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<p>The increasing importance of sustainable development has forced manufacturing companies to switch from traditional production methods to more environmentally friendly ones. However, existing green manufacturing studies often address isolated aspects such as energy efficiency or waste reduction, lacking an integrated and implementation-oriented framework, particularly for small and medium-scale enterprises (SMEs). This study proposes a holistic green manufacturing framework for automotive component manufacturing that integrates carbon emission reduction, energy optimization, waste minimization, eco-friendly material adoption, and Industry 4.0–enabled smart manufacturing tools. A systematic literature review (2016–2025), combined with expert validation and case-based performance evaluation, was employed to the identify critical practices and assess their effectiveness. Results of this study indicates that the adoption of optimized machining strategies, i.e., circular manufacturing practices, and digital enablers such as energy-aware CAM and digital twins can demonstrates carbon emission reductions in the range of 15–35%, which is based on validated case-study evidence and comparative analysis with recent industrial benchmarks, energy consumption savings of 10–25%, and material waste reduction of up to 40% across selected automotive manufacturing processes. The substitution of lightweight and environmentally friendly materials results in additional life-cycle CO₂ reductions of about 50&#xa0;kg per component in the representative scenarios. The novelty of this work reflected by the development of an integrated, SME-oriented green manufacturing framework that simultaneously addresses emissions, energy, materials, and digitalization—an aspect insufficiently explored in prior green manufacturing assessments. The proposed framework offers practical guidance for industry practitioners and policymakers seeking scalable and data-driven pathways toward sustainable automotive manufacturing. Future research directions include policy integration, digital adoption challenges, and cross-sector validation of the proposed framework.</p> Graphical abstract <p></p>

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Minimizing carbon emissions, energy consumption, and waste in manufacturing: a green manufacturing approach

  • 期刊论文

  • 发表日期：

    2026年6月17日

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  • Jagdeep Singh,
  • Kanwaljeet Singh Khaira

摘要

The increasing importance of sustainable development has forced manufacturing companies to switch from traditional production methods to more environmentally friendly ones. However, existing green manufacturing studies often address isolated aspects such as energy efficiency or waste reduction, lacking an integrated and implementation-oriented framework, particularly for small and medium-scale enterprises (SMEs). This study proposes a holistic green manufacturing framework for automotive component manufacturing that integrates carbon emission reduction, energy optimization, waste minimization, eco-friendly material adoption, and Industry 4.0–enabled smart manufacturing tools. A systematic literature review (2016–2025), combined with expert validation and case-based performance evaluation, was employed to the identify critical practices and assess their effectiveness. Results of this study indicates that the adoption of optimized machining strategies, i.e., circular manufacturing practices, and digital enablers such as energy-aware CAM and digital twins can demonstrates carbon emission reductions in the range of 15–35%, which is based on validated case-study evidence and comparative analysis with recent industrial benchmarks, energy consumption savings of 10–25%, and material waste reduction of up to 40% across selected automotive manufacturing processes. The substitution of lightweight and environmentally friendly materials results in additional life-cycle CO₂ reductions of about 50 kg per component in the representative scenarios. The novelty of this work reflected by the development of an integrated, SME-oriented green manufacturing framework that simultaneously addresses emissions, energy, materials, and digitalization—an aspect insufficiently explored in prior green manufacturing assessments. The proposed framework offers practical guidance for industry practitioners and policymakers seeking scalable and data-driven pathways toward sustainable automotive manufacturing. Future research directions include policy integration, digital adoption challenges, and cross-sector validation of the proposed framework.

Graphical abstract