1.

DEFINITION

The Brundtland Commission's report (1987) defined sustainable development as "development which
meets the needs of current generations without compromising the ability of future generations to meet
their own needs". Although this didnt speak to manufacturing, but the key words that require for
sustainability is do not harm. Manufacturing has traditionally been associated with undesirable
environmental side effects such as pollutions. It is necessary for the manufacturers to implement a
manufacturing strategy that integrates environmental and social considerations in addition to the
technological and economic.
Dr. Jawahir, I.S. (2008) define sustainable manufacturing is design and manufacture of
high quality/performance products with improved/enhanced functionality using energy-efficient,
toxic-free, hazardless, safe and secure technologies and manufacturing methods utilizing optimal
resources and energy by producing minimum wastes and emissions, and providing maximum
recovery, recyclability, reusability, remanufacturability, with redesign features, and all aimed at
enhanced societal benefits and economic impact.
Sustainable manufacturing is an integrated field of study that combines technical
feasibility with environmental responsibility and economic viability (Department of Mechanical and
Mechatronic Engineering and Sustainable Manufacturing, 2015). Sustainable manufacturing is the
pathway to re-establishing manufacturing as the main activity in the future clean economy, built on
the principles of sustainability. Sustainable manufacturing includes two main products: manufacturing
of sustainable products, and sustainable manufacturing of all products (NACFAM, 2009). The field
cover the manufacturing of renewable energy, energy efficiency, green building, and other green &
social equity-related products. Sustainable manufacturing of all products taking into account the full
sustainability/total life-cycle issues related to the products manufactured.
The main objective of sustainable manufacturing is to reduce the environmental impact
related to manufacturing. For example, U.S. National Institute for Standards and Technology (n.d.)
states that sustainable manufacturing is a systems approach for the creation and distribution (supply
chain) of innovative products and services that: minimizes resources (inputs such as materials, energy,
water, and land); eliminates toxic substances; and produces zero waste that in effect reduces
greenhouse gases, e.g., carbon intensity, across the entire life cycle of products and services.
In summary, sustainable manufacturing are economically sound since the process of
manufactured products can conserve energy and natural resources, minimise the negative environment
impacts, and safe for everyone (US Department of Commerces, 2015).

2.0

INNOVATION BASED MANUFACTURING ENGINEERING

In the manufacturing sector, innovation usually refers to: product innovation, the introduction of
innovative processes and equipment, often IT driven, and green technologies which reduce waste and
use consumables more efficiently (NIBIS, 2015). The benefits of innovation can comprise: greater
responsiveness to customer demands, faster turnaround times, reduced waste levels and downtime,
improved product design and quality, greater potential for a wider product range, streamlined
relationships with suppliers and customers (NIBIS, 2015).
There are many areas with opportunities for manufacturers to innovate. It can divide into
two major categories: strategy thinking and marketing strategy. For strategy thinking, it includes:
competent sourcing, materials technology, factory process control, equipment maintenance, stock
control and order processing, and logistics and warehousing (NIBIS, 2015). Component sourcing
involves new components, new suppliers or an improved deal with current suppliers could improve
the profits and product quality (NIBIS, 2015). Materials technology involve new materials that could
improve the products or their packaging and presentation (NIBIS, 2015). Factory process control
depends how to automate process control, including quality control, to give better efficiency and
products (NIBIS, 2015). For equipment maintenance, an automatic scheduling of maintenance will
ensure that equipment is kept running smoothly and comply with health and safety regulations
(NIBIS, 2015). Stock control and order processing which is constantly look for better ways to
streamline the order processing and stock control to ensure the right amount of stock (NIBIS, 2015).
Logistics and warehousing involves how to deliver the products to the customers by taking advantage
of new transport opportunities and keep warehousing costs to a minimum (NIBIS, 2015).
For marketing strategy, it involves the IT systems, accounting procedures, customer and
supplier relationship management, marketing, and design. IT systems must always keep up to date
with developments in the IT systems used by manufacturer (NIBIS, 2015). Accounting procedures
include accounting, invoicing and payments procedures should be streamlined with the stock control
and order processing and must updated regularly (NIBIS, 2015). Customer and supplier relationship
management is a valuable insights is gain into how to improve the products and their delivery from
the customers and suppliers (NIBIS, 2015). Innovative marketing strategies are also an important way
to set the products that manufacture apart from those produced by competitors (NIBIS, 2015). Design
is another process for designers help to develop new products and services, or redesign the existing
products to improve their functionality and client appeal (NIBIS, 2015).

2.1

Hard and Soft Technologies

Swamidass (2000) classify manufacturing technologies into hard and soft technologies. Hard
technologies are hardware and software intensive whereas soft technologies are manufacturing and
production know-how, techniques and procedures. The major difference between soft and hard
technologies is soft technologies are not necessarily hardware or software dependent (Swamidass,
2000, pg. 5). The example of soft technologies include concurrent engineering, bar codes,
manufacturing cells, JIT manufacturing, MRP, SQC, simulation and modelling, TQM, TPM, and so
on (Swamidass, 2000, pg. 4-5). The example of hard technologies are CAD, CAM, CNC machines,
CIM, FMS, automated inspection, robots, LAN, WAN, and so on (Swamidass, 2000, pg. 4). Some of
the innovation manufacturing technologies are explained for further understanding.

2.1.1

Concurrent Engineering

Concurrent engineering, also known as simultaneous engineering, is a long term business strategy,
with long term benefits to business (PTC, 2015). Concurrent engineering is a method of designing and
developing products, in which the different stages run simultaneously, rather than consecutively (PTC,
2015). It decreases product development time and also the time to market, leading to improved
productivity and reduced costs (PTC, 2015). Concurrent engineering can lead to three kind of
business benefits: competitive advantage, enhance productivity, decrease design and development
time (PTC, 2015).

2.1.2

Just-in-time (JIT) production

Just-in-time (JIT) production, also known as lean production, a type of innovation based
manufacturing, turns traditional manufacturing thinking beyond its limit. . JIT processes focus on
producing exactly the amount require by manufacturer at exactly the time the customers require,
rather than producing goods and supplying customers from stock (NIBIS, 2015). The main advantages
of JIT is can improve production efficiency and therefore competitiveness. The other benefits by JIT
are: preventing over-production, saving resources by streamlining the production systems, dispensing
with the need for inventory operations, minimising waiting times and transport costs, reducing the
capital that have tied up in stock, and decreasing product defects. However, implementing thorough
JIT procedures can involve a major renovate of the business systems, hence it may be difficult and
expensive to introduce. Besides, JIT manufacturing also opens businesses to a number of risks,
especially those together with the supply chain. With no stocks to fall back on, a minor disruption in
supplies to the business from just one supplier could force production to terminate at very short
notice.
3

2.1.3

Agile-, Quick Response- and Virtual Manufacturing

Another type of flexible and responsive manufacturing is agile manufacturing, quick response
manufacturing, and virtual manufacturing. Agile manufacturing is a term that has been coined to
indicate the use of the principles of lean production on a broad scale (Kalpakjian, 2001). For an
example, it has been predicted that the automotive industry could configure and build a car within
three days, and that eventually, the traditional assembly line will be replaced by a system in which a
nearly custom made car will be produced by connecting individual modules (Kalpakjian, 2001).
Virtual manufacturing refers to new manufacturing entities created through very rapid integration of
scattered resources in one or several firms (Swamidass, 2000, pg. 10). The rise of information
technologies and Internet fuels the growth of virtual manufacturing (Swamidass, 2000, pg. 10).

2.1.4

Total Quality Management (TQM)

A core definition of total quality management (TQM) describes a management approach to longterm
success through customer satisfaction (ASQ, n.d.). There are 8 primary elements of TQM, are
customer-focused, total employee involvement, process-centred, integrated system, strategic and
systematic approach, continual improvement, fact-based decision making, and communications (ASQ,
n.d.). Total quality management can be summarized as a management system for a customer-focused
organization that involves all employees in continual improvement (ASQ, n.d.). It uses strategy, data,
and effective communications to integrate the quality discipline into the culture and activities of the
organization (ASQ, n.d.).

2.1.5

Statistical Quality Control (SQC)

Statistical Quality Control (SQC) is the term used to describe the set of statistical tools used by
quality professionals (Improsys, 2010). SQC is used to analyse the quality problems and solve them.
Statistical quality control refers to the use of statistical methods in the monitoring and maintaining of
the quality of products and services (Improsys, 2010). SQC provides a means of detecting error at
inspection, leads to more uniform quality of production, improves the relationship with the customer,
reduces inspection costs, reduces the number of rejects and saves the cost of material, provides a basis
for attainable specifications, points out the bottlenecks and trouble spots, provides a means of
determining the capability of the manufacturing process, promotes the understanding and appreciation
of quality control (Improsys, 2010).

2.1.6

Material Requirements Planning (MRP) and Manufacturing Resource Planning

(MRP II)

Material requirements planning (MRP) and manufacturing resource planning (MRPII) are both
incremental information integration business process strategies that are implemented using hardware
and modular software applications linked to a central database that stores and delivers business data
and information (Monk, E. et al, 2006) . MRP is concerned primarily with manufacturing materials
while MRPII is concerned with the coordination of the entire manufacturing production, including
materials, finance, and human relations (Monk, E. et al, 2006). The goal of MRPII is to provide
consistent data to all players in the manufacturing process as the product moves through the
production line (Monk, E. et al, 2006). MRPII systems begin with MRP, material requirements
planning. MRP allows for the input of sales forecasts from sales and marketing. These forecasts
determine the raw materials demand (Monk, E. et al, 2006).
MRP and MRPII systems draw on a master production schedule, the breakdown of
specific plans for each product on a line (Monk, E. et al, 2006). While MRP allows for the
coordination of raw materials purchasing, MRPII facilitates the development of a detailed production
schedule that accounts for machine and labour capacity, scheduling the production runs according to
the arrival of materials (Monk, E. et al, 2006). An MRPII output is a final labour and machine
schedule. Data about the cost of production, including machine time, labour time and materials used,
as well as final production numbers, is provided from the MRPII system to accounting and finance
(Monk, E. et al, 2006).

2.1.7

CAD, CAE, and CAM

The constructing and studying analytical models is simplified through the use of computer-aided
design (CAD), computer-aided engineering (CAE) and computer-aided manufacturing (CAM)
techniques. CAD allows the designer to conceptualise objects more easily without having to make
costly illustrations, models, or prototypes (Kalpakjian, 2001, pg. 11). Using CAE, the performance of
structures subjected to static or fluctuating loads ad to varying temperatures can now be simulated,
analysed, and tested more efficiently, accurately and quickly than ever (Kalpakjian, 2001, pg. 12).
CAM involves all phases of manufacturing by utilising and processing further the large amount of
information on materials and processes collected and stored in the organisations database
(Kalpakjian, 2001, pg. 12).

2.1.8

CNC Machines

The CNC in CNC Machining means Computer Numerical Control. CNC Machining is a process used
in the manufacturing sector that involves the use of computers to control machine tools. Tools that can
be controlled in this manner include mills, lathes, routers and grinders. On the surface, it may look
like a normal PC controls the machines, however there is a unique software and control console are
inside the computer to set the system apart for use in CNC machining.
Under CNC Machining, machine tools function through numerical control. A computer
program is customized for an object and the machines are programmed with CNC machining
language (called G-code) that essentially controls all features like coordination, feed rate, location and
speeds (Ryan, 2009). With CNC machining, the computer can control exact positioning and velocity.
CNC machining is used in manufacturing both metal and plastic parts.
Firstly, a CAD drawing is created (either 2D or 3D), and then a code is created that the
CNC machine will understand. The program is loaded and finally the operator runs a test of the
program to ensure there are no problems (Ryan, 2009).This trial run is referred to as "cutting air" to
avoid any mistake with speed and tool position that could result in a scraped part or a damaged
machine.
There are many advantages to using CNC Machining. The process is more precise than
manual machining, and can be repeated in exactly the same manner over and over again (Ryan,
2009).. Because of the precision possible with CNC Machining, this process can produce complex
shapes that would be almost impossible to achieve with manual machining (Ryan, 2009). CNC
Machining is used in the production of many complex three-dimensional shapes (Ryan, 2009). It is
because of these qualities that CNC Machining is used in jobs that need a high level of precision or
very repetitive tasks (Ryan, 2009). Table 2.1 shows the advantages and disadvantages of CNC
machines.
Table 2.1: The advantages and disadvantages of CNC machines.
Advantages
CNC machines can be operated continuously 24 hours
a day, 365 days a year and only turn off for irregular
maintenance.
CNC machines are programmed with a design and

CNC

Disadvantages
machines
are

more

expensive than manually operated

machines,

although

costs

are

can then be manufactured hundreds or even thousands

slowly coming down.

The CNC machine operator only

of times. Each manufactured product will be exactly

needs basic training and skills,

the same with high precision and exact match.

Less trained/skilled people can operate CNCs unlike
manual lathes / milling machines which require
6

enough

to

supervise

several

machines. In years gone by,

engineers needed years of training

skilled engineers.
CNC machines can be updated by improving the

to operate centre lathes, milling

software used to drive the machines

Training in the use of CNCs is available through the

operated machines. This means

use of virtual software that allows the operator to

machines and other manually

many of the old skills are been

practice using the CNC machine on the screen of a

lost.
Less workers are required to

computer.
CNC machines can be programmed by advanced

operate CNC machines compared

design software such as Pro/DESKTOP, enabling

the manufacture of products that cannot be made by

to manually operated machines.

Investment in CNC machines can

manual machines, even those used by skilled

lead to unemployment.
Many countries no longer teach

designers / engineers.
Modern design software allows the designer to

pupils / students how to use

simulate the manufacture of his/her idea. There is no

need to make a prototype or a model. This saves time
and money.
A skilled engineer can make the same component

manually operated lathes / milling

machines etc... Pupils / students
no longer develop the detailed
skills required by engineers of the

many times. However, if each component is carefully

past. These include mathematical

studied, each one will vary slightly. A CNC machine

and engineering skills.

will manufacture each component as an exact match.

2.1.9

Computer-Integrated Manufacturing (CIM)

Computer-integrated manufacturing (CIM) is the use of computer techniques to integrate

manufacturing activities. According to the U.S. National Research Council, CIM improves production
productivity by 40 to 70 percent, as well as enhances engineering productivity and quality (Advameg,
2015). CIM can also decrease design costs by 15 to 30 percent, reduce overall lead time by 20 to 60
percent, and cut work-in-process inventory by 30 to 60 percent (Advameg, 2015). CIM is particularly
effective because of its capability and responsiveness to rapid changes in market demand and product
modification, better use of materials, machinery, and personnel, and reduction in inventory
(Kalpakjian, 2001, pg. 24). It also has a better control of production and management of total
manufacturing operation and high quality products at low cost (Kalpakjian, 2001, pg. 24). CIM play a
major role in manufacturing in application of Computer Numerical Control (CNC) machines,
Adaptive control (AC), Industries robots and so on. Besides, it is a major tool use in JIT, FMS, and
automated systems.

3.0

ELEMENTS OF SUSTAINABLE MANUFACTURING

There are many basic elements for sustainable manufacturing. However, all these basic elements must
work integrally to form the sustainable manufacturing. Fully integrated sustainable manufacturing
will become an effective platform for developing sustainable products from sustainable processes and
with related system integration. Developing the products, processes and systems is a significant aspect
of sustainable manufacturing to promote integrated sustainable manufacturing.

3.1

Basic Elements of Sustainable Manufacturing

The expectations of sustainable manufacturing (Jawahir, 2008, pg. 34):

3.2

Reducing energy consumption

Reducing waste
Reducing material utilization
Enhancing product durability
Increasing operational safety
Reducing toxic dispersion
Reducing health hazards/Improving health conditions
Consistently improving manufacturing quality
Improving recycling, reuse and remanufacturing
Maximizing sustainable sources of renewable energy

Integral Element of Sustainable Manufacturing

Developing innovative products, processes and systems is a significant aspect of sustainable

manufacturing, and it involves a holistic approach to manufacturing different from the traditional
manufacturing practices where the quality and performance characteristics are measured and
quantified independently, often without consideration of the effects of other integral elements. The
emerging holistic and integrated approach requires all stakeholders to work together on common
objectives with total commitment. To enable innovation in sustainable manufacturing, innovation
must be embraced at the product, process and systems levels with close interactions among each other.

Figure 3.1: Sustainable manufacturing at integrated product, process and system levels
Product sustainability: Consideration of a total and comprehensive evaluation of
product sustainability can lead to reduced consumer costs over the entire life-cycle of the product,
while the initial product cost could be slightly higher in some cases (Jawahir, 2013). This benefit is
compounded when a multiple life-cycle approach is adopted on the basis of continuous material flow
(Jawahir, 2013). The overall economic benefits and the technological advances involving greater
functionality and sustained quality enhancement are far too great to outscore with the current practice
(Jawahir, 2013). The technological and societal impacts are also significant. Recent research on
product sustainability evaluation shows a consistent trend towards the long-range development of a
product sustainability rating system for all manufactured products (Jawahir, 2013). This rating would
be expected to represent thelevel of sustainability built in a product by taking into account all major
contributing sustainability elements and their sub-elements (Jawahir, 2013). Early work shows the
following six product sustainability elements (Jawahir, 2013):

Environmental Impact
Societal Impact (Safety, Health, Ethics, etc.)
Functionality
Resource Utilization and Economy
Manufacturability
Products Recyclability/Remanufacturability
These interacting elements and sub-elements need to be fully studied for their effects on

product sustainability. Other influencing elements and sub-elements will be identified as appropriate.
This systematic study should provide a solid foundation for involving relevant priority roles and
trade-offs, when this project is extended to the next level (Jawahir, 2013). The preliminary work in
this area also considered ratings at all three levels (sub-element, element and overall).

Process sustainability: Manufacturing processes are many, and each of them depend on
the product being manufactured, method of manufacture, and their key characteristics, these processes
differ very widely (Jawahir, 2013). This makes the identification of the factors/elements involved in
process sustainability and the demarcation of their boundaries complex (Jawahir, 2013). The primary
objective of identifying and defining the various contributing elements and sub elements of
manufacturing process sustainability is to establish a unified, standard scientific methodology to
evaluate the degree of sustainability of a given manufacturing process (Jawahir, 2013). This
evaluation can be performed irrespective of product life-cycle issues, recycling, remanufacturability,
etc., of the manufactured product (Jawahir, 2013). For example, if the production process of a simple
component is considered, it goes through a few clearly defined production stages; component design,
tool/work material selection, metal removal/forming, finishing, packaging, transporting, storage,
dispatching, etc (Jawahir, 2013).
It is extremely hard to consider all of these stages in evaluating manufacturing process
sustainability although they may directly or indirectly contribute to the manufacturing process
sustainability. Besides, the processing cost largely depends on the method used to produce the
part/component and the work material selected (Jawahir, 2013). In a never-ending effort to minimize
the manufacturing costs, the industrial organizations are struggling to maintain the product quality,
operators and machine safety, and power consumption (Jawahir, 2013). If the processing includes the
use of coolants, lubricants, emission of toxic materials or harmful chemicals, this poses
environmental, safety and personnel health problems (Jawahir, 2013). In general, among the various
factors, the following six factors can be regarded as significant to make a manufacturing process
sustainable (Jawahir, 2013):

Energy consumption
Manufacturing cost
Environmental impact
Operational safety
Personnel health
Waste reduction
The motivation for recent sustainability studies of manufacturing processes comes from

recent efforts in developing a manufacturing process sustainability index (Jawahir, 2013). The idea in
developing this concept is to isolate the manufacturing process from the global picture of
sustainability, and to develop it up to the level of acceptance for common practice in industry
(Jawahir, 2013). The observations and the existing modelling capabilities can be used to model the
impact of the manufacturing process on contributing major sustainability parameters (Jawahir, 2013).
Models developed for manufacturing variables can be integrated for achieving optimized performance

10

(Jawahir, 2013). Finally, the optimized results can be used in defining the sustainability rating for the
specific manufacturing process with appropriate weighing factors (Jawahir, 2013).
Fully integrated sustainable manufacturing will become an effective platform for
developing sustainable products from sustainable processes and with related system integration
(Jawahir, 2013). Examples of establish innovative aspects in sustainable manufacturing are shown in
Figure 3.2 for each component of innovation (Jawahir, 2013). The innovation must enable developing
an integrated sustainable value system for sustainable manufacturing with many value-contributing
factors: value propositions such as socioeconomic value, technological value, socio-political value,
and socioenvironmental value can be derived from this integrated system (Jawahir, 2013).

Figure 3.2: Examples of innovative aspects in sustainable manufacturing at product, process and
system levels.
Source: Jawahir. (2013). Innovation in sustainable manufacturing education.

3.2.1

Sustainable Products from Sustainable Processes

As efforts continue to develop sustainable products and sustainable manufacturing processes, a recent
trend observed is to develop sustainable products from sustainable processes, thus enabling,
potentially, doubling environmental, economic and societal values of product manufacture (Jawahir,
2013). Case studies involving the use of sustainable machining methods such as dry, cryogenic and
minimum quantity lubrication (MQL) machining have been shown for producing functionally
superior machined products with significantly improved, product sustainability, in terms of

11

performance, quality and life (Jawahir, 2013). Figure 5 shows a schematic of activities involved in
producing sustainable products from sustainable processes.

Figure 3.3: Proposed methodology for producing sustainable products from sustainable processes
Source: Jawahir. (2013). Innovation in sustainable manufacturing education.

3.2.2

Sustainability Issues at the Systems Level

The transformation of raw materials into more sustainable products through sustainable
manufacturing processes requires careful coordination of various activities across and within the
organizations that span the closed-loop supply chain (Jawahir, 2013).
However, for sustainability improvement, manufacturing system and supply chain
design and operation must not only consider the behaviour of the socio-technical system, but also
integrate complexities of the interactions between the sociotechnical systems and the natural
environmental environment to minimize the unintended consequences (Jawahir, 2013).

Besides,

systems are adaptive and emergent entities characterised by various feedback and reinforcing loops
without a proper understanding of which can lead to catastrophic behaviours of these systems given
the complex contexts in which they operate (Jawahir, 2013). Thus, sustainable manufacturing systems
and supply chains must be designed and managed as integrated socio-techno-environmental systems
from a total life-cycle perspective by considering the interfaces and interactions among the different
sub-systems (Jawahir, 2013). Also, given the intractable nature of systems for sustainability, the
ability to think and communicate systematically, or systems thinking, becomes an important capability
12

that must be developed to increase the capability to design and manage such systems (Jawahir,
2013).The design protocol for designing such sustainable systems is shown in Figure 3.4.

Figure 3.4: Protocol for Sustainable System Design.

Source: Jawahir. (2013). Innovation in sustainable manufacturing education.
Recent advances in sustainable supply chain design that follows some aspects of the
approach have addressed coordinating the design of sustainable products and systems by considering
the social, economic and environmental implications of a variety of stakeholders; the time-variant,
adaptive behaviour of supply chains and implications on sustainability performance is also considered
(Jawahir, 2013). Developing tools such as sustainable value stream mapping (Sus-VSM) to assess the
socio-techno environmental aspects at the manufacturing systems level have also been presented
(Jawahir, 2013). The modelling risks due to negative and unintended influences of economic,
environmental and social implications from and on other interdependent systems (Figure 3.4) through
probabilistic Bayesian Belief Networks can provide methods to develop mitigations/interventions to
improve sustainability of manufacturing systems and supply chains (Jawahir, 2013).

4.0

6Rs APPROACH
13

The 6R name was inspired by work done at the University of Kentucky, Center for Sustainable
Manufacturing (6RBIO, 2014). The 6Rs are the innovative elements whose additive implementation
achieves sustainable manufacturing. 6R Manufacturing can be thought of as environmentally benign,
closed-loop manufacturing system that creates durable goods without negatively impacting the
environment. The 6R BIO product line is applicable to many industries, not just manufacturing, and
has the potential to be used effectively by many organizations.
There is a requirement to move beyond the traditional 3R concept which promotes green
technologies (reduce, reuse, recycle) to a more recent 6R concept to form the basis for sustainable
manufacturing (reduce, reuse, recycle, recover, redesign, remanufacture) at the product level.
There is a need to model and achieve optimized technological improvements and develop process
planning to reduce energy and resource consumptions, toxic wastes, and occupational hazards without
weaken the product quality or the manufacturing productivity at the process level. At the system level,
there is a need to consider all aspects of the entire supply chain, by taking into account all the major
life-cycle stages pre-manufacturing, manufacturing, use and post-use over multiple life-cycles
(Jawahir, 2008).

Figure 4.1: Closed loop Material Flow The 6R Approach

Source: I.S. Jawahir. University of Kentucky. Sustainable Manufacturing: The Driving Force for
Innovative Products, Processesand Systems for Next Generation Manufacturing.
The 3Rs is promoted through Green Manufacturing are (Kiritsis et al, 2011) are
Reduce, Reuse, and Recycle. Reduce primarily focuses on the first three stages of the product life
cycle and refers to the reduced use of resources or source reduction in pre manufacturing, reduced
14

use of energy and materials during manufacturing and the reduction of waster during the use stage
(Kiritsis et al, 2011, page 309). Reuse is referring to the reuse of products or its components, after
usage in its first life cycle, for subsequent life cycles to reduce the usage of new raw materials to
produce such products and components (Kiritsis et al, 2011, page 309). Recycle involves the process
of converting material (such as paper, glass, and metal) that are considered waste into new materials
or products Kiritsis et al, 2011, page 309).
The additional 3 Rs in 6R Approach are recover, redesign, and remanufacture. Recover
involves the process of collecting products at the end of the use stage, disassembly into components,
sorting and cleaning for utilisation in subsequent lifecycles of the product (Kiritsis et al, 2011, page
309). Redesign is the act of redesigning products for better resource utilisation during manufacture,
use and to simplify future postuse processes through the application of techniques such as Design for
Environment (DfE) to make the product more sustainable (Kiritsis et al, 2011, page 309).
Remanufacturing involves the re-processing of already used products for restoration to its original
state or a like new form through the reuse of as much components and parts without loss of
functionality (Kiritsis et al, 2011, page 309).
The 6Rs approach provide the framework to implement sustainable manufacturing,
where the performance in all life cycle stages must be considered in making decision at any
lifecycle stage. The application of the 6Rs across the four stages for multiple life cycles, where the
frustum depicts the reduced resource footprint (for subsequent life cycle) is illustrated in Figure 4.2.

Figure 4.2: Application of 6Rs Across Product Life cycle Stages

Source: Kiritsis et al (2011). Engineering Asset Management.
5.0

EVOLUTION OF SUSTAINABLE MANUFACTURING

15

There are four stages activities involved in the life cycle of a product: pre manufacturing,
manufacturing, use, and post use (Kiritsis et al, 2011, page 309). All four product life cycle stages
and impacts (economic, environmental, and social) must be clearly stated and integrated to ensure
sustainability in the supply chain. Since manufacturing is the core operation in a supply chain
(limiting the focus to physical products), designing the system and promoting sustainability in its
operations must centre on a sustainable manufacturing approach (Kiritsis et al, 2011, page 309). This
kind of approach requires two important considerations: a tool lifecycle emphasis and multi
lifecycle emphasis (Kiritsis et al, 2011, page 309). A tool lifecycle emphasis is required to that
manufacturing is pursued while explicitly considering activities across all four life-cycle stages and
the impacts (Kiritsis et al, 2011, page 309). Multilifecycle emphasis is needed to ensure closed-loop
material flow from the post-use stage of one life-cycle to the pre-manufacturing of the next, which is
mandatory for sustainable manufacturing (Kiritsis et al, 2011, page 309). Besides, current more
advance thinking also emphasises on the need for active integration of business partners who
contribute to the sustainability stakes of a product (Kiritsis et al, 2011, page 309).
The evolution of manufacturing strategies over the years and their impact on the
stakeholder value (much broader than shareholder value) is shown in Figure 5.1 (Kiritsis et al, 2011,
page 309). From Figure 5.1, traditional manufacturing was substitutionbased and relied upon
relentless resource consumption to deliver value to customers; the value addition to the wider group of
stakeholders was very limited (Kiritsis et al, 2011, page 309). Subsequent practice of lean
manufacturing by Toyotas Production System, focused on waste reduction (one R) and was able
to deliver more value to customers while also appreciating the role of team members (Kiritsis et al,
2011, page 309). Green manufacturing practices, advocates environmentally-benign practices through
the 3R approach of Reduce, Reuse, and Recycle, gained significant popularity over the last several
years (Kiritsis et al, 2011, page 309).

Figure 5.1: The exponential shareholding growth of innovation-based sustainability

16

Source: Jawahir. University of Kentucky. Sustainable Manufacturing: The Driving Force for
Innovative Products, Processesand Systems for Next Generation Manufacturing.
A significant effort has been undertaken by various groups from a range of disciplines to
characterize, define, and formulate different forms and means of sustainable development (Jawahir,
2013). Continued progress in sustainable development heavily depends on sustained growth,
primarily focusing on three major contributing areas of sustainability: environment, economy, and
society (Jawahir, 2013). A relatively less-known and significantly impacting element of sustainability
is sustainable manufacture, which includes sustainable products, processes, and systems in its core
(Jawahir, 2013). The understanding of the integral role of these three functional elements of
sustainability in product manufacture is important to develop quantitative predictive models for
sustainable product design and manufacture (Jawahir, 2013). This integral role of sustainable
manufacture, with its three major functional elements (innovative product developmentvalue
design, manufacturing processesvalue creation, and value recovery), all contributing to the
sustained growth through the economic sustainability component, has been discussed (Jawahir, 2013).

6.0

DESIGN OF SUSTAINABILITY

17

Sustainability can be included into design, during all phases of the design process, and also many
tools may use to support such effort have been developed and applied. There are ten designs of
sustainability proposed by Jawahir (n.d.): Designing for Repair, Reuse and Recycling, Designing for
Waste Minimization, Designing for Product Disassembly, Designing for Energy Efficiency, Designing
for Product Demanufacturing, Designing for Remanufacturing , Designing for Serviceability,
Designing for Reduced Materials Use, Design and Manufacture for Reduced Costs, and Sustainable
Design and Manufacture (Designing for Sustainability). Some of these are described in this section,
including design for environment, design for resources and energy, and design for sustainability.

The design practices for sustainable manufacturing system and supply chain design must
consider a variety of interactions between the methods and technical models, all the stakeholders who
have an influence on the system or can be influenced by the system as well as the complex
dependencies between these aspects and the natural environment. Evaluating the system performance
from these aspects therefore will require comprehensive sustainability metrics at the plant, enterprise
and supply chain levels; the adaptive and emergent behaviour of the system designed with all other
interactive systems, must be assessed through predictive models

6.1

Design for Environment and Life Cycle Assessment (LCA)

18

Design for environment involves the consideration of environmental impact throughout the design
process, and forms an integral component of designing for sustainability. To develop a holistic and
comprehensive understanding of environmental impacts, the full life cycle of a product or process
normally is needed (Rosen, 2012). All these observations contribute to the development of life cycle
assessment (LCA).
LCA is a tool for improving the environmental performance of processes and systems,
and is often used in sustainability work (Rosen, 2012). In LCA, the environmental impacts of a
product or service are analysed through all phases of its life, with the objective of reducing
environmental damage, in part by enhancing resources conservation and efficiency. A life cycle
assessment consists of four steps: goal and scope definition, life-cycle inventory analysis, impact
assessment and interpretation (Rosen, 2012). Consumption of energy and other resources and
environmental discharges of material and energy wastes are examined in LCA for existing process and
design alternatives (Rosen, 2012). Strategies for the design/selection of products, materials, processes,
reuse, recycling, and final disposal can be obtained with LCA. LCA is also used in pollution
prevention and green design efforts (Rosen, 2012). LCA is incorporated into the ISO series 14040
standards and is often used in conjunction with evaluation of toxicity and risk potential to promote
manufacturing sustainability (Rosen, 2012).

6.2

Resource and Energy Sustainability

Sustainability has been applied to many fields related to manufacturing, including energy and
resource use. From the perspective of resource utilization, Smith and Rees (1998) describe sustainable
development as a pattern of resource use that aims to meet human needs while preserving the
environment so that these needs can be met now and in future generations.
Rosen and Abu Rukah (2010) shows the concept of energy sustainability can be viewed
as the application of the general definitions of sustainability to energy, but it is in actuality more
complex and involved. Energy sustainability involves the supplying of energy services in a
sustainable manner, which in turn necessitates that energy services be provided for all people in ways
that, now and in the future, are sufficient to provide basic necessities by means which are affordable
and not detrimental to the environment, and acceptable to communities and people.

6.3

Design for Sustainability

19

Design for sustainability involves the incorporation of sustainability objectives in design activities.
Although in its infancy, interest in design for sustainability is growing. Several approaches aimed at
design for sustainability have been reported, including the following:
A triple bottom line approach to design for sustainability is described by McDonough and
Braungart (2002), in which firms balance traditional economic objectives with social and
environmental concerns.
An EcoDesign approach (Figure 6.1) is described by Karlsson and Luttropp (2006).
Eco-efficient strategies, which focus on maintaining or increasing the value of economic output
while decreasing the impact on ecological systems, are examined by Braungart et al (2007).
The relationship between quality function deployment, life cycle analysis and contingent
valuation is investigated by Borea and Wang (2007), and these factors are compared with
customer willingness to pay for environmentally benign products.
A product development approach using design for X (DFX) tools, such as life cycle analysis and
theory of inventive problem solving (TRIZ) is discussed by Grote et al. This approach seeks to
assist the design engineer in employing eco-design principles without significant economic tradeoffs (2008).
Integration of quality function deployment, life cycle analysis and TRIZ into a methodology for
environmentally conscious design is described by Sakao.

Figure 6.1: EcoDesign approach for designing for sustainability

Source: Rosen et al. (2012). Sustainable Manufacturing and Design: Concepts, Practices and Needs.

6.4

Needs for Enhanced Design for Sustainability

Many feel that methodologies for design for sustainability are not advanced, and that numerous
improvements are needed. Some examples follow:
Morgan and Liker (2006) suggest an engineering approach within lean product development systems
for managing product development, noting that companies like Honda and Toyota use such an
approach. This approach permits design alternatives to be examined throughout the product
development process, and allows the costs and benefits of design for sustainability issues to be

20

evaluated. These benefits in part stem from the fact that lean product development focuses on key
customer needs and manufacturing capabilities, and tends to avoids errors and improve quality.
Johnson and Srivastava (2008) indicate that engineering tools for design for sustainability need better
capabilities to evaluate the complex trade-offs between process parameters, customer needs, as well as
environmental and other constraints, and that these tools must be usable in a straightforward manner
by design teams.
Johnson and Srivastava (20080 also suggest that a more sophisticated inclusion of environmental and
sustainability issues in constraints and design parameters is needed to yield a broader range of design
alternatives, and to permit evaluation of the effect of sustainability on product cost, project
complexity and process design in a more holistic and data driven manner. Johnson and Srivastava [9]
feel sustainability is not suitably considered using engineering design tools, or modified versions of
them, such as design for manufacturing and assembly, design for Six Sigma, quality function
deployment and design structure matrix.

6.5

Steps to improve and design Sustainable Product

There are nine simple steps to improving the products and design it to be more sustainable. First of
all, it is very likely to have a target product in mind, presumably because market intelligence suggest
that there are environmental and social characteristics of that product that are becoming critical to its
future success. Aware of societal or market pressures which could impact the reputation of company.
Experience has shown that selection of the first test product should be made carefully. Generally the
product should fit the following characteristics in that it should be in a market where its
environmental or social characteristics are under scrutiny, or where there is competition from products
claiming to be more sustainable.
The second step is to prepare a product dossier. The product and its usage need to be
understand in term of its history, the market information, the distribution and typical transport
information, typical product life and end of life path. The information will lead to design and
manufacturing of the products. The key components and sourcing of the components can be
determined and come out with a material list. A simplified diagram of the manufacturing process can
be organized and associated with the each steps.
Third, review the important Environmental and social impacts area in the market. It is
very important to be sensitive to emerging issues, redesigning a product should last in the market for a
good period of time. Start by listing environmental and social issues which are currently important in
the particular region and market, for customers. Review the competing products in your dossier to

21

check what priorities are expressed. Consult company personnel about standards and regulations in
the market.
Fourth steps is reflect the product in light of simple design for sustainability assessment.
Use it as a way to start thinking critically and creatively about possible product improvements. It is
useful to identify any missing information for in the dossier. Use the two blank sections of the dossier
to collect observations and ideas about the product characteristics and possible areas of improvement.
Return to this list later when begin to select appropriate improvement option for the product.

Step 5 is to develop a quick picture of the products impact profile by taking social and
ethical issues into account. A design for sustainability methodology relates the different design
approaches to the environmental and social impacts of the particular product, providing a way to
select those that will be relevant and fruitful.
Step 6 is to define the products improvement targets and design approaches by a
simplified design brief. Most of the information needed is collected and proceed to identifying design
for sustainability strategies and design responses that address the life cycle phases and product
characteristics requiring focus.
Step 7 is a redesign option which is focus on the creativity of the design. After redesign
the product, step 8 is prioritizing ideas and concepts of sustainability. There are a series of ideas with
some estimation of their environmental, social and market value. For the ideas selected there will still
be different degrees of difficulty and cost as well as different degrees of environmental (and social)
gains. Therefore, prioritize is needed.
The last step is to make a case for design for sustainability work in the company by
getting resources and support for a pilot project. As in step 8, the range of possibilities to improve the
product and reduce its overall life cycle impact is identified, therefore, a case for undertaking a full
pilot project within the company or organization. (UNEP, Design For Sustainability A Step-by-Step
Approach, 2009)

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7.0

TECHNOLOGICAL CHALLENGES FOR SUSTAINABLE MANUFACTURING

Research has shown that companies that adopt sustainable practices are able to achieve increased
product quality, increased market-share and increased profits. However, there is a general
misconception about the true meaning of sustainability and companies often end up focusing only on
single aspect especially in energy consumption. The factors motivating companies to embark upon
sustainable development include social responsibility and investor demands, government regulations
and international standards, and increased customer consciousness. Researchers also have tended to
focus more on the environmental aspects of sustainable development. The challenges for energy
consumption associated with reducing the carbon footprint. Limited attention has been granted to the
social dimension of sustainability as visualised by United Nations Division for Sustainable
Development (UNDSD) such as fostering equity both economic and gender-related, improving
health-care and sanitation facilities, and raising literacy levels among other indicators.
One of the technological challenges for sustainable manufacturing is where it requires
new materials technologies for sustainable products to reduce material waste and optimize the usage
of the material. When there are introduction of new materials, it will cause far less attention to
unexpected impacts. There are three case studies about how the introduction of new materials will
brings adverse environmental impacts on other parts of the materials use and reuse systems. For
example, light weighting using plastics, the introduction of electric steel mills will cause upsetting
existing reuse and recycling systems for glass and steel scrap.
Furthermore, the product innovation for sustainable manufacturing is one of the
challenges for sustainable manufacturing. For product innovation for sustainable manufacturing, its
product sustainability metrics need to be considered. The ability of the product design of transforming
from 1R to 3R to 6R also needed (Nambiar, 2010). Besides, with increased focus on sustainable
manufacturing, the product designer is restricted with additional responsibility of considering the
environmental impact of his/her decisions (Nambiar, 2010). Thus, it becomes imperative for the
designer to first adapt himself/herself with the various issues concerning sustainability (Nambiar,
2010).
Other than product innovation, process innovation for sustainable manufacturing also is
one of the challenges will face by sustainable manufacturing. The choice of materials and processes
has a significant bearing on the environmental impact (Nambiar, 2010). Then under process
innovation for sustainable manufacturing, it should always be environmentally friendly or responsible
manufacturing process development. It should always maintain to be toxic-free, hazardless, safe and
secure technologies, minimal use of energy, water including metal working fluids, chemicals and
other resources (Nambiar, 2010).

23

Skill of innovation and creativity in supply or value chain operations also is one of the
challenges that sustainable manufacturing face. The integrated manufacturing systems for
sustainability, sustainable supply chain operations and sustainable quality systems for manufacturing
need to be considered time by time (Jawahir, 2008). Besides that, the production of sustainable
manufacturing need to compliance with regulations such as REACH, WEEE, RoHs, EuP, ELV and
etc. (Jawahir, 2008).
Other than that, economic analysis and business case for sustainable manufacturing need
to be determined time by time. This is because consumers need or trend are changing time by time.
Therefore without economic analysis and business care, the stakeholder value will decrease (Jawahir,
2008).
During sustainable manufacturing, safety, health, public policy and regulatory issues
need to be considered as always. This is important challenges faced by sustainable manufacturing.
Safety is very important. This is to remain the reputation of the manufacturing company. Besides that
education and training issues need to be considered as well (Jawahir, 2008). For example, training
courses in a manufacture company need to be carried out as always to maintain workers capability to
produce sustainability products (Jawahir, 2008).

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8.0

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