Sustainable Manuf

8/4/2019 Sustainable Manuf

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STUDY OF SUSTAINABILITY

IN A

MANUFACTURING SYSTEM

Prince Pal Singh

PG/ME/098307Mech. Dept.


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Plan of Presentation

Introduction Need Motivation

Literature review Research gaps Objectives Methodology


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Introduction

Manufacturing industries are facing tough competitiondue to increasing raw material cost and depletingnatural resources.

There is great pressure to produce environmentalfriendly products using environmental friendlyprocesses.

To address the above said issues modern

manufacturing industries are focusing on sustainablemanufacturing


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What is Sustainable Manufacturing?

Sustainable manufacturing is a systems approach forthe creation and distribution (supply chain) ofinnovative 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 ofproducts and services.


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Sustainable Vs Unsustainable

Lifecycle

Approximately 25% ofwhat goes in the pipe

comes out as goods and

services

Recycle

ReuseReduce

Fig: Unsustainable life cycle

Fig: Sustainable life cycle


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Indicators of Sustainability

Air Emissions indicators

Energy useindicators


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What are the effects?

Environmental imbalance

Floods,

glaciers melting ,

damage to habitat,

contaminated water etc.

Wastage ,depletion resources

In equilibrium all are related tohuman health


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Output Indicators: Green House

Gases

S.no gases sources

1. CO2 Fuel combustion, manufacturing processes

2. CH4 Waste (landfill activities)

3. HFCs Refrigerants, foams, aerosols

4. N2O Chemical manufacture, agriculture

5. PFCs Aluminum, electronic manufacture

6. SFO6 Magnesium smelting, electronics manufacturing


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Indicator measure: Carbon weight

Environmental indicators (energy use) can be quantified byknowing 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 carbondioxide emissions that are directly and indirectly caused by anactivity.


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Indicator Measuring Units


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Finalproduct

Raw barStep

turningdrilling grinding


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Litrature Review

Indicators of sustainable production ,Damjan krajnc,Peter Gavic(2003)

Attempt: Classification of indicators focused on environmental aspects of sustainableproduction

Issues addressed:

a)Explored measurable indicators

b)Dimensioned and classified indicators.

Methodology: researched for the simple measurable and can be expressed with theinput output relation in a manufacturing industry.

Achievements: provided strategic metric for assessing sustainability matrices andidentifying better option for future.

Limitations: formulation for the determination of environmental impact not assessed.


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Need


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Motivation

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

health.


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Literature Review

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

Attempt:Analysis of the manufacturing processes and provides insight into howequipment 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 conceptualmodel for electrical energy requirements for manufacturing parts and plotted on a singleplot.

Achievements: Provide a simple conceptual model for estimating the electrical energyrequirements for a manufacturing process.


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Literature Review

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

Attempt:To calculate carbon emission using carbon emission signature(CES) andgreen house gas labeling

Issues addressed:

a)Energy source and its conversion

b) Energy usec) Conversion of energy use to carbon weight by usingCESTM

Methodology: Calculated the total energy including ancillary energy (energy neededto 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 fossilfuels used for an electrical power grid.

Limitations: Limited manufacturing process were considered.


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Literature Review

Carbon weight analysis for machining operation and allocation for redesign, Gaurav Ametaaet 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 andstatistical case CW of a product.(CW tolerance approach (CWTA))

Achievements: (a)CW estimates can be utilized during the design evaluation stages of aproduct to make environmentally friendly decisions both regarding the product and themanufacturing process.

Limitations: (a) CW allocation carried out manually for machining processes only


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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 thenmodify design and compared the CW change due to design change

Achievements: Linked the life cycle data of power consumption from machiningprocess to the design feature

Limitations: Manually done and for machining process only(turning)


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Comparison chart

Author(year) Title Objective Methodology Limitation

Damjan krajnc,PeterGavic(2003)

Indicators of sustainableproduction

Timothy Gutowski et

al. (2006)

Electrical Energy Requirements

for Manufacturing Processes

J. Jeswiet , S.Kara(2008)

Carbon emissions and CESTMin manufacturing

Gaurav Ametaa etal.(2009)

Carbon weight analysis formachining operation andallocation for redesign

Zahari Taha et.Al(2010)

Linkage or power consumptionto design feature on turningprocess


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Research Gaps

Primary manufacturing processes not taken intoconsideration


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Objectives

To purpose a methodology for determining carbonweight for a part manufacturing including primaryprocesses 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.

Sustainable Manuf

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