Green Issues in Manufacturing

- Greening processes, systems and products

Ir. Aulia Ishak, MT, Ph.D/Tania Alda, ST, MT

Department of Industrial Engineering
Universitas Sumatera Utara
 Outline

• Background, motivation, drivers

• What is “sustainable” (or “green”)?
• What are the opportunities/challenges?
• What about manufacturing processes,
systems and machine tools?
 Why does industry care?
• Pressure from Government
– Regulations
– Penalties
– Tax benefits
• Interest in Efficiency/Reduced CoO
• Scarcity of Resources/Risk
• Continuous Improvement
• Pressure from Society/Consumers/Customers
• Pressure from Competitors
• Maintain Market Leadership
• Supply Chain Effects (what’s happening outside of
your facility?)
 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
• Machine tools using less energy, materials, and space
• Efficient factory operation
• Comply with government regulations
These can all be competitive advantages if addressed by the
machine and tool manufacturers and industry
 Let’s look at autos -
What kind of car are we building?
Chevy Volt

AIRPod

Nissan Pivo 2

“There isn’t going to be any part of the vehicle

that will remain untouched by the search for
better mileage.” Paul Lacy, IHS Global Insight

Source: P. Grier and M. Clayton, “Cars - The shape of a new industry,” Christian Science Monitor, June 28, 2009.
 What manufacturing technology will it rely on?

Chevy Volt

• More plastic - dies and molds production

• More “hybrid” technology (mixing
process requirements)
• Higher precision components (fuel efficiency
Nissan Pivo 2 and performance)
• Wider range of materials to machine
AIRPod
• Design/build for reuse, recycling, reman.
• Larger production volumes (?)
• Sustainable production
• More complex supply chains/distribution
• Sustainable supply chain
• Low “life-cycle costs” of operation

New materials - New energy sources - New processes - New business models
What does sustainable mean?
Green manufacturing is a first step towards sustainability

“Sustainable manufacturing is defined as the creation

of manufacturing products that use materials and
processes that minimize negative environmental
impacts, conserve energy and natural resources, are
safe for employees, communities, and consumers
and are economically sound.”

Adapted from the Department of Commerce Definition

Brundtland Commission, i.e. World Commission on Environment and

Development (WCED), 1983
 Ricoh “comet circle”
- an excellent visualization of the green supply chain

economy

environment society

- The Comet Circle represents a sustainable society; tighter circles - more sustainable
- Circles indicate partners we work together with to achieve a sustainable society.
- The upper and lower routes represent the upstream and downstream supply chain
- Resources taken from the natural environment at the upper right are processed into products
- The end-of-life products move from left to right along the lower route.
Source: Ricoh, 1994; http://www.ricoh.com/environment/management/concept.html; accessed 6/29/09
Source: D. Dornfeld, Path of Precision - Machine Tools and the Products they Make, Mori Seiki, 2008.
 Sustainability frame of reference

“Technology Wedges”
Consumption or
Rate of

Impact

Sustainable rate

Today Future
How do we achieve this?
Wedge Technologies
 How do we define sustainability?

• Global warming gases emission (CO2, methane CH4,

N2O, CFC’s) Measuring progress - return on investment (ROI)
• per capita
or similar concepts of:
• per GDP
• per area/nation
• greenhouse gas return on investment (GROI)
• Recyclability • energy payback time
• Reuse of materials • water (or materials, consumables) payback time
• carbon footprint
• Energy consumption • efficiency improvement (for example, wrt exergy)
• Pollution (air, water, land)
• Ecological footprint - “fair share”
• Exergy (available energy) or other thermodynamic measures
Metrics - measuring where we are
and where we are going
Dimensions of design, manufacturing and environment

co$t
design
(functionality,
complexity,(energy, consumables, waste mass,
life) waste, hazards, end-of-life) materials, and
resources

production/distribution
energy
(quality, yield, throughput, flexibility/lean)
(sp. energy x vol)

MRR
(production time)
 Opportunities for improvement
Improve manufacturing process

Technology
1
Cost
Cost
issue Improve Improve issue
energy material
efficiency Green efficiency
manufacturing
system triangle

2 Reduce
embedded
3
Energy energy Material
Use clean Use lower impact
energy materials
sources

Cost issue
Ref: Chris Yingchun Yuan, LMAS Presentation, 2009
 Look how far we’ve come
Key to each transition

Automation
“F. W. Taylor”
Break complex tasks
into elements; control

Move non-essential
elements outside
Computer Aided productive time
Manufacturing (CAM)
“M. E. Merchant”
Minimize working capital
Lean Manufacturing Include whole life cycle cost
“Toyoda, et al” of environmental impact,
After: F. Jovane, et al, “Present and Future of Flexible Automation:
Towards New Paradigms,” CIRP Annals, 52, 2, 2003, 543. externalities
 The “drivers”
Manufacturing Processes Machinery
Customer - plant/HVAC & Systems & Tooling
Competitor - cafeteria, HR, - energy - design
mgmt - water - setup
Society - packaging - materials - operation
Gov’t/Regs - shipping - consumables - maintenance
- other waste - compressed - other waste
air
- other waste

Repeat

Across the supply chain

 Supply Chain Impacts
(Depends on the product/process!)

Materials
Energy
Impact/Consumption

Water “upstream”
impact
GHG

Big reductions if
recycling/reuse
Big variation depending
on mfg supply chain(s)
 Product “life-cycle”
- focus on manufacturing -
All phases are important and
impact manufacturing!

Manufacturing
Strategies for greening manufacturing

• Create products/systems that use less material and

energy
• Substitute input materials: non-toxic for toxic,
renewable for non-renewable
• Reduce unwanted outputs: cleaner production,
industrial symbiosis
• Convert outputs to inputs: recycling and all its
variants (zero waste)
• Changed structures of ownership and production:
product service systems and supply chain structure
 Energy use in manufacturing
In Process Out
In Process Out
Process or
or
Machine
Machine
Embedded

Machine Tare

Energy modes

EP Production/ EP
operation
consumption

Production/operation
ET

consumption
Energy

Energy
Machine or process
“tare” consumption
ET
Machine or process “tare” consumption
Embedded Embedded

Time Time
 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”
Energy- multi-process vs individual machines
Embedded and process

Individual
machines
Potential
reduction
energy/part*

Multi-process
in energy
machine per part

Time saving
finished part
Time or process step

Multi-process Individual
machine machines

* Energy in materials and construction/transport and setup/operation + energy for operating for
specific part, including floor space and factory HVAC, etc.
Laboratory for Manufacturing and Sustainability © 2010
 Power demand vs cutting load

Conventional
machining
Precision/micro-
machining
Power demand

Variable

Machining

Constant (run time)

Spindle, jog, tool change etc.

Constant (startup time)

Computer, fans, coolant pump etc.

Load
For small loads (low chip load) most power
consumed by “non-cutting”
 Reducing the mass
- machine tool design affects energy consumption

Composite construction saddle and table

Component mass influences

tool path, machining time
Relative energy use for motion and energy consumption
with “stacked” axes
Source: J. Chien and S. Choi, “Design of Polymer Machine Tool for Reduced Energy Use,
MEC223 Project, 2009
Laboratory for Manufacturing and Sustainability © 2010
 Tool path effects

1200 2500
Process Time
Energy Demand
Tool path, for a machine
1000
2000 and process influences
machining time, energy
Processing Time (s)

Energy Demand (Wh)

800
1500 consumption and impact
600 (GHG)
1000
400
Pocket milling example
500
200 with differing tool paths
0 0 Source: S. Choi, et al., “Evaluation of Toolpath w.r.t. Precision
zigzag 0° zigzag 45° zigzag 90° constant true spiral and Environment,” ME290C Project, UC-Berkeley, Fall 2009.
overlap spiral

Laboratory for Manufacturing and Sustainability © 2010

 Enabling Energy Monitoring
Challenge: integrate energy data with the operational data from the machine

How much machine is consuming along with what it is doing

Source: System Insights, 2009

Laboratory for Manufacturing and Sustainability © 2010
Green Machine Design - Linking Design to
Sustainability
How about mass, stiffness, thermal conductivity or
thermal expansion/unit of primary water
consumption, or primary energy consumption?

equal consumption

Material C
or
Water consumption, equal property lines
energy consumption,
Material A Material E
or greenhouse gas
footprint
Material B

Material D

Thermal conductivity or thermal expansion

Laboratory for Manufacturing and Sustainability © 2010

 Manufacturing Sustainability Footprint
Social
Water Materials

better
New Design

Greenhouse
Economic
Gases

Existing
Design

Environmental Energy

Recycle/reuse
Laboratory for Manufacturing and Sustainability © 2010