© 2007 dornfeld/uc berkeley draft sustainable design and manufacturing: can we “engineer our...

© 2007 Dornfeld/UC Berkeley DRAFT

Sustainable Design and Manufacturing: Can we “Engineer our way” to a

Sustainable Future?

David DornfeldWill C. Hall Family Professor of Engineering

University of CaliforniaMechanical Engineering Department

Berkeley CA 94720-1740

Laboratory for Manufacturing And Sustainability (LMAS)


Outline

• Defining sustainability• Sustainability in an engineering context• Sustainability in a manufacturing context• Summary and tasks


So…what does sustainable mean?

One good definition of sustainability-

"an economic state where the demands placed upon the environment by people and commerce can be met without reducing the capacity of the environment to provide for future generations.....your business must deliver clothing, objects, food or services to the customer in a way that reduces consumption, energy use, distribution costs, economic concentration,soil erosion, atmospheric pollution, and other forms of environmental damage. Leave the world better than you found it."

From Paul Hawken, The Ecology of Commerce, Collins, 1993, p. 139.


Then…what does sustainable require?If you are presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands ofthe future. This is a net zero impact.

If you are NOT presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands ofthe future by reducing the environmental load/unit of commerce to offset any increase in unit production so as to achieve a sustainable state overtime.

That is, in the words of Hawken, your business must deliver clothing, objects, food or services to the customer in a way that reduces consumption, energy use, distribution costs, economic concentration,soil erosion, atmospheric pollution, and other forms of environmental damage at a rate greater than the normal growth in consumption would require. Business must have a “net positive impact.”


Sustainability Frame of Reference

Required Consumption Rateto reach Sustainability

Today Future

Rat

e of

Con

sum

ptio

n*

Sustainable rate

Consumption with

increased efficiency

Consumption at

“today’s rate”

How do we achieve this “slope change”?

•Any resource: energy, material, water,air …


Mind the gap!Responses to the situation

Time Scale Response Drivers

Short regulations (green buildings gov’t/EU marketEnergy Star, CAFÉ, etc.) driven

Medium alternate energy, hybrids, H2, resource limits andphotovoltaic long range market

Long tools to engineer sustainable change of approach,systems, life cycle env costs holistic view of effectsincluded in product cost


Think Global - Act Local

Design and Manufacturing - think supply chain…act process

Is the process - coupled? - decoupled?

with respect to environmental impacts (materials, energy required, consumables, waste generated)


Think supply chain…act process

Questions:

- Can you improve the process/product withoutaffecting up/down stream processes/products?

- If you cannot…what is the impact on adjacent elements?- What are the “closed loop” parts of the design or process?

Process1 Process2 Process3 ProcessN…


More details

Let’s define the terms more specifically wrt manufacturing…


Closed Loop Manufacturing: Renewing Functions while Circulating Material

Ref: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655

Source: T. Tani, “Product Development and Recycle System for Closed Substance Cycle Society,” Proc. Environmentally Conscious Design and Inverse Manufacturing, 1999, 294-299.


Closed Loop Manufacturing: Renewing Functions while Circulating Material

Source: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655

• Each orbit in the figure corresponds to a life cycle option, such as prolonged use by means maintenance, product reuse, part reuse,recycling, and energy recovery.

• To realize “closed-loop manufacturing” the product life cycle should be managed by selecting proper life cycle options.

• In selecting life cycle options, need to consider the environmentalperformance or “eco-efficiency” of the option…defined as the ratioof provided value to environmental load.

• The closer the “loop” is to the user…the lower the load on the environment.


After Ishii, K., "Incorporating End-of-Life Strategy in Product Definition," Invited paper, Eco Design '99: First International Symposium on Environmentally Conscious Design and Inverse Manufacturing, February 1999, Tokyo, Japan.

Product design, manufacturing and recovery

Detail design

ManufacturingProductdefinition

End-of-life

Recycling organizations

Process selection/development

DFE

LCA

DFA

All includedin Sustainability


Green Machines

Clean PowerGreen

ManufacturingProcesses

Green Products

“Ecofacturing*” or “Ecomanufacturing**”

Source: * TM Taiheiyo Cement, Japan**IGPA Newsletter, Dec. 2003

Closer Focus on Manufacturing


Evolution of Production Paradigms

Source: F. Jovane, et al, “Present and Future of Flexible Automation: Towards New Paradigms, CIRP Annals, 52, 2, 2003, 543.

Green…yes…but…isthis really sustainable?


Key transitionsWhat’s needed to make the last transition?

Automation“F. W. Taylor”

Computer Aided Manufacturing (CAM)

“M. E. Merchant”

Lean Manufacturing“Toyoda, et al”

Positive Impact Manufacturing


Key to each transition- the enabler

Break complex tasks into elements;

organization and control

Move non-essentialelements outsideproductive time

Minimize working capital(cost of lack of quality)

Include whole life cycle cost of environmental impact


Dimensions of design, manufacturing and environment

design(functionality,complexity,life)

production/distribution(quality, yield, throughput, flexibility/lean)

environment

(energy, consumables, waste, hazards, end-of-life)

co$t


So….what do we learn from all this?• Think globally…act locally!

think corporate…..act departmentally!think department…act system!think system…act process!think process….act machine!think machine…act tool! (ok…ok…point made)

• Waste, of any resource (time, money, energy, space,consumables, etc.) costs…..eliminate waste (followDeming!)

• Make the business case for sustainable manufacturingby including life cycle cost of environmental impact

• Include your suppliers/distributers in this through the design process

• Need analytical/engineering tools (design/process plan) to enable decisions/tradeoffs


How do we respond as engineers?• Make sure we evaluate the “real” impact of our technical solutions

in terms of how much of the “gap” we are removing (i.e. howmuch is a particular technology “wedge” going to reduce the gap?*) OR design our technical solutions to have the largest impact on the gap.

• Make the business case for sustainable manufacturingby including life cycle cost of environmental impact (the “true cost” of the product including the ‘environmental capital’)

• Include the supply chain in this through the design process• Develop analytical/engineering tools (design/process plan) to

enable decisions/tradeoffs based on life cycle costs…ie EnviroCAD

• Make sure to include our social science/policy friends in the discussion as there will be “side effects”

• Capitalize on the technology innovations as entrepreneurs• Educate…educate…educate

•Ref. S. Pacala and R. Socolow, "Stabilization Wedges: Solving the Climate Problem for the next 50 •Years with Current Technologies," Science, August 2004, Vol. 305, pp. 968-972.

© 2007 dornfeld/uc berkeley draft sustainable design and manufacturing: can we “engineer our...

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