Investigation of Sustainable Production Concepts Available in Traditional Manufacturing Industries in Sri Lanka A. K. Kulatunaga*, P.R. Jayatilaka, M. Jayawickrama Dept. of Production Engineering, Faculty of Engineering, University of Peradeniya, Sri Lanka (
[email protected],
[email protected],
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The history of metal based manufacturing industry in Sri Lanka goes back to many centuries. This is evident that some ancient literature found in Middle East states that world famous Damascus swords were manufactured in Sri Lanka. Over the centuries some of these traditional manufacturing industries have evolved and survived with rapid globalization and some succumbed due to the invading of similar type of products from other countries. However these industries use to practice some traditional methodologies which are even could not be compared with the present productivity levels achieved in modern manufacturing industries. When inquired deep roots about these industries it can be found that though some of the techniques are not very much efficient, some of them are closely associated with Sustainable Production concepts. Therefore this research’s main focus is to identify the Sustainable Production practices currently available in Sri Lankan traditional industries and how those concepts evolved and survived with diverse kind of treats over the centuries. Several types of traditional industries were identified initially for further studies based on their type of product. Later an evaluation criterion was developed based on the sustainability concepts along the triple bottom lines. Ground level information was gathered by field visits, surveys and discussions done with practitioners as well. It can be identified that there are number of sustainable production concepts being adopted in almost all the phases of life Cycle of the products without knowing the appropriateness to the present global crisis in the direction of energy and resource scarcity, environmental pollution and even social aspects as well. There are number of possibilities to get adopt those sustainable Production concepts to local small and medium sector manufacturing organizations thereby to brand even the product they manufacture as eco designed eco friendly products and to have economic sustainability as well. Keywords: Sustainable Consumption and Production, Traditional manufacturing, Sustainable Manufacturing
Introduction The history of manufacturing industry goes back to many centuries. There is famous folk tale that at the time of Ariyans settled in the Island way back in 200 BC, aboriginical people had technology to spinning cotton yarns. Even there are some evidence that metal-based manufacturing industry was evolved over the centuries after Ariyans settled in the island over the centuries and there are number of metal based products belongs to Anuradapura era (200 BC to 900 AD) can be seen in local Museums. This further reinforced by the facts found by Jill Juleff [1] that wind based steel smelting was available in 11th century in Sri Lankan and south Asian region. In fact there are some evidence that these steel was used for world famous Damascus swords according to ancient literature found in Middle East states. Over the centuries, some of these traditional manufacturing industries have been evolved and survived. After western invasions in 15th century, some of these industries switch to new product ranges with new techniques brought by the westerners (Batic fabric industry, Traditional Laze industry etc.) However, according to Cumaraswamy’s famous findings [2] of traditional art and craft on Singhalese (native people of Sri Lanka) during the late 1800s, operated with many difficulties due to the economical, socio-cultural changes taken place during late 1800s and early 1900 when British’s were ruling the island. With the rapid globalization and especially
after opening its economy, Sri Lankan traditional manufacturing industry (TMI) had to face double blow with cheap yet good quality products arrived from other nations in early 1980s. Due to the market pressure, some of these industries succumbed and few of them managed to survive over the years with less modernization and currently contribute about 16% for the local manufacturing sector. When inquired deep into these industries, it can be easily recognized that main reason for their survival with the same issues face with modern day manufacturing industries, is the sustainable consumption and Production practices (SCP), though they do not know about that as a concept which is emerging in western world. Conversely, modern manufacturing industries currently facing many problems for their own sustainability from all three directions: economical, social and environmental. As a way forward, some manufacturers already moving towards sustainable manufacturing direction and some even establish new plants or have changed their manufacturing plants to match with sustainable built environment (SBE) [3] and some already converting the hydrocarbon based energy sources to biomass and renewable energies. Although there are some researches already carried out in Sri Lankan manufacturing sector in the direction of the sustainable manufacturing [4, 5, 6 and 7] in recent past, it is very rare to find any research work carried out in Sri Lankan traditional manufacturing industry in SCP or SM directions. Therefore, it is a need of hour to investigate how traditional manufacturing industries evolved and survived with SCP concepts over the years in Sri Lanka so that these concepts can be taken as lessons for the modern manufacturing industries at the high time where industries driving towards sustainability. Therefore, this research focus on investigation the SCP concepts practiced in local traditional manufacturing industries and how they survive with current issues such as resource scarcity, environmental and social issues as well as economic issues as well and to identify probable methodologies to adapt SCP concepts in modern manufacturing industries. The rest of the paper is arranged as follows; section 2 presents the methodology of the research been carried out while section 3 is dedicated to present the case study and the results. This is followed by the discussion and conclusion. Methodology The methodology used for the research consists of three-fold approach. In the first fold, design was established to collect information and data of the TMIs. The main challenge at this stage was to to put down a comprehensive model, which could contain all probable SCP concepts based on [8]. It is somewhat difficult to find generic models specifically developed to evaluate manufacturing plants potential sustainability options in literature. However, there are number of studies done with respect to the sustainability options in product design and development stage [9. 10, 11]. Their main focus was to define a product sustainability index by considering sustainability options in three different bottom lines of sustainability; economics, social and environmental aspects. However, when local manufacturing industry is concerned, it is very harder to see any organization has their own systematic product design and development process and some are dependent on the designs given from foreign business partners. Therefore, even though the model proposed in [10] is comprehensive, we cannot use straightaway for our own evaluation of plants. Since there is no popular standard model, development of such a model was useful as well. This was developed by going along the triple bottom lines of sustainability: Economical, Social and Environmental. The well-known SCP concepts and sustainable manufacturing concepts (SM) were clustered under these three lines, along with different phases of the business: pre-manufacturing, manufacturing, product inherent characteristics and post manufacturing phases. In the premanufacturing phase, focus was given to selection of raw material, planning of the business, order/market driven manufacturing, and search for other resources such as availability of raw material close-by, labour availability issues. In manufacturing phase, type of processes, energy
sources used, workstation design, ergonomics, health etc. considered. Eco design, type of raw material used, product design related aspects along with market specific information were considered in product related phase. The market based issues such as supply demand, user related considerations such as safe for use and product quality and functional efficiency related aspects as well as disposability related characteristics were taken in to account. The generic model developed for the research is given in Table 1. A comprehensive questionnaire was developed based on above metrics, for the data collection purpose. The site visits were carried out to complete questionnaires. In addition to above factors, basic information of the industry such as, product range, market segment, number of employees etc. also noted down during the site visits. Further, need analysis was done for these industries mainly to further sustain on three sustainability bottom lines.
Figure 1: Schematic representation of the methodology
Industry Focus
Social Economical
Sustainability Focus
Environmental
Pre-Manufacture
Manufacturing
Receiving form of raw material
Source of energy use in the process.
Consideration of raw material regeneration Resource efficiency
Day light usage Natural ventilation Power driven machineries and hand driven machineries. Avoid technologies that generate hazard waste
Usage of recycle material
Design for social needs
Ergonomics in Workstation and Process design
Identifying the market requirement
Maintaining quality requirement of products
Product design for durability
Consideration of job security of workers
Training new generation
Health and safety in work Welfare of the workforce Employment for local community Provide by products /waste for locals Ergonomics in workstation design
Raw material receiving form (Waste min.) Local Raw material usage Adequate storing quantity (cash flow) Supply demand concept
Energy saving options Reduce packaging Appropriate technology usage (eco & quality) Flexibility of process (product variation)
Tendency to use new technologies
Reluctance to adapt new user friendly tech.
Product
Post-manufacturing
Environmental friendly products Adaptation of eco design concepts Product Life Cycle Analysis
Product disposability
Product quality enhancement
Easiness for usage
Product reusability Product recyclability
After sales service User safely conscious Product customization for different requirements Concern on culture and religious issues when designing product & selection of raw material Ergonomics of the product
Health and safety of users
Customer loyalty/faithfulness
Table 1: Generic sustainability options available in different phases with respect to sustainability triple bottom lines
Case study, analysis and Results A case study was carried out by considering traditional manufacturing industries fall into three main categories: metal based, wooden industry, pottery sector. Number of industries of the three categories was evaluated based on the SCP guidelines shown in the Figure 2. The information were collected by field visits. Due to the time constraints, only three districts: kandy, Kegalle, Polonnaruwa were selected for the case study. According to Cumaraswamy [2] these districts, were famous for traditional manufacturing as far as in early 1900s. The overall adaptations of SCP concepts within three industrial sectors were initially analyzed and the overall adaptations are shown in Figure 3. Further, main drivers behind adaptation or usage of SCP concepts and barriers for continuation and or implementation have also investigated along with the survey during the field visit and the outcomes are presented in summarized form in Figure 4.
Environmental
Social
Economical
90.0%
Sustainability Adaptation %
80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Metal Based Industry
Woodcraft Industry Industries
Pottery Industry
Figure 3: Level of adaptation of sustainability concepts in three main traditional industrial sectors
When three industrial sectors are concerned, it can be seen that, all of them are equally perform Sustainability options with respect to overall evaluations. However, each sustainability bottom lines are concerned; metal-based industries have fewer performances with respect to social aspects. The woodcraft industries shown higher percentage in social aspects than economical and environmental aspects. The pottery industry shows least percentage with respect to social aspects among the three industry categories. The metal-based industries show higher percentage of economical aspects while woodcraft industries show least values in environmental aspects.
5 Economic barriers/Restrictions
1 Lack of awareness of the concepts/benefits 30% 25% 20% 15% 10% 5% 0%
4 limitations of the related area
2 Less focus
3 Cultural & religious issues
(a)
6 Government support
1 Concern on the environment 30% 25% 20% 15% 10% 5% 0%
5 Traditional technology
2 As a support to people/social responsibility
3 Cultural & religious issues
4 Economic benefits
(b) Figure 4: Drivers (a) and barriers (b) for adaptation and continuation of SCP concepts When motivational and barriers for sustainability options implementation are concerned, highest percentage was given in lack of awareness category and followed by lack of focus on SCP concepts. Cultural issues and none-relevancy to the specific industry was shown moderate percentages and economic barriers or restrictions for go for SCP shown the least percentage among the others. When motivating factors are concerned, economic benefits, as a social responsibility and due to religious and beliefs related comments scored highest percentages while assistance from government to
implement these concepts shown least percentage. Concern on environment and traditional technology related aspects shown moderate results. Finally, level of adaptation of sustainability concepts falling into triple bottom lines of traditional manufacturing industries were compared with the modern Sri Lankan manufacturing industries subdividing into three groups: Apparel, FMCG and Heavy industrial sectors. In addition to investigating the adaptation of SCP in the traditional manufacturing industries, similar type of work carried out in the modern industries as well. Later these two types of industrial sectors were compared to recognize the most importantly the probable sharing factors between the two types. This information is given in Figure 5. Though there are more detailed analysis done when modern manufacturing industries are concerned then in traditional industries, when percentage adaptations are concerned based on the sub-categories are considered, traditional industries shows better results than the modern once. This justified that our original plan to extract SCP concepts already established with TMIs is valid. If there is a serious concern on this, there is number of social, environment as well as few economic related sustainability factors can be easily implemented in modern manufacturing sector as well.
Sustainability Adaptation of Modern Industries Sustainability Adaptation of Traditional Industries 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Garment & Synthatic Fiber
FMCG
Heavy & Assembly
Traditional Industries
Figure 5: Variation of level of sustainability adaptation in modern and traditional manufacturing industries
Discussion and conclusion Based on the above results it can be seen that still there is much opportunities available in TMI to extract SCP concepts to the modern industries mainly in the environmental and social aspects. When reasons behind adaptation or continuation of SCP’s are concerned, there are significant influence from cultural and religious values of the country may be there is a considerable impact of Buddhist philosophy lasted for nearly last 2600 years. There may be significant impact between
Buddhist values and SCP concepts. This is more relevant in the sub categories of social and economic aspects. However, further research is necessary to carried out in future to develop new models, which can be used to convey modern industries to adapt SCP concepts in future.
Acknowledgement Authors would like to acknowledge the assistance given my Mr. B. Wijesinghe of Archeological Department of Sri Lanka and International Research council (InRC) of University of Peradeniya for providing partial funding as a travel grant. Finally, all the traditional industrialists who contributed positively, during the field visits and for Mr. I.M.S.S Jayatissa for assisting in the field visits.
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