STUDY OF SUSTAINABILITY IN A MANUFACTURING SYSTEM

Prince Pal Singh PG/ME/098307 Mech. Dept.

Plan of Presentation

Introduction Need Motivation Literature review Research gaps Objectives Methodology

Introduction

Manufacturing industries are facing tough competition due to increasing raw material cost and depleting natural resources. There is great pressure to produce environmental friendly products using environmental friendly processes. To address the above said issues modern manufacturing industries are focusing on sustainable manufacturing

What is Sustainable Manufacturing?

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 Produces zero waste that in effect reduces green house gases e.g., carbon intensity, across the entire lifecycle of products and services.

Sustainable Vs Unsustainable Lifecycle

Approximately 25% of what goes in the pipe comes out as goods and services

Fig: Unsustainable life cycle

Recycle Reuse Reduce

Fig: Sustainable life cycle

Indicators of Sustainability

Energy use indicators

Air Emissions indicators

What are the effects?

Environmental imbalance Floods, glaciers melting , damage to habitat, contaminated water etc. Wastage ,depletion resources In equilibrium all are related to human health

Output Indicators: Green House Gases

S.no 1. gases CO2 sources Fuel combustion, manufacturing processes

2.
3. 4. 5. 6.

CH4
HFCs N2O PFCs SFO6

Waste (landfill activities)

Refrigerants, foams, aerosols Chemical manufacture, agriculture Aluminum, electronic manufacture Magnesium smelting, electronics manufacturing

Indicator measure: Carbon weight

Environmental indicators (energy use) can be quantified by knowing the gases causing green house gas effect (air emission). Green house gases are classified as direct ,indirect ,other indirect emissions. Carbon weight: a measure of exclusive total amount of carbon dioxide emissions that are directly and indirectly caused by an activity.

Indicator Measuring Units

Raw bar

Step turning

drilling

grinding

Final product

Litrature Review
Indicators of sustainable production ,Damjan krajnc,Peter Gavic(2003) Attempt: Classification of indicators focused on environmental aspects of sustainable production

Issues addressed: a)Explored measurable indicators b)Dimensioned and classified indicators.

Methodology: researched for the simple measurable and can be expressed with the input output relation in a manufacturing industry.
Achievements: provided strategic metric for assessing sustainability matrices and identifying better option for future. Limitations: formulation for the determination of environmental impact not assessed.

Need

Motivation

If a system is developed that could determine different product design alternatives at design stage for achieving sustainability in product life cycle it will be beneficial for industry, planet, and human health.

Literature Review
Electrical Energy Requirements for Manufacturing Processes, Timothy Gutowski et al. (2006)

Attempt: Analysis of the manufacturing processes and provides insight into how equipment can be redesigned in order to be more energy efficient. Issues addressed: a)Specific energy requirements for manufacturing processes b) Process rate c) Energy use by breakdown by type Methodology: Specific energy consumption ,process rate computed using conceptual model for electrical energy requirements for manufacturing parts and plotted on a single plot. Achievements: Provide a simple conceptual model for estimating the electrical energy requirements for a manufacturing process.

Literature Review
Carbon emissions and CESTM in manufacturing, J. Jeswiet , S. Kara(2008)

Attempt: To calculate carbon emission using carbon emission signature(CES) and green house gas labeling Issues addressed: a)Energy source and its conversion b) Energy use c) Conversion of energy use to carbon weight by using CESTM Methodology: Calculated the total energy including ancillary energy (energy needed to run the process i.e. pumps, cooling media etc.) then conversion of energy to CW Achievements: CESTM Is used , this signature based on the carbon content of fossil fuels used for an electrical power grid. Limitations: Limited manufacturing process were considered.

Literature Review
Carbon weight analysis for machining operation and allocation for redesign, Gaurav Ametaa et al.(2009)

Attempt: Computing CW for machining operations, specifically turning and milling. Issues addressed: (a)Energy for different stages of product life cycle (b)Carbon weight (c)Conversion of energy to CW Methodology: (a)Mechanical tolerance principles applied for computing worst case and statistical case CW of a product.(CW tolerance approach (CWTA)) Achievements: (a)CW estimates can be utilized during the design evaluation stages of a product to make environmentally friendly decisions both regarding the product and the manufacturing process. Limitations: (a) CW allocation carried out manually for machining processes only

Literature Review
Linkage or power consumption to design feature on turning process , Zahari Taha et. Al(2010)

Attempt: Analysis of environmental impact in machining process at the design stage. Issues addressed: a)Power consumption during machining processes b)Effect of design on power consumption c)Calculation for CW Methodology: Experimenting by varying some machining parameters(depth of cut, feed rate, cutting speed) on a predesigned part then compute specific energy then modify design and compared the CW change due to design change Achievements: Linked the life cycle data of power consumption from machining process to the design feature Limitations: Manually done and for machining process only(turning)

Comparison chart
Author(year)
Damjan krajnc,Peter Gavic(2003)

Title
Indicators of sustainable production

Objective

Methodology

Limitation

Timothy Gutowski et al. (2006)

Electrical Energy Requirements for Manufacturing Processes

J. Jeswiet , S. Kara(2008)

Carbon emissions and CESTM in manufacturing

Gaurav Ametaa et al.(2009)

Carbon weight analysis for machining operation and allocation for redesign

Zahari Taha et. Al(2010)

Linkage or power consumption to design feature on turning process

Research Gaps

Primary manufacturing processes not taken into consideration

Objectives

To purpose a methodology for determining carbon weight for a part manufacturing including primary processes in addition to part machining. To purpose a automated system for determination of carbon weight from process plan of the part. To purpose a integrated framework for carbon emission this would include manufacturing activities at the micro-level.