Author :Dr. Kruthika Rajan
Abstract :Hybrid manufacturing lines—particularly those integrating laser cladding, precision milling, and automated inspection—present complex and interdependent flows of energy, materials, and emissions. These flows are typically non-linear and vary widely with process parameters such as re-clad depth, machine state transitions, and energy source fluctuations. To quantify and analyze these real-time variabilities, we present a novel integration of line-side programmable logic controller (PLC) data with internationally recognized emission benchmarks, specifically ISO 14067 standards for product carbon footprinting. Our approach enables high-resolution, second-level carbon footprint dashboards that reflect the instantaneous environmental impact of each machining operation. These dashboards fuse process-specific energy metrics (e.g., spindle power, gas flow, thermal cycles) with dynamic emission factors, allowing for transparent and time-synchronized carbon tracking throughout the production lifecycle.
A pilot deployment on a turbine blade remanufacturing cell revealed significant insights: the carbon footprint per part exhibited a variance of ±12%, primarily driven by differences in re-cladding volume and energy consumed during post-processing. Such fine-grained carbon accounting not only enhances environmental transparency but also enables data-driven decisions in procurement and supplier evaluation. Specifically, the variability captured in per-part emissions provides a robust foundation for implementing dynamic eco-supplier rating systems, where vendors can be ranked and rewarded based on verified real-time sustainability performance. This framework demonstrates how hybrid manufacturing environments can transition from static environmental reporting to live, actionable insights that drive greener and more accountable production strategies
Keywords: Carbon footprint; Hybrid machining; PLC integration; Sustainability dashboard; Turbine repair
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