Industrial Symbiosis

Greening processes, systems and products for

sustainable manufacturing
David Dornfeld
Chair, Department of Mechanical Engineering
Will C. Hall Family Professor of Engineering
Director, Laboratory for Manufacturing and Sustainability
University of California, Berkeley, CA

e-mail: dornfeld@berkeley.edu; web: lmas.berkeley.edu

blog: http://green-manufacturing.blogspot.com/
 Major Opportunities
• All future energy, transport, medical/health, life style,
dwelling, defense and food/water supply systems based on
increasingly precise elements and components
• Manufacturing for an energy and environmentally aware
consumer (autos, consumer products, buildings, etc.)
• Manufacturing alternate energy supply systems
• Machines/systems using less energy, materials, and space
• Efficient factory operation
• Minimize risk
• Comply with government regulations
These can all drive competitive advantage …
and save energy/materials/resources

Laboratory for Manufacturing and Sustainability © 2011

 Symbiosis

Industrial symbiosis can be defined as sharing of services,

Fundamental Issue
utility, and by-product resources– Effective and industrial
among diverse efficient
actors in order to add value, reduce costs and improve the
utilization of resources
environment. (Source: Wikipedia; accessed 10/23/11)

Source: Ricoh, http://www.ricoh.com/environment/management/concept.html, accessed 10/21/11

Laboratory for Manufacturing and Sustainability © 2011

 Sustainability frame of reference

“Technology Wedges”
Consumption or
Impact
Rate of

Sustainable rate

Today Future
Source: after Pacala, S., and Socolow, R. (2004), “Stabilization Wedges: Solving the Climate
Problem for the Next 50 Years with Current Technologies,” Science, 305: pp. 968-972.

Laboratory for Manufacturing and Sustainability © 2011

 Product “life-cycle”
- focus on manufacturing -
All phases are important and
impact manufacturing!

Manufacturing

Laboratory for Manufacturing and Sustainability © 2011

 Effects at different scales
Enterprise

Facility

Line/system

Machine

Tooling/setup
www.caranddriver.com/features/7207/virtual-tour-of-vws-transparent-factory.html
Process
www.remmele.com/flash/contractManu/pca.html

Laboratory for Manufacturing and Sustainability © 2011

 Greening…effects at different scales

Machine Operation
(Build/Run) (Macroplan)

Process System
(Microplan) (Factory)

Laboratory for Manufacturing and Sustainability © 2011

Greening…system performance tracking/optimization

1 2 3 4 5 6 7 N

Synchronous cycles
Power

Asynchronous cycles

time
• Energy “load balancing” over line/system
• Energy “load balancing” over plant
• Resource/consumable optimization

Laboratory for Manufacturing and Sustainability © 2011

 Greening…multi-process machine?

drill + turn + vertical mill + horizontal mill

Is one better than the other

from an energy point of view?

drill + turn + mill

• One machine with extended capability to replace
several individual machines; for example,
milling + drilling + turning “mill-turn”

Laboratory for Manufacturing and Sustainability © 2011

 Production Planning
Investment Operating
Quality Efficiency
cost cost

Energy use

Water use

Waste

GWP

Source: Machsources.com; accessed 3/2011

Laboratory for Manufacturing and Sustainability © 2011

 Conclusions
• Energy, green manufacturing and related issues are a big
opportunity for industry/manufacturing
- new products/services/market leadership
- better overall performance/lower CoO
- more competitive, reduce risk
- repond to growing regulatory environment
• Aggressively use symbiosis, energy recovery/storage
• Including energy and green manufacturing aspects can be
part of a successful sustainable business strategy
• This requires careful analysis and development of metrics
and CAD tools for process/machine/system/enterprise
• The problem is too large for individual companies
to solve - must be a cooperative effort among industry,
associations, researchers, government

Laboratory for Manufacturing and Sustainability © 2011

 Thanks for your attention!
Follow-on questions, comments, suggestions?

Feel free to contact me:

e-mail: dornfeld@berkeley.edu
web: lmas.berkeley.edu

blog: http://green-manufacturing.blogspot.com/

Laboratory forforManufacturing
Laboratory Manufacturing and Sustainability© ©
and Sustainability 2009
2011