresponding to high production volume, the manufacturing sector is a
major impact to the environment. As a major pillar of sustainability, enhancement of environmental performances of
the manufacturing sector has become a critical need to prevent global environmental impacts. Design for Sustainability
(DfS) [1] is the most appropriate solution in manufacturing eco-products. It emphasizes that a complete awareness of
environment exchanges and its’ behaviour is required in order to evaluate environmental performance and to prove
the ecological validity of the designs.
Life cycle assessment (LCA) [2] is the scientific methodology standardized with ISO 14044 under environmental
management category [3][4] to evaluate environment performances and can be directly used for manufacturing
industries. It can be used in any scope from the cradle of the product to its grave [3]. LCA researcher should have a
complete understanding of manufacturing process flow, environment exchanges, appropriate data collection and LCA
methodology. A comprehensive life cycle inventory (LCI) of impact generating sources moves the LCA towards the
life cycle impact assessment (LCIA) [2][4]. Impact assessment can be conducted accurately with the assistance of
environmental impact assessment methodologies [5] by using a bottom-level advanced LCA software such as SimaPro
[6]. A computational LCA software contains a number of impact assessment methodologies such as IPCC 2013 GWP,
RECIPE 2016, Eco Indicator 99 etc. [7]. Interpreted results of LCI and LCIA support to understand the risk levels and
distribution of different impact categories. DfS procedure could be used for validation of environmental performance
gain by using advance LCA techniques like scenario analysis and parametric analysis [6]. Complexities of industrial
processes and LCA methodology verify that LCA based eco-design procedure is an advanced and time consuming
research methodology.
The complexity of the DfS concepts has been known to create a barrier for professionals in industries to move
forward with LCA. In addition to the large time consumption and a huge effort requirement, the difficulty of providing
real-time information strengthens the barrier. This has led to a slow development in the environmental pillar relative
to the economic and social pillars of sustainability. That phenomenon raises the need for an efficient and effective
decision support system (DSS) to follow LCI, LCIA and Eco-design procedures and to generate results automatically
with less involvement of professionals. This paper expresses the conceptual DSS which was specially designed for the
manufacturing sector and it validates the system by a simple practical application.
When compared to the existing sustainability based DSS tools, this model covers many areas of environmental
aspects in the manufacturing sector. Several DSS tools have been developed for other sustainability concepts rather
than the strong LCA base [8][9][10][11]. Although several LCA based DSS tools are available, these tools were
constructed for specific uses in factories and cannot be used as a generic system for any industrial system [12][13][14].
Most of existing LCA based tools do not generate comprehensive impact assessment results [15][16][17]. With this
context, specialties of the DSS model include: the ability to provide deep LCI and LCIA comparative analysis within
different levels (process, product, factory, industry); self-structure modification with process parameters; eco-design
validity analysis with high-level techniques; real-time user-friendly system setups; and applicability in any pre-defined
industry. Authors expect to develop this DSS for several industries as a web-based detailed computer application in
future and validate the applicability of the tool.

Nomenclature

FU Functional Unit
SVt Input/output Substance Volume per time duration t in a particular process
SVfuA Input/output Substance Volume for product A per FU in a particular process
CSVfuA Cumulative Input/output Substance Volume for product A per FU in overall process
PAFA Product Allocation Factor of the input/output Substance for product A in a particular process
SAFA Sectional Allocation Factor of the input/output Substance for product A in a particular process
PVt Final Production Volume per time duration t
PCA Final Product Contribution for product A
 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90 85
Author name / Procedia Manufacturing 00 (2018) 000–000 3

2. Architecture of DSS

2.1. Life cycle levels contained in the model

This conceptual DSS model can be used for the viewpoint of industrialist in the factory. Hence, manufacturing
phase is considered as the main zone and other phases are connected according to the perspective of the factory.
Automated computational analyses are done for the system within user-defined boundary in following four levels:
• Industry level – a group of factories (affecting factors ex: product type, geography, technology level)
• Factory-level – a group of products as a bulk production
• Product-level – a group of processes (affecting factors ex: product type, specification)
• Process level – a group of processes (affecting factors ex: department, section)

Raw
Material 1

Material 1 Product 1
Waste 1
Raw
Material 2 Material 2 Waste 2
Product 2

Raw
Material 3 Life Cycles of Product 1 Life Cycles of Product 2 Combined Life Cycles of Product 1 & 2

Fig. 1. Flow diagram of product life cycles up to factory level

In factory level, bulk production and whole manufacturing system are considered. Product-level is introduced for
multi-product manufacturing systems to isolate one product. Process level is beneficial for factories due to operational
comfortability. Industry level has been introduced to compare aggregated factories in the same industry. Based on
factory viewport, tool has capability to combine any level of system by linking each other.

2.2. Overview of the DSS model

Industry A1 (Type 1)
Consumptions
Factory 2 Data Base 1 Environment
Factory 1
(Structure Performance
Industry A Parameters)
PC1 PC2 PD2 PC3
A2 A1
PD1 PC4 PC5 PD3
Automatic Guide
Different User Eco
Feed
Life Cycle to
Design
Scenarios User
Industry B Assesment
Industry A2 Industry B Industry C
DSS Tool LCA Tool
Setup Excecution
Industry C FC3 FC4 B1 B2 B3 C1 C1 Redesign
Data Base 2
with User Analyses
(Impact
Productions
Coeficients)

Fig. 2. Overview of proposed LCA based DSS framework (PC: Process, PD: Product, FC: Factory)

The initial part of the execution of program is the setup of life cycle inventory structure. Inventory structure is based
on the different scenarios of resource, process, technology and data availability. Structure parameter database is
maintained to construct the inventory with assistance of user. Development of life cycle inventory is begun after
feeding life cycle data by user. After this point user involvement is not necessary up until results interpretation.
Functional unit based LCIA is developed automatically by processing predefined inventory structures.
For an industry, impact assessment results are dynamic due to different process scenarios and dynamic
consumptions and productions. However, unit processes are static and do not change due to flow quantities. Hence,
an impact coefficient database is developed for each unit process and combined with the inventory database to generate
86 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90
4 Author name / Procedia Manufacturing 00 (2018) 000–000

final results. As main output, current environment performances are given by cumulative impacts according to user
preferences. Eco-design capabilities are tested by comparing existing and estimated redesigned scenario.
Mainly, this system motivates industrialists to conduct LCAs and analyze eco-design capabilities. User involvement
is not needed between data collection and results interpretation. No literature work could be found which has satisfied
fully automated calculation of dynamic LCA according to dynamic exchange conditions and generically application
in a particular industry. Additional analysis component of eco-design capabilities motivates industrialist to go towards
eco-designs easily rather than other DSS frameworks. According to the working mechanism of DSS, computer
application can be loaded by three sequential stages: industrial system setup and data feeding stage; LCI development
stage; and LCIA and eco-redesign analysis-based interpretation stage.

2.3. Setup of the model and life cycle inventory (LCI)

For setup of the inventory system, developer should have constructed abstract structures of inventory tables. The
developer should have a broad knowledge in the industry to build the appropriate abstract structures by past
experiences of research-based LCAs. According to different scenarios, structures are modified such as adding columns,
removing columns and enabling tables. A setup parameter database is used to store possible changes. Complete
dynamic inventory database structure is constructed by the system based on user fed setup parameters. Setup
parameters should be decided according to process, product and system variations. The following table shows
examples.

Table 1. Example user input parameter set to construct LCI structure

Input category
Geographical Region
Type of manufacturing
Product varieties
Grade varieties
Specifications
Waste treatment types
User input
Sri Lanka
Method A - Conventional
Type X, Type Y, Type Z
Grade I, Grade II, Grade III
100x200 mm2, 200x200 mm2
Product X: Landfill + Incineration

Pre-defined different types of inventory table structures should be stored by developers. Well-constructed inventory
tables should be provided to the user by modifying according to user-defined setup parameters. In most of the factories,
data is recorded in time domain like shift wise, daily, monthly, yearly etc. Therefore, it is better to construct time-
based inventory tables by the DSS to collect following data types:

• Raw material consumption and transport

• Production data and transport
• Energy/Resource consumption and transport
• Auxiliary materials/Wastes and transport

As an example, the following figure shows the general structures of abstract inventory tables of a developer, which
has been constructed for energy/resource consumption data. If the factory has used electricity, there might be several
sources of electricity supply. In such cases, electricity consumption of each source can be collected separately because
environmental impacts in electricity generation depends on the type of generation. If there are varieties of other energy
sources, it is better to collect consumptions in each source type. If consumptions cannot be measured directly, the
system should have capabilities to collect data by alternative methods through indirect ways. In addition to that
transport data is required to calculate impacts generated during the transport process. In most cases, energy is
consumed for non-manufacturing purposes inside the factory like administration and staff usage. If product life cycle
is considered without infrastructures, allocation data for the manufacturing process is required.
 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90 87
Author name / Procedia Manufacturing 00 (2018) 000–000 5

Energy/Resource consumption & Transport data

Electricity Other energy & water

Tnasport data of energy susbtances

Type Firewood logs Saw dust Diesel Water
Distance (km) p q r s

Monthly Electricity consumption (kWh) - 2017 Monthly other energy/resource consumption - 2017
Country grid electricity supply Own generator Solar Firewood logs Saw dust Diesel Water
Month Month
Peak Day Off-Peak Total kWh liters kWh m3 kg liters m3
Jan - - - - - - - Jan - - - -
Feb - - - - - - - Feb - - - -

Nov - - - - - - - Nov - - - -
Dec - - - - - - - Dec - - - -
Total - - - - - - - Total - - - -

Allocation for manufacturing process % Allocation for manufacturing process %

Fig. 3. Proposed inventory structure for Energy/Resource consumptions

After feeding significant data to the system by the user, life cycle inventory assessment can be done. For that,
system developer should have setup calculations to quantify system inputs and outputs respect to a functional unit
(FU). The developer should suggest the possible functional units which represent the functions of product based on
past experiences. The easiest way of FU-based calculation is the linearizing inputs and outputs for production volume.
allocation criteria might be required for multi-product or multi-section system. In such case, following linearized
equations can be used easily.
For product A,

SVt  PAFA
SV fuA = (1)
PVt  PC A

SV fuA = CSV fuA  SAFA (2)

After constructing FU based life cycle inventory, DSS should generate a summary report of FU-based LCI. In
addition to that comparative graphs can be shown to the user in different levels. Automatically generated inventory
analysis reports are the first guidance for the user to take sustainable decisions in the industry.

2.4. Life cycle impact assessment stage (LCIA)

Once life cycle inventory assessment is completed, DSS should have the capability to conduct impact assessment
automatically and give meaningful results of environmental performances. All environmental impacts of a factory can
be divided into 5 groups such as raw material, processes, energy/resource supply, final product and waste material
based on key points and external life cycles are connected to it. Hence an array system of environmental impact (EI)
coefficients is introduced to store impacts for unit processes in different impact categories. Following figure shows
main 5 different types of EI coefficient arrays.

Impact on pre Impact on pre Impact Impact Impact on post Impact on post
life cycles of raw life cycles of generation by generation by life cycles of life cycles of
material energy source process 1 process 2 wastage product
EI 1 EI 2 Energy EI 3 EI 4 Waste EI 5 EI 6

Intermediate
Raw Material Process 1 Process 2 Product
Product 1

Fig. 4. Structure of constructing environmental impact database for the DSS

88 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90
6 Author name / Procedia Manufacturing 00 (2018) 000–000

EI arrays can be maintained by standard indicators like GWP, DALY, Species.yr according to the impact categories
such as carcinogens, land use, eco-toxicity and acidification. By considering links in each unit process and inventory
values total impacts can be calculated per functional unit. If an assumption made that impact level of a considered
impact category is varied linearly with driving exchange, total impact level can be calculated easily by multiply unit
impact with exchange amount. Obviously, it emphasizes the capability of the system to conduct LCIA more similar
to advanced LCA software except high-level techniques such as tree diagram and uncertainty analysis. After
constructing LCIA, DSS should have capability to generate a complete summary report by showing environment
performances in different groups (process/product/factory/industry). It is the second guidance given by DSS.
For eco-design guidance, system should know main eco-design executable spots and it should provide a comparison
of environmental impacts before and after modifications. Scenario analysis and parametric analysis are better LCIA
methodologies which can be used by DSS developer to express the effectiveness of design changes. The following
table expresses several available scenario or parameters for comparison with practical numerical examples.

Table 2. Practical example for available scenario or petameter identification

Eco-design category Practical example
Scenario(S)/Parameter(P)
Raw material consumption P - Material composition
Energy selection S - Energy type
Product specification P - Thickness of tile
Wastage content P - Rejection rate
Transport energy S – Location of collector
Technology P – Power of motors
Waste treatment S – treatment
Current situation
90% of clay contribution
LPG for burning
15 mm
47% rejection of caps
Exported from China
3 kW
Incineration
Expected situation
85% of clay contribution
Biomass for burning
14.4 mm
28% rejection of caps
Colombo – Sri Lanka
1.5kW
Landfill

This automatically generated Eco-design performance evaluation report is the third guidance given by DSS for
users to make sustainable decisions in the industry.

3. Case study results and Discussion

Authors have developed a simple version of DSS tool to validate the applicability of the system. Authors have
constructed LCAs in ceramic industry and identified varieties of ceramic products and manufacturing practices [18].
In this context, the modern practice of clay roof tiles was considered for constructing the basic version DSS tool.
A simplified version of the DSS was developed in a macro-enabled workbook in Microsoft Excel software. In the
same workbook, five data input worksheets (Materials, Energy, Production, Auxiliary and Waste tables and Technical)
and three result worksheets (LCI, LCIA and Eco-Design) were developed. This DSS tool was developed for the
“Cradle to Gate” scope. Based on the data fed by user functional unit-based inventory and allocations were calculated.
Above figures show a snapshot of energy data collection sheet (a) and automatically generated LCI summary (b).
LCIA results were automatically generated for GWP100 and Eco-Indicator 99 by the system due to stored EI
coefficient arrays quantified by reparative LCA results of SimaPro software. By indicating contributions, graphs were
plotted in different aspects by considering process sections. LCIA analysis highlights the main hotspot of as drying
and firing process and the reason was highlighted as high consumption of LP Gas. Eco-Indicator 99 (H) –
characterization graph has been shown in figure (a) below.
In an eco-design sheet of DSS tool, different design capabilities have been added. Reduction of wastages during
clay tile processes is a one of eco-design which can be conducted by the user. Before that user should have evaluated
performance enhancement level. Hence, authors have included facilities to check by reducing the rejection rate in
different stages like forming, drying and firing and sorting. For this case, the formed tile rejection at forming sections
was reduced from current rate 25.9% to expected rate 18%. DSS tool has automatically plotted comparative graphs to
show the reduction of impacts by eco-indicator 99 (H) and IPCC2007 GWP100a methods. In addition to that impact
reduction percentage has been indicated. The following figure shows the results generated for eco-design.
 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90 89
Author name / Procedia Manufacturing 00 (2018) 000–000 7

a Energy/Resource consumption & Transport data b Life Cycle Inventory (LCI)

Electricity Other energy & water Resource per FU (m2) Material/Resource/Waste/Process Alloc (%)
Resource
& Process Unit Amount Mat Pri Sec For Fir Sor Oth
Tnasport data Main Clay - NC kg/m2 25.9 100%
Type LP Gas Diesel materials Clay - DT kg/m2 25.9 100%
Dist (km) 181 181 Grog kg/m2 2.9 100%
Filter Press kg/m2 2.9 100%
Electricity consumption (kWh) - 2017 Res. consumption - 2017 Auxiliary BaCO3 kg/m2 0.037 100%
Country grid electricity supply LP Gas Diesel materials Coconut Oil kg/m2 0.042 100%
Month Month
Peak Day Off-Peak Total MT liters Energy LP Gas kg/m2 4.17 100%
Jan 10949 52948 15315 79212 Jan 72.5 4857 Diesel L/m2 0.26 19.5% 9.0% 40.1% 11.2% 20.2%
Feb 24132 73938 37124 135194 Feb 71.3 3427 Electricity kWh/m2 3.56 24.2% 29.4% 11.7% 34.7%
Mar 22230 71672 42860 136762 Mar 75.4 1985 Other Water L/m2 21.03 92.1% 6.6% 1.3%
Apr 20321 69088 32902 122311 Apr 76.3 4997 Packaging Shrink Wrapping kg/m2 0.055 77.6% 22.4%
May 25816 76521 38984 141321 May 69.8 4269 materials Wood Pallets kg/m2 1.730 100%
Jun 22768 75684 37578 136030 Jun 74.3 3963 Stapping kg/m2 0.021 100%
Jul 27487 82239 41552 151278 Jul 72.1 4391 Black Polythene kg/m2 0.002 100%
Aug 27668 79341 45176 152185 Aug 71.9 4672 Processes Evapouration kg/m2 16.77 100%
Sep 26953 76037 43483 146473 Sep 72.8 4555 Oil fume L/m2 0.017 100%
Oct 23088 74647 36777 134512 Oct 72.7 2426 Diesel burning L/m2 0.105 49.1% 22.7% 28.3%
Nov 20360 65274 30768 116402 Nov 67.8 2215 LPG firing kg/m2 4.17 100%
Dec 8140 42348 8401 58889 Dec 72.7 4004
Total 259912 839737 410920 1510569 Total 869.6 45761 Generate LCI
Avg 21659 69978 34243 125881 Avg 72.47 3813

Allocation for mfg. % 75 Allocation for mfg.

LP Gas 100%
Clear Calculate Diesel 100%
Water 90%

Fig. 5. (a) energy data entry sheet; (b) calculated LCI sheet of DSS application for clay roof tile case

a Life Cycle Impact Assesment (LCIA) b Eco-design checker

Scenario Analysis - Rejection rate change

Eco-Indicator 99 (H) - Characterization

100.0 Current Rejection Level Rejection level after modification Generate
80.0
25.9% 18% Graphs
60.0
Slow Medium Fast
40.0
Eco-Indicator 99 (H) - Characterization
Percentage (%)

20.0
100.0
0.0 80.0
Radiation

Minerals
Climate change

Ozone layer
Carcinogens

Ecotoxicity
Resp. organics

Eutrophication

Fossil fuels
Resp. inorganics

Land use
Acidification/

-20.0 60.0
40.0
Percentage (%)

-40.0
20.0
Current (25.9%)
-60.0 0.0
Acidification/…
Resp.…

New (18%)
Radiation

Minerals
Climate change

Ozone layer

Fossil fuels
Ecotoxicity
Carcinogens
Resp. organics

Land use

-80.0 -20.0
-40.0
-100.0
-60.0
Material supply Primary Secondary -80.0

Forming Drying & Firing Sorting -100.0

EI99(H) - Characterization
Radiation

Plot Graph (Eco-Indicator)

Res. Org.

Res. Ino.

Mineral
Ecotox.
Carcin.

Impact Category
Ozone

Fossil
Acid.

Land
CC

Reduction % 2.8 3.4 4.4 1.4 4.6 2.4 4.8 5.0 0.3 11.4 2.0

Fig. 5. (a) LCIA result graphs; (b) eco-design checker of DSS application for clay roof tile case

Automatic generation of LCI and LCIA reports provide huge benefits for industrialists to identify environment
hotspots and enhancing product value in market with eco performances. In addition, it may be a useful tool for eco-
label providing organizations who are addressed by industries. As well as, this report generation method can be
improved up to third level eco-labeling method which is called as Environment Product Declaration (EPD). On the
other hand, the analytic tool provides the advantage of checking whether or not the re-design projects are eco-effective.
Operating ability without broad knowledge of LCA and automatic operation without much user involvement can
be considered as the major conveniences of this tool. With this comfortability, the tool provides more accurate real-
time data during the short time period in a comprehensive way of making decisions.
90 R.L. Peiris et al. / Procedia Manufacturing 33 (2019) 83–90
8 Author name / Procedia Manufacturing 00 (2018) 000–000

4. Conclusion

The complexity of LCA can be identified as the ultimate barrier to the enhancement of sustainability in
manufacturing sector. Most of the other barriers depend on that complexity. Most of the time, industrialists are used
to considering economic benefits. Due to the barriers towards the environmental sustainability enhancements,
spreading of eco-design techniques within manufacturing sectors might be impossible. But this smart DSS model
motivates the industrialists to think about environmental aspects by themselves without external consultants. And it
cases for spreading life cycle thinking dramatically among Industries. It caused the securing of products as eco-
products and it creates high reliability for the general community too. Furthermore, it reveals that administration of
any country has a responsibility to promote DSS tools for industries and make policies to verify the environmental
security of products in order to move towards an eco-friendly industrial network. Authors expect to transform this
conceptual model to a cloud-based application with graphical user interface (GUI) for future work. Next extension of
the application will be real time data feeding to the system with Industry 4.0 based internet of things (IoT) techniques.

Acknowledgements

Authors would like to acknowledge the National Research Council (NRC) in Sri Lanka which provided the
financial assistance under the project NRC 15-151. As well as, sincere gratitude goes to all manufacturing
organizations in ceramic and tea industry which provided the life cycle data and facilities to collect information.
Another sincere acknowledge goes to Department of Manufacturing and Industrial Engineering, Faculty of
Engineering, University of Peradeniya, Sri Lanka for various supports given during the research period.

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