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<p>The leather manufacturing sector faces increasing pressure to enhance sustainability while maintaining operational efficiency under strict environmental regulations. In a multi-product manufacturing system, the beamhouse operation is performed by Machine 1 in the first stage, followed by tanning with Machine 2 in the second stage and in the third stage, leather goods are produced using delayed differentiation on Machine 3. This study creates an integrated overtime-based multi-delivery optimization model that integrates rework management, hybrid delayed differentiation, zero-waste technologies, and effluent treatment. The model also embeds carbon cap-and-trade policies to account for emission-related costs and encourage cleaner production practices. The first stage and phase one of stage three provide partial subcontracting of standard components, while second stage restart manufacturing following repair, cutting down on replenishment cycle time and total system costs. By combining production postponement, controlled rework, and environmentally responsible waste handling, the proposed framework minimizes total system cost while reducing carbon emissions and wastewater impacts. Triangular Fuzzy Numbers (TFN) are used to represent the total anticipated cost function, which is constructed and shown to be convex, assuring optimum decision making under ambiguity. Optimal overtime choices, delivery schedules, and delayed differentiation tactics greatly increase cost effectiveness and environmental performance, as shown by analytical formulations and numerical trials.</p>

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Sustainable Process Integration and Production Optimization in Leather Manufacturing Considering Carbon Constraints and Operational Flexibility

  • 期刊论文

  • 发表日期：

    2026年6月27日

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  • C. Sugapriya,
  • L. DhivyaBharathi,
  • D. Nagarajan

摘要

The leather manufacturing sector faces increasing pressure to enhance sustainability while maintaining operational efficiency under strict environmental regulations. In a multi-product manufacturing system, the beamhouse operation is performed by Machine 1 in the first stage, followed by tanning with Machine 2 in the second stage and in the third stage, leather goods are produced using delayed differentiation on Machine 3. This study creates an integrated overtime-based multi-delivery optimization model that integrates rework management, hybrid delayed differentiation, zero-waste technologies, and effluent treatment. The model also embeds carbon cap-and-trade policies to account for emission-related costs and encourage cleaner production practices. The first stage and phase one of stage three provide partial subcontracting of standard components, while second stage restart manufacturing following repair, cutting down on replenishment cycle time and total system costs. By combining production postponement, controlled rework, and environmentally responsible waste handling, the proposed framework minimizes total system cost while reducing carbon emissions and wastewater impacts. Triangular Fuzzy Numbers (TFN) are used to represent the total anticipated cost function, which is constructed and shown to be convex, assuring optimum decision making under ambiguity. Optimal overtime choices, delivery schedules, and delayed differentiation tactics greatly increase cost effectiveness and environmental performance, as shown by analytical formulations and numerical trials.