Institute for Sustainable Manufacturing 1

Sustainable manufacturing

A (very) brief overview + evaluation matrix

Institute for Sustainable Manufacturing 2

• Sustainable materials (energy-efficient material design for manufacture: molecular, microstructural and metallurgical transformation of materials; self-healing materials and memory alloys)

• Sustainable product development (energy-efficient products; sustainability metrics for products; 6R-based product design for sustainability)

• Sustainable manufacturing processes (energy-efficient, environmentally benign manufacturing process development – toxic-free, hazardless, safe and secure technologies; minimal use of metal working fluids and chemicals; tribological interface science; coatings; surface and sub-surface integrity studies)

• Sustainable manufacturing systems (metrics for sustainability performance, ontology for interoperability of sustainable supply chains; sustainable quality systems; energy-efficient supply chain operations and manufacturing systems)

• Society, Public policy and Regulatory issues in Sustainable Manufacturing (Societal Impact studies; legislative and administrative issues; policy implementation; product and process liability; ethics)

• Sustainable service and health care systems (interdisciplinary work on the interaction between social systems and manufacturing systems)

• Economic analysis of sustainable products and processes (marketing strategies and business economics for sustainable products and processes)

Current Research Focus Areas

Institute for Sustainable Manufacturing 3

• Emphasis on all four product lifecycle stages

Manufacturing

Pre-manufacturing

Use

Post-use

Holistic and Total Life-cycle Approach

Institute for Sustainable Manufacturing 4

3R CONCEPT

6R CONCEPT

EMISSIONSWASTES

Closed-loop Material Flow – The 6R Approach

RAWMATERIALS

ENERGY

RAWMATERIALS

Source: Jawahir et al. (2006)

Institute for Sustainable Manufacturing 5

Sustainable Manufacturing(Innovative, 6R-based)

Innovation Elements

Remanufacture

Redesign

Recover

Recycle

Reuse

Reduce

Evolution of Sustainable Manufacturing

Lean Manufacturing(Waste Reduction-based)

Green Manufacturing(Environmentally-benign, 3R-based)

Traditional Manufacturing(Substitution-based)

Time1990 2000 20101980 2020 2030 2040 2050

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Institute for Sustainable Manufacturing 6

The creation of manufactured products that use processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and consumers and are economically sound

(US Department of Commerce, 2009)

Sustainable manufacturing includes:

(a) manufacturing of “sustainable” products, and

(b) sustainable manufacturing of all products.

The former includes:

manufacturing of renewable energy, energy efficiency, green building, and other “green” & social equity-related products,

and, the latter emphasizes:

sustainable manufacturing of all products taking into account the full sustainability/total life-cycle issues related to the products manufactured

(National Council for Advanced Manufacturing (NACFAM), 2009)

Sustainable Manufacturing: Definition

Institute for Sustainable Manufacturing 7

Three Major Focus Areas

Overall focus on holistic view and integration of sustainability issues at the product, process and system levels across all four life-cycle stages (pre-manufacturing, manufacturing, use and post-use) and considering all three sustainability aspects (environment, economy and society)

ProductsImproved metrics for product sustainability evaluation

Product design for sustaibnability

Case studies: Autobody sustainability, Suatainability evaluation in laser printers, Sustainable biomedical implants, DfS study of aluminum beverage cans

ProcessesMachining: Improved metrics for process sustainability scoring; Dry, near-dry and cryogenic machining; Improving surface integrity, and hence product life, through machining; Process modeling and optimization

Brazing: Experimental development of lead-free soldering; Modeling and optimization of wetting mechanics and joint formation

Friction stir processing and Super plastic forming: Experimental development of FSP to produce ultrafine grain materials for superplastic forming of sustainable, light-weight alloys; Process modeling and optimization

SystemsSustainable supply chains, and sustainable production and service systems

Improved metrics for evaluation of environmental, economic and societal impacts

Development of interoperability platforms for sustainable manufacturing

Institute for Sustainable Manufacturing 8

Fazleena BadurdeenSustainable Manufacturing Systems and Supply Chains

• Focus: Design and optimization of sustainable manufacturing systems and supply chains to improve economic, environmental and societal performance

• Emphasis:– Total product life-cycle (pre-manufacturing, manufacturing, use and post-use ) focus– Closed-loop material flow across the four lifecycle stages– Application of 6R’s for sustainable manufacturing

• Reduce, Reuse, Recycle, Recover, Redesign, Remanufacture– Multiple product life-cycle emphasis

• Research projects: – Next Generation sustainable supply chain modeling –

developing measurement systems and performance metrics– Risk analysis for sustainable supply chains– Coordinated sustainable product and supply

chain design for closed-loop flow– Sustainable supplier performance evaluation modeling– Product-service system modeling to increase sustainable value-added

1st Lifecycle

Recover

2nd Lifecycle

Recycle

Manufacturing

Use

Reduce

3rd Lifecycle & beyond

Reuse

Post Use

Pre-Manufacturing

Institute for Sustainable Manufacturing 9

Symbol

ScoreExcellent 85-90%

Good 70-84%

Average 50-69%

Poor < 50%

Pre-manufacturing Manufacturing Use Post-useScore

out of 10Score

out of 10Score

out of 10Score

out of 10

Material Extraction 7 Production Energy Used 7 Emissions 9 Recyclability 7

Design for Environment 8 Hazardous Waste Produced 9 Functionality 8 Remanufacturability 8

Material Processing 6 Renewable Energy Used 8 Hazardous Waste Generated 9 Redesign 7

Landfill Contribution 7

(%) PSI (en_pm) = 70 (%) PSI (en_m) = 80 (%) PSI (en_u) = 86.67 (%) PSI (en_pu) = 72.5

Worker Health 8 Work Ethics 7 Product Pricing 7 Take-back Options 7

Work Safety 8 Ergonomics 7 Human Safety 9 Re-use 6

Ergonomics 7 Work Safety 8 Upgradeablility 7 Recovery 7

Complaints 8

(%) PSI (so_pm) = 76.67 (%) PSI (so_m) = 73.33 (%) PSI (so_u) = 77.5 (%) PSI (so_pu) = 66.67

Raw Material Cost 6 Production Cost 6 Maintenance Cost 7 Recycling Cost 7

Labor Cost 3 Packaging Cost 7 Repair Cost 6 Disassembly Cost 8

Energy Cost 8 Consumer Injury Cost 8 Disposal Cost 4

Transportation Cost 5 Consumer Warranty Cost 7 Remanufacturing Cost 7

(%) PSI (ec_pm) = 45 (%) PSI (ec_m) = 65 (%) PSI (ec_pu) = 70 (%) PSI (ec_pu) = 65

(%) PSI pm = 63.89 (%) PSI m = 72.78 (%) PSI u = 78.06 (%) PSI pu = 68.06 (%) PSI TLC = 70.69

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Society

Environment

Economy 61.25

77.29

(%) PSI so = 73.54

(%) PSI ec =

Influencing Factors in the Product Life-cycle Stages

(%) PSI en =

Total Life-cycle Evaluation Matrix for Product Sustainability