Designing Sustainable Manufacturing · PDF fileSpring, Tension Guide, Cable Block, Shaft Holding, ... Separation Clip, Cable Tray, Face-Up Output Spring ... *Environment Health and

building a sustainable future through innovative technologies

Prof. Nabil NasrDirector, The Sustainability Institute

Rochester Institute of Technology (RIT)

Rochester, NY USA

Copenhagen, June 21, 2007

Designing Sustainable Manufacturing Practices

Presentation to:OECD Workshop on Sustainable Manufacturing

Production and Competitiveness



Traditional Manufacturing

“Produce the best quality product at the least possible cost”


“Imagine a world in which socially responsible and eco-friendly practices actually boost a company’s bottom line. It’s closer than you think.”


TransportTransport Raw Materials Acquisition

Raw Materials Acquisition

ManufacturingTransportTransport Raw Materials

AcquisitionRaw Materials

Acquisition

ManufacturingManufacturing

Use/Reuse/Maintenance


Recycle/Waste Management

TransportTransport

TransportTransport

TransportTransport

EmissionsWaterborne WasteSolid WasteHazardous WasteLand Change

EmissionsWaterborne WasteSolid WasteHazardous Waste

Energy DemandsEnvi. Wastes

Other Releases (energy/environ.)

System‐Based Comprehensive Production & Consumption Model

Investigation Criteria

EconomicsEfficiency (material flow)

Energy DemandEnergy Efficiency

Material ConsumptionPollution

Social ImpactWaste (Solid, Hazardous)

Water Consumption

Manufacturing


TransportTransport Raw Materials Acquisition

Raw Materials Acquisition

ManufacturingManufacturing




TransportTransport

TransportTransport

TransportTransport





System‐Based Comprehensive Production & Consumption Model






Water Consumption



TransportTransport

TransportTransport

TransportTransport





System‐Based Comprehensive Production Model






Water Consumption

OEMMarketing

Distribution

Support

Finance

Risk Mgmt.

Production

‐‐ ‐‐Comprehensive Supply‐Chain Production Model

Evaluate Best Options & Work Across the Supply ChainSupply Chain

Suppliers

Suppliers

The Core Elements of a System Based Sustainable Production Model

• Systems-based approach

• Comprehensive and strategic

• Industry specific platform


Pathway to a Sustainable EconomySome key elements

Sustainable Manufacturing•Pollution Prevention•Safe & Healthy Workplaces•Environmental Management Systems•Workforce Engagement

Sustainable Products•Life-cycle Driven Product Design•Healthy Products•Product Labeling•Green Procurement

Closed-Loop, Sustainable Product Systems•Cradle-to-cradle Product Management•Reuse, Remanufacturing Recycling•Zero-to-waste•Transition from Products to Service

Sustainable Economy•Closed-loop, Sustainable Product Systems•Stakeholder Engagement•Renewable Energy•Dematerialized Economy•Green Chemistries•Biobased Products

The Path to a Sustainable Economy


3 Phased Journey to Sustainable Product Systems

Innovation Based Design Design for the Life-Cycle System/integrationProd. & Service Support Strategies

Sustainable Design Tools & MethodsClean ProcessesLife-Cycle DesignKnowledge Base

Life Cycle AnalysisTotal Cost of OwnershipSustainable MaterialsProcess TechnologyEducation & Certification

PHASE 1Sustainable Tools, Methodology, &

Education

PHASE 2Sustainable Design

Processes

PHASE 3Sustainable Product

Systems

DISCOVERY Opportunistic STRATEGIC

Marketing Logistics

Remanufacture Service

Product Disposition

TransportationElements of Product Life‐Cycle


The Science of Sustainability

Social &EconomicImpacts

EnvironmentalScience

& Management

Business Enterprise

Production Engineering

SustainableSystems


Active Integration

Product Development and Realization

Environmental Studies Business Enterprise

Energy Systems

Industrial Ecology

Technology, Society and Policy

Market Design Manufacturing Use Retirement

Life Cycle

Modeling - Decision Systems – Material Flow – Life Cycle Analysis –

Clean Production - Environmental Impacts – System Analysis - …..

System View

Integration

System Tools

Society Environment Economy


Principles ( the 3 Laws of sustainable products)

• Minimize Material, Energy, and Resources Needed to Satisfy Function/Requirement

• Maximize Usage of Expended Resources

• Minimize/Eliminate Product’s Adverse Impacts

Sustainable Design is aimed at developing closed-loop, environmentally and economically sustainable product systems.


Product Life Cycle

Design

Raw Material Acquisition

Earth & Ecosystem

Processing of Materials

Manu-facturing

Assembly

Use

Service

Upgrade

Retirement

Treatment & Disposal

Emissions

- Reverse Logistics

-Disassembly & Separation

-Identification Technologies

Sustainable Product Design

Closed-Loop Product Systems

- Decision Support Systems

- Condition Assessment

- Reuse & Remanufacturing

Disassembly & Inspection

ReuseRemanu-facturing

Material Recycling


Sustainable Design Considers of the Complete Product Lifecycle During the Entire Design Effort

DESIGN

RAW MAT’L ACQUISITION

PROCESSING OF MATERIALS

MANUFACTURING ASSEMBLY

USE SERVICEUPGRADE RETIREMENT

REUSEREMANUFACTURINGMATERIAL RECYCLE

INVENTORY DISASSEMBLY & INSPECTION

TREATMENT AND DISPOSAL

EARTH ECOSYSTEM

FUEL INFRASTRUCTURE

ELVINFRASTRUCTURE

EMISSIONS

EMISSIONS

EMISSIONS

Sustainable Design ToolsObjective of Sustainable Design Tools Is to Provide Design and Engineering Insights and Guidance When:

– Determining the Optimum End-of-life Strategy for Product, Assembly or Subassembly

– Selecting Specific Design Elements to Achieve the Optimum End-of-life Strategy

Specification of Design Intent

Product Manufacture

Development of Preliminary Design

Concept DesignConcept Generation

Development of Detailed Design

DESIGN PROCESS

Class I Tools

Class II Tools


Materials Innovation• Recycled content• Bio-based plastics• Halogen-free cables• Halogen-free flame retardants for circuit

boards


What is Remanufacturing?

An industrial process in which non-functional or retired products are restored to like-new conditions.



Disposition % by Weight

Fuser (Fixing) Assembly, 220V

Fuser (Fixing) Assembly, 220V Feeder Assembly

Laser/Scanner Assembly Cover, Delivery Cover, Delivery

Printer Drive Assembly

Guide, Separation, Upper Cover, Right Roller, Feed Duct, Scanner Spring Tension Hinge, Stopper Spring, TorsionPlate, Roller Holder Roller, Upper, Fuser Guide, Paper Cover, Coupler Cover, Front Plate, Hinge Plate, GuideClaw , Separation Roller, Low er Spring, Torsion Rail, Fuser (Fixing) Cover, Front, Engine Upper Cover Assy Coupler, FixingLever, Delivery Sensing, Fuser Cover, Fixing Roller Guide Feeder Spring, Leaf Cover, Front, Sub

Top Cover Assembly Gear, 42T/99T

Lever, Holding, Right, Fuser Cover, Upper Plate, Terminal Plate, Holder Label, Jam Removal Plate, Grounding Gear, 17T/57T

Lever, Holding, Left, Fuser Cover, Left Sheet, Insulating Plate, Duct, Front Latch Cover, Electrical Gear, 41TCrossmember, Separation Guide Guide, Entrance Block, Shaft Holding, F Mount, Fan Cover, Left, Low er

Open/Close Cover, Assembly Gear, 17T/75T

Spring, Tension Guide, Cable Block, Shaft Holding, R Arm, Lock, Inter Cover, Electrical Stopper. Delivery Gear, 73T

Label, Caution Holder Bushing Spring, Leaf ShutterTray, Face-Dow n Output Tray, Delivery Gear, 27T/30T

Diode Holder Assembly Holder, ThermostatArm, Registration, Paper Sensor Fan Cover, Pow er Sw itch

Cover, Right Door Assembly Gear, 26T/39T

Fixing, Cable, 2 Lever, ControlCover, Static Charge Eliminator Spring, Tension Spring, Compression Cover, Right

Heater, Halogen, 110V Plate, Thermosw itch Frame, Transfer Cable, Laser Cover, Right RearCover, Open/Close, Right

Heater, Halogen, 220V Ring, Grounding Eliminator, Static Charge Cable, Scanner Motor Guide Cover Guide, CoverSurface Temp. Sensor Unit Plate, Grounding Plate, Terminal Cable, BD Spring, Torsion

Stopper, Open/Close

Thermosw itch Plate, Right Cable, Paper Sensor Cable, ILS Panel, Control Front Lever

Gear, 29T Plate, LeftCompression Spring, Front Cover, Cable Control (Display) Panel

Gear, 25T Guide, SeparationCompression Spring, Rear Support, PCB

Panel, Control Front (WX)

Gear, 18TScrew , Stepped, W/Washer, M3 Varistor Spring, Tension Label, Jam Removal

Gear, 14T Frame, Fixing IC, Photo, TLP1230 Spring, Compression Cable AssemblyGear, 48T Guide, Separation Clip, Cable Tray, Face-Up OutputSpring Compression Roller, Delivery Cover, Cable, DC Gear, 20TBearing, Ball Bushing Mount, Control RollerLabel, Caution Gear, 20T Plate, Shield Plate, Guide

Plate, Compression Guide Spring, Torsion Spring, CompressionFixing, Cable, 3 Guide, SeparationLabel, 110V Holder, HeaterLabel, 220V Roller, Delivery, FixingBushingRoller, Cold Offset

Remanufacturing is Diverse


Case Study: PhotocopiersXerox Document Center 265*

designed to include easily removable subassemblies and more durable parts

Xerox takes back the used copiers.

80% of the parts are remanufacturable

designed to be upgraded

Remanufacturing diverted 4 million cubic feet of material from landfill in one year company-wide.

Xerox saves several hundred million dollars per year by designing parts for remanufacture and recycling.

*Environment Health and Safety Progress Report. Xerox Corporation. Available through: www.xerox.com


www.Sustainability.rit.edu

Documents

Designing Sustainable Manufacturing · PDF fileSpring, Tension Guide, Cable Block, Shaft Holding, ... Separation Clip, Cable Tray, Face-Up Output Spring ... *Environment Health and