Overcoming Six Obstacles in Transitioning to Green Manufacturing

Summary

Many automation and manufacturing experts feel motivated to transition to green manufacturing. However, several hurdles stand in their way. Fortunately, the most prominent have several solutions the sector can employ to gain the benefits of sustainable operations.

1. High initial investments

Green manufacturing requires a monumental mechanical and technological overhaul. Adopting a reliable renewable energy portfolio could require solar panels and backup geothermal assets. These come alongside energy-efficient machinery made with ethically sourced materials. Every light in the facility needs replacing as well. The list continues.

Two strategies will help stakeholders overcome the brunt of the frontload. First, companies can do cost-benefit analyses. Many adopt green, lean practices because they save money in the long term. Having clarity on how much businesses could save will keep teams motivated. Commercial solar had an 8% year-over-year growth in the United States in 2024. Even northern states like New York and Maine experienced growth. This demonstrates how much corporations believe they will benefit.

Second, government incentives and tax breaks ease purchasing decisions. Countless sustainable financial initiatives are available at federal, state and local levels to get manufacturers established.

2. Lack of technical expertise

The manufacturing sector is already experiencing a labor shortage. The influx of new technologies also creates knowledge gaps. The adoption of green skills has only risen by 60% despite the demand for green jobs going up 260%. Manufacturing is one of the most at-risk sectors. Stakeholders can mend these gaps by preparing their workers with specialized skills.

If a facility is unable to create or invest in proprietary training programs, it can outsource upskilling with green certifications and coursework. These will build the confidence employees need to work productively with eco-friendly tech.

3. Supply chain complexity

Stakeholders must communicate with partners in the supply chain to create consistency. Otherwise, there will be aspects of the manufacturing process that are not sustainable, compromising the reputation of everything after. For example, Amazon’s footprint has gone up by 40% since its net-zero commitment because of a rise in e-commerce.

Making eco-conscious commitments across the value chain is critical for preventing unnecessary spikes. It boosts transparency and traceability while forcing corporations to challenge other suppliers to adopt sustainable policies, too.

Overcoming complexity requires strict third-party evaluation guidelines and supplier diversity. Establishing long-term partnerships with those already implementing environmental transitions creates a community with like-minded entities.

4. Resistance to change

Manufacturers have worked with the same machines and procedures for decades, so they may be reluctant to change because they feel the alterations could disrupt workflow or change workloads. Challenging these established routines also risks people feeling like they have lost agency in their fields of expertise.

Mitigate this by involving employees in the green transition. Let them view the catalog of machines they can use and get their input on what would improve the company from a productivity and environmental perspective.

This makes them feel like they have ownership and authority, reducing resistance.

5. Regulatory compliance

Finding time to undergo auditing and implement changes is time-consuming. Small- to medium-sized
manufacturers may struggle more, as compliance can be costly. Finding out what rules to follow is also complicated, as they change frequently.

For example, rules regarding carbon emissions are emerging, and decarbonization efforts can help with adherence. The long-term goal of decarbonization is to eliminate carbon dioxide emissions resulting from human activity.

A sustainability compliance consultant can answer any preliminary questions, point stakeholders in the right direction and instruct them on how to stay up to date with critical regulations.

6. Performance measurement and reporting

Any green transition is laden with goal-setting and reporting to track progress. It is also vital for compliance. Taking accurate measurements and finding what key performance indicators to track could be difficult at first.
Thankfully, environmental management systems are out there to automate collection and visualization. Many also collate information into reports to help people find improvement opportunities. They are proven to support circular economies and support sustainable policy.

Bigger than the obstacles

Manufacturers can invest time and money into overcoming some of these obstacles in the next year. Even gradual implementation and green improvements are better than pushing them onto the back burner. After the business overcomes the challenge, then the rest will feel easier to beat.