Design principles for sustainable materials ...stage.cchem.berkeley.edu/~bcgc/sites/default/files/PH290007-2012... · Design principles for sustainable materials & manufacturing processes,

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Laboratory for Manufacturing and Sustainability © 2012

Design principles for sustainable materials & manufacturing processes, I

David Dornfeld UC Berkeley

02/13/12

Laboratory for Manufacturing and Sustainability © 2012 Class 2 Class 4

Outline •  Topics:

–  first … dimensions of impact! –  operation and control of manufacturing processes –  optimizing energy use –  supply chain management –  OECD framework

Readings • “Greening the Industrial Facility,” TE Graedel and JA Howard-Grenville,

Springer, 2005 • “Materials and the Environment: Eco-Informed Materials Choices,” MF

Ashby, Elsevier, 2009 • OECD, Eco-Innovation in Industry: Enabling Green Growth, OECD

Publishing, 2010 (download at no charge at http://www.oecd-ilibrary.org/content/book/9789264077225-en)

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Laboratory for Manufacturing and Sustainability © 2012 Class 2

Manufacturing Sustainability Footprint Social

Economic

Environmental

Materials

Energy

Greenhouse Gases

Water

Recycle/reuse

Existing Design

New Design better

Laboratory for Manufacturing and Sustainability © 2012 Slide 4 /53

Dimensions of impact and influence

Lecture 8

The typology of eco-innovation*

**Source: “Sustainable Manufacturing and Eco-innovation: Towards a Green Economy,” OECD Policy Brief, June 2009.

Use vs manufacturing

*Source: http://info.industry.siemens.com/press/Details.aspx?pressArticleId=2028, accessed 3 Oct. 2011

Environment vs Economic Benefit** Spatial vs temporal

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Lecture 8








Lecture 8







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Lecture 8






Spatial vs temporal



Lecture 8






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One more! BASF SEEbalance

Lecture 8

Source: www.prosa.org/fileadmin/user.../SEE_Balance_Kicherer_BASF.ppt and http://www.basf.com/group/corporate/en/sustainability/eco-efficiency-analysis/seebalance

BASF SEEbalance®


Dimensions of impact and influence – one more!

Lecture 8

Source: www.prosa.org/fileadmin/user.../SEE_Balance_Kicherer_BASF.ppt and http://www.basf.com/group/corporate/en/sustainability/eco-efficiency-analysis/seebalance

BASF SEEbalance®

3-d version of Eco-care matrix

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The product life-cycle

11 Source: Ashby, et al, “The CES Eco-selector - background reading,” Univ. of Cambridge White Paper, Feb. 2005.


How do things get made?

Process1 Process2 Process3 ProcessN …

•  Macro planning •  Micro planning

•  Precedence •  Availability •  Balance •  Yield

•  BOM •  Tasks

Detailed decisions

Lecture 8

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Material problems for starters…

Source: http://www.activedisassembly.com/guidelines/ADR_050202_DFD-guidelines.pdf

Lecture 8

Rule of Thumb:

You want to take the shortest path for material recycling


Sustainable design

Source: The Designer’s Field Guide to Sustainability, 2011, www.lunar.com

Design guides usually:

•  Propose a methodology •  Offer examples/do’s/don’ts •  Ask questions

Example – Designer’s Field Guide

What is it trying to accomplish? How is it brought to life? How is it used? Where does it end up?

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■  Design for Short Time to market ■  Design for reliability ■  Design For Test ■  Design for safety ■  Design for quality ■  Design Against Corrosion Damage ■  Design for Minimum Risk ■  Design to cost ■  Design to standards ■  Design for assembly ■  Design for manufacturability ■  Design for logistics ■  Design for Electronic Assemblies ■  Design for Low-Quantity Production ■  Design for user-Friendliness ■  Design for Ergonomics ■  Design for Aesthetics ■  Design for Serviceability ■  Design for Maintainability ■  Design for Environment ■  Design for Sustainability ■  Design for Reuse ■  Design for Remanufacturing ■  Design for Recycling ■  Design for Disassembly

Lists and more lists … DfX

Lecture 8

Usually centered on the stage of life – design, production, distribution, use, disposal, re-use…


Opportunities for improvement

Technology

Material Energy

Green manufacturing system triangle

Improve energy

efficiency

Improve material efficiency

Reduce embedded energy

Improve manufacturing process

Use lower impact materials

Use clean energy

sources

Cost issue

Cost issue

Cost issue

1

2 3

Ref: Chris Yingchun Yuan, LMAS Presentation, 2009

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

And across

the supply c

hain…

Effects at different scales Enterprise

Process

Tooling/setup

Machine

Line/system

Facility


The “drivers” Manufacturing -  plant/HVAC -  cafeteria, HR,

mgmt -  packaging -  shipping -  other waste

Processes & Systems -  energy -  water -  materials -  consumables -  compressed

air - other waste

Machinery & Tooling -  design -  setup -  operation -  maintenance -  other waste

Repeat

Across the supply chain

Customer

Gov’t/Regs

Society

Competitor

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Social -  Quality of Life -  Pay Rates -  Working Conditions -  Health Care

Economic -  Part Quality -  Resource Availability -  Lead Times & Inventory -  Risk

Environmental -  Electricity Mix -  Resource Availability -  Electricity Demand -  Emissions Fate -  Regulations

TRANSPORTATION SUPPLIER - Location Economic

-  Accessibility -  Availability -  Lead Times - Risk

Environmental -  Emissions -  Resource Use -  Distance

Supply chain considerations


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

Materials Energy Water GHG

Impa

ct/C

onsu

mpt

ion

Big variation depending on mfg supply chain(s)

Reductions if recycling/reuse

“upstream” impact

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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

Source: after J. Allwood, Cambridge University


Energy Reduction Tools and Strategies

Big Losses That Lower Equipment Efficiency

Increased equipment operating efficiency reduces energy waste. When machines are optimally tuned to accomplish the desired work, energy inputs are most efficient. Total productive maintenance’s (TPM) emphasison equipment efficiency can lead to reduced costs, increased productivity,and fewer defects.

TPM focuses on the six big losses that lead to equipment inefficiency:

•  Breakdowns •  Setup and adjustment loss •  Idling and minor stoppages •  Reduced speed •  Defects and rework •  Start and yield loss

Source: http://www.epa.gov/lean/energytoolkit/ch4.htm

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Embedded

Process

Machine Tare

Embedded Embedded

Process or

Machine

Process or

Machine

In In Out Out

Time Time

Ene

rgy

Ene

rgy

Machine or process “tare” consumption


Production/ operation

consumption

Pro

duct

ion/

oper

atio

n co

nsum

ptio

n

ET

ET

EP EP

Energy use in manufacturing

Energy modes


Energy reduction strategies

Operation (with process)

Operation (w/o process)

Embedded (no operation)

EP >> ET EP << ET

EP >> ET EP << ET EP ~ ET

Highest MRR Shortest tc

Power/unit product? or Power/unit time?

Optimize process (tooling, path, f, v)

Highest MRR or Optimize process

Idle/sleep or Reduce tare

Reduce tare? Idle/sleep or Reduce tare

Reduce embedded energy: material, fabrication, transport and installation, maintenance, removal and recycle/reman

Mod

e

Embedded Embedded

Time Time

Ene

rgy

Ene

rgy



Production/ operation

consumption

Pro

duct

ion/

oper

atio

n co

nsum

ptio

n ET

ET

EP EP

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60% of electricity consumption is coolant-related.　

in automotive parts machining systems

Components of electricity consumption

Source: M. Mori, EERE Presentation, CIRP, Pisa, 2010


•  Backlight of in-machine lighting and display hibernates when machine is idle

•  Power of spindle, servo motor, cutting oil, and chip conveyor shuts off, when machine is idle

•  Power state resumes on keyboard input

Automatic power off

Illumination

Spindle

Servo drive

Coolant Chip conveyor

Source: M. Mori, EERE Presentation, CIRP, Pisa, 2010

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Use matrix for manufacturing

What if we looked at manufacturing in the same manner...that is a “use matrix of manufacturing classes”?

High load factor Modest load factor Low load factor

Primary power-consuming

Secondary power-consuming

Non power-consuming

Energy intensive

Material intensive

High impact Low impact

How would this look for manufacturing?


Ashby- matrix for energy/impact

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Draft use matrix for manufacturing

Energy intensive

Material intensive




Process energy: furnaces, rolling mills (electric motors), smelting, refining ore, semiconductor mfg

Process energy: machine tools, inj. mold presses, server farm (electric motors), welding

Process energy: converting machinery, conveyors, ASR(electric motors), food processing


Hi tech factory heat + a/c, light, compressed air, de-i water, etc., traditional farming

Service center (server) with HVAC, sewing

Warehouse, office, service center (non server), non-organic farming, recycling ctrs.

Non power-consuming Buildings, foundations (incl. machine tool), logging

Furniture, workstations, tooling (drills, mills), hand crafts

Landscaping, composting




Process energy: furnaces, rolling mills (electric motors)

Process energy: machine tools, inj. mold presses, server farm (electric motors)

Process energy: converting machinery, conveyors, ASR(electric motors)


Hi tech factory heat + a/c, light, compressed air, de-i water,etc.

Service center (server) with HVAC

Warehouse, office, service center (non server)

Non power-consuming

Buildings, foundations

Furniture, workstations

Landscaping

Back to the matrix

Energy intensive

Material intensive


Consider: material production manufacture use disposal

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Example: 1500 ton Verson

CAPACITY..............................: 1500 TONS"(CENTER CYL 900 TONS @ 2,500 PSI"2 x OUTER CYLS 600 TONS @ 2,500 PSI)"BED (RL/FB)...........................: 144" x 96""STROKE................................: 48""ADJUSTMENT............................:"SHUT HEIGHT...........................: 32""KNOCKOUT CAP..........................: 100 TONS @ 2,500 PSI"KNOCKOUT STROKE.......................: 36""KNOCKOUT EJECTION SPEED...............: 318 IPM"PRESSING SPEED........................: 62.5 IPM"FAST ADVANCE SPEED....................: 632 IPM"FAST RETURN SPEED.....................: 550 IPM"CUSHIONS CAP..........................: 200 TON"CUSHIONS STROKE.......................: 24""

EQUIPPED WITH:"

200 HP MOTOR & CONTROLS"4 POINT EJECTOR SYSTEM"


Press design What do we design for?

- tonnage (pressure/power) - stiffness - speed/strokes per minute - ease of load/unload -  die changing/handling/setup

And, don’t forget other efficiencies/savings: •  Breakdowns •  Setup and adjustment loss •  Idling and minor stoppages •  Reduced speed •  Defects and rework •  Start and yield loss

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But it moves ... a lot!

so material density matters also...


Tradeoffs

What is best for the press?

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Production Planning

Source: Machsources.com; accessed 3/2011

GWP

Waste

Water use

Energy use

Investment cost

Operating cost Quality Efficiency


■  Assess resource consumption for multi-station operations using life cycle assessment methodology

■  Develop/apply tool to provide decision support for manufacturing process and process chain selection

■  This tool can be used to better understand resource consumption and environmental and financial impacts of manufacturing process chains used to make a product

Goals & Approach

Energy use Water use Waste

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Process Analysis

other

material

energy

water

product

waste

other

water

Process A

Process B

Process C Product Raw

Material

■  Each manufacturing process of the process chain must be analyzed individually

■  For each process multiple inputs and outputs need to be assessed

Source: Institute for Machine tools and Industrial Management (G. Reinhart, S. Reinhardt)


■  Associated impacts ■  Operating Cost ■  GWP

■  LCA tools (e.g. GaBi, Umberto, etc. can assist)

Impact Analysis

Process Chain 1

Process Chain 2

Product

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■  Comparing different manufacturing processes and process chains can be used to inform trade-off decisions that influence operating costs, resource consumption, and impacts on the environment.

■  These comparisons could also inform additional production decisions including: ■  Production location ■  Production floor and line layout ■  Future factory planning

■  Production location considerations ■  Local cost of resources (energy, water, etc.) ■  Carbon intensity of energy mix at production location

Decision Making

This requires link to CAD/CAM tools

Laboratory for Manufacturing and Sustainability © 2012 40

OECD Toolkit

Source: OECD, Eco-Innovation in Industry: Enabling Green Growth, OECD Publishing, 2010 (http://www.oecd-ilibrary.org/content/book/9789264077225-en)

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OECD Sustainable Manufacturing


OECD Methodology

And see http://green-manufacturing.blogspot.com/2011/10/tools-of-trade-part-1.html, and parts 2, 3 for discussion of OECD Toolkit

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Mapping Example


Assessing impacts

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Issue priority matrix


Normalization factors

Then consider ROI!

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Backup Slides


Leveraging

Source: Georg Fischer, “Competence Brochure – Move more with lightness,” http://www.automotive.georgfischer.com/docs/content1.aspx?id=23976, Accessed 2 October 2011.

What if it seems that manufacturing doesn’t really matter in the long run?!

For example … little impact over product life cycle

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Recall: Use vs Manufacturing Impacts

What if you are here?


Impact- Manufacturing vs Use

Source: Volkswagen AG, and Harald Florin, PE Europe/IKP-University of Stuttgart, Germany

Manufacturing phase energy requirements for VW Golf A3 Automobile (circa late 1990’s)

machining

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Impact- Manufacturing vs Use

Source: Volkswagen AG, and Harald Florin, PE Europe/IKP-University of Stuttgart, Germany

Life Cycle Impact of VW Golf A3 Automobile (circa late 1990’s)

Mfg energy consumption

Machining (not including any in supply chain) accounts for ~ 10% of total energy

Let’s assume we do something to reduce machinining process energy by 10% by, say, some new fancy tooling

That will save 1% of manufacturing energy

That accounts for 0.1% of lifecycle impact

Why bother?!


Leveraging Manufacturing in Performance

Source: K. Berger, Daimler from Giesserei 1/2005

2x

4x

Precision manufacturing “introduced”

Same size engine (displacement)

But

-  Reduced friction -  Better tolerances -  Enhanced fluid flow

and cooling -  Higher injection pressures -  Smaller injection orifices

•  •  • 

All based on improved manufacturing technology

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Leveraging Manufacturing Mfg process or

System improvement

Product life cycle impact improvement

air pollution reduction

manufacturing improvement

product performance improvement

fuel savings

water use/ pollution reduction

CO2/GHG reduction

this

gets us this!

Documents

Design principles for sustainable materials ...stage.cchem.berkeley.edu/~bcgc/sites/default/files/PH290007-2012... · Design principles for sustainable materials & manufacturing processes,