Sustainable Manufacturing: A Product, Process and Systems ......• demonstrate reduced negative environmental impact, • offer improved energy and resource efficiency, • generate

© Copyright University of Kentucky

Fazleena Badurdeen, Ph.D.

Professor of Mechanical Engineering, Director of Graduate Studies for Manufacturing Systems Engineering

Institute for Sustainable Manufacturing, University of Kentucky,

Lexington KY USA

Sustainable Manufacturing: A Product, Process and Systems-integrated Approach


• Resource Consumption – 90 billion tons in 2017

(Source: Measuring Progress Towards achieving the environmental dimension of the SDGs, UNEP, 2019)

Current Outlook


• Growth in resource extraction

(Source: UNEP Global Environment Outlook, 2019)

Current Outlook (Contd.)


• More than 50% of resources dispersed or emitted as waste – Less than 10% channeled back (UNEP, 2019)

(Source: Growth Within: A Circular Economy for a Competitive Europe, 2015)




• Waste Generation – ~ 50 million tons in 2018 – ~ 50% increase in less than a decade

(Source: Verisk Maplecroft - Waste Generation and Recycling Indices 2019 - Overview and findings)



• Energy Consumption – Renewable energy vs. fossil fuels – Total electricity generated more than doubled since 1990

(Source: Measuring Progress Towards achieving the environmental dimension of the SDGs, UNEP, 2019)


UN Sustainable Development Goals

(Source: UNEP, The 6th Global Environment Outlook, 2019)

Sustainable Manufacturing


VALUE RECOVERY & DISPOSAL

An Enlarged Framework – The Total Lifecycle Approach

• Emphasis on all product lifecycle stages for closed-loop material flow

Manufacturing

Pre-manufacturing

Use

Post-use

(Source: Badurdeen et al., 2009)

Post-use activities are an after-thought!


6R Approach for Sustainable Manufacturing Recycle

Pre- Manufacturing

Manufacturing

Use

Reuse

Material Processing

Product/Process Design

Sales, Marketing, and Distribution

Post-Use

Recover

Extraction

(Source: Jawahir and Bradley, 2015)

Reduce resources, waste/emissions,

impacts over the total lifecycle


Evolution of Sustainable Manufacturing

Exponential Increase in Value for all Stakeholders by Managing Embodied Energy and Material Flow in Closed-Loop Lifecycles

6R-based approach enables a ‘Circular Economy’

(Source: Badurdeen and Jawahir,, 2017)


Product, Process, System Integration

• 6R-based sustainable manufacturing requires emphasis across different domains

Systems

Products

Processes


( Source: Badurdeen et al., 2011)

Coordinating Product and Process Design

Coordinating Product and Supply Chain Design

Coordinating Process and Supply Chain Design


Sustainable Manufacturing - Definition

Sustainable manufacturing at product, process and systems levels must:

• demonstrate reduced negative environmental impact,

• offer improved energy and resource efficiency,

• generate minimum quantity of wastes,

• provide operational safety, and

• offer improved personnel health;

• All while maintaining and/or improving the product and process quality with overall lifecycle cost benefits

(Source: Jawahir, Badurdeen, and Rouch,, 2014)


(Source: Ellen MacArthur Foundation)

Circular Economy and Sustainable Manufacturing

• Moving from a linear ‘take-make-consume-dispose’ model to a ‘restorative and regenerative’ industrial economic model

Operationalize the Circular Economy


Assessment of Sustainable Manufacturing Performance

Improvement Horizon for Sustainable Manufacturing

Manufacturing Processes

Production Lines

Manufacturing Plants

Product Lifecycle

Closed-loop Supply Chain

Objective: Improving resource efficiency, reducing waste & emissions and improving employee health and safety

Objective: Improving sustainability performance at the production line level considering all processes

Objective: Improving resource utilization and reducing negative environmental impacts at the factory level

Objective: Improving total lifecycle product sustainability through closed-loop material flow

Objective: Improving economic, environmental and societal performance for all stakeholders


The Performance Measurement House

System Metrics

Employees

Shareholders

Suppliers

Others

Communities

Governments

Customers

Performance Measurement Framework

Line Plant Enterprise Supply chain

Stakeholders

Triple Bottom Line Emphasis • Economic impacts • Environmental impacts • Societal impacts

Total Lifecycle Focus • Pre-manufacturing • Manufacturing • Use • Post-use

6R Methodology • Reduce • Reuse • Recycle

• Remanufacture • Redesign • Recover

Sustainable Manufacturing Philosophy

Process Metrics • Manufacturing cost • Operator safety • Energy

consumption • Waste management • Environmental

impact • Personnel health

Product Metrics • Product safety and

related impact • Product quality and

durability • Resources use and

efficiency • Direct/Indirect cost …

…

(Source: Huang and Badurdeen, 2016)


Sustainable Manufacturing Processes

• Six elements for assessing manufacturing processes – Deterministic/quantifiable aspects

– Less deterministic/qualitative aspects

Personnel Health

Energy Consumption

Environmental Friendliness

Operational Safety

Manufacturing Cost


Processes

Waste Management

(Source: Wanigarathne et al., 2004)


Process Sustainability Clusters and Sub-clusters

(Source: Lu, , Shuaib, Rotella, Badurdeen, Dillon, Jr., Rouch, and Jawahir , 2020 - Forthcoming)


Environmental Impact Energy Consumption CostGHG emission from energy consumption of the line (ton CO2 eq./unit)Ratio of renewable energy used (%)Total water consumption (ton/unit)Mass of restricted disposals (kg/unit)Noise level outside the factory (dB)

In-line energy consumption (kWh/unit)Energy consumption on maintaining facility environment (kWh/unit)Energy consumption on transportation into/out of the line (kWh/unit)Ratio of use of renewable energy (%)

Labor cost ($/unit)Cost for use of energy ($/unit)Cost of consumables ($/unit)Maintenance cost ($/unit)Cost of by-product treatment ($/unit)Indirect labor cost ($/unit)

Operator Safety Personnel Health Waste ManagementExposure to Corrosive/toxic chemicals (points/person)Exposure to high energy components (points/person)Injury rate (injuries/unit)

Chemical contamination of working environment (mg/m3)Mist/dust level (mg/m3)Noise level (dB)Physical load index (dimensionless)Health related absenteeism rate (%)

Mass of disposed consumables (kg/unit)Consumables reuse ratio (%)Mass of mist generation (kg/unit)Mass of disposed chips and scraps (kg/unit)Ratio of recycled chips and scraps (%)

Process Sustainability Metrics for ProcSI



ProcSI Example

Near-dry (MQL) machining Dry machining Cryogenic machining

Scores for the six process sustainability clusters



Assessing Product Sustainability

Product Sustainability Index

(ProdSI)

Economy

Initial Investment

Direct/Indirect Costs and Overheads

Benefits & Losses

Environment

Material Use and Efficiency

Energy Use and Efficiency

Other Resources Use and Efficiency

Wastes & Emissions

Product End-of-Life

Society

Product Quality and Durability

Functional Performance

Product EOL Management

Product Safety and Health Impact

Product Societal Impact Regulations and Certification

• Product Sustainability Index (ProdSI)

(Based on Shuaib, Seevers, Zhang, Badurdeen, Rouch, and Jawahir, 2014)


Metrics Clusters Example MetricsUnit(D/L

dimensionless)

PM(pre-mfg.)

M(mfg.)

U(use)

PU(post-use)

Residues Emissions Rate (carbon-dioxide, sulphur-oxides, nitrous-oxides etc.) mass/unit √ √ √ √

Energy Use and EfficiencyRemanufactured Product Energy kWh/unit √ √ √

Maintenance/ Repair Energy kWh/unit √Product End-of-Life

Management Design-for-Environment Expenditure $/$ (D/L) √Material Use and efficiency Restricted Material Usage Rate mass/unit √ √ √Water Use and Efficiency Recycled Water Usage Rate gallons/unit √ √ √

Cost Product Operational Cost $/unit √Innovation Average Disassembly Cost $/unit √Profitability Profit $/unit √

Product QualityDefective Products Loss $/unit √

Warranty Cost Ratio $/unit √Education Employee Training Hours/unit √ √ √Customer

SatisfactionRepeat Customer Ratio (D/L) √ √

Post-Sale Service Effectiveness (D/L) √Product End-of-Life

Management Ease of Sustainable Product Disposal $/unit √

Product Safetyand Societal Well-being

Product Processing Injury Rate incidents/unit √ √ √Landfill Reduction mass/unit √ √ √ √

Example Metrics for ProdSI and Lifecycle Stages


SI13.0%

12.2%

12.6%

11.7%

6.5%

6.5%

4.47

4.80

4.49

5.05

4.80

4.80

5.14

5.47

5.14

5.72

5.14

5.14

4.30 4.80 5.30 5.80

Regulation Compliance

Mass of Water Used

Waste Management Regulation Compliance

Ratio of Recycled Water Used

Energy Regulation Compliance

Energy Certification

Environment - Gen1

Toner Cartridges

ProdSI Example

Comparison of ProdSI for Toner Cartridges

Performance Comparison

(Based on Shuaib, Seevers, Zhang, Badurdeen, Rouch, and Jawahir, 2014)

(Source: Swiftink.com)


Sustainability Improvement in Products & Processes

Case studies conducted on three major manufactured products -

Automotive Product Aerospace Product Consumer Product

(www.cdw.com) (www.foundry,ag.com)

http://www.google.com.sg/imgres?hl=en&biw=1147&bih=620&tbm=isch&tbnid=Jzf1HEjfUALL9M:&imgrefurl=http://www.enginehistory.org/GasTurbines/Blades/blades.shtml&docid=PsAYnGP6UT4VmM&imgurl=http://www.enginehistory.org/GasTurbines/Blades/PaoloPisani/Comparisons/comp_4.JPG&w=1280&h=700&ei=ezpvUZ2VCIeaiQefrIGQBQ&zoom=1&ved=1t:3588,r:1,s:0,i:82&iact=rc&dur=338&page=1&tbnh=166&tbnw=296&start=0&ndsp=14&tx=125&ty=43

http://www.google.com.sg/imgres?hl=en&biw=1147&bih=620&tbm=isch&tbnid=Jzf1HEjfUALL9M:&imgrefurl=http://www.enginehistory.org/GasTurbines/Blades/blades.shtml&docid=PsAYnGP6UT4VmM&imgurl=http://www.enginehistory.org/GasTurbines/Blades/PaoloPisani/Comparisons/comp_4.JPG&w=1280&h=700&ei=ezpvUZ2VCIeaiQefrIGQBQ&zoom=1&ved=1t:3588,r:1,s:0,i:82&iact=rc&dur=338&page=1&tbnh=166&tbnw=296&start=0&ndsp=14&tx=125&ty=43


Product and Process to System Assessment

System Metrics

Employees

Shareholders

Suppliers

Others

Communities

Governments

Customers

Performance Measurement Framework

Line Plant Enterprise Supply chain

Stakeholders

Triple Bottom Line Emphasis • Economic impacts • Environmental impacts • Societal impacts

Total Lifecycle Focus • Pre-manufacturing • Manufacturing • Use • Post-use

6R Methodology • Reduce • Reuse • Recycle

• Remanufacture • Redesign • Recover

Sustainable Manufacturing Philosophy

Process Metrics • Manufacturing cost • Operator safety • Energy

consumption • Waste management • Environmental

impact • Personnel health

Product Metrics • Product safety and

related impact • Product quality and

durability • Resources use and

efficiency • Direct/Indirect cost …

…



System Metrics – Production Line Level

Production line: Example: Satellite Dish Production Line

Line-level Sustainability Evaluation

Other materials Energy Labor

Stamping Wash Paint Cure Oven Pad Printing Kitting Steel Coils Dish Kit

Waste Emissions By-products

Raw material usageProcess water consumptionProcess energy consumptionTransportation energy consumption

Environmental Sustainability

Evaluation

Physical Load Index (PLI)NoiseRisk Circle

Societal Sustainability Evaluation

Cycle timeChangeover timeUptimeInventory

Economic Sustainability Evaluation



Systems Metrics – Enterprise Level

Manufacturing Purchasing

Logistics Marketing

Human R. Mgt. Finance

R & D

Plant Level

Enterprise/Corporate Level

Plant 1 Plant 2

Plant 3

Line 1 Line 2

Line Level



Science-based Targets Initiative

(Source: World Resources Institute, Apparel and Footwear Sector Science-based Targets Guidance)


From Lean to Sustainable Manufacturing

Adapting and improving lean tools for sustainable manufacturing

Sustainable Value Stream Mapping (Sus-VSM)

Sustainable Total Productive Maintenance (Sus-TPM)

(Source: Badurdeen and Jawahir, 2016)


Sustainable Value Stream Mapping (Sus-VSM)

• Value Stream Map (VSM): Tool to visualize the flow of materials and information to identify value add vs. non-value add activities


Environmental and Societal Metrics for Sus-VSM

Criteria Visual Representation

Raw material usage: amount of raw material used per unit

Energy consumption: amount of energy consumed per unit during and between each process

Process water consumption: amount of water used per unit for cooling, lubrication, etc. (not in product)

Criteria Visual Representation

Physical work: evaluating work-related physical hazards to employees [Physical Load Index (PLI) to assess body postures and frequency]

PLI: 21.2/34.3

Work environment: evaluating potential hazards to employees due to the work environment [Noise, Electrical systems (E), Hazardous chemical/ materials used (H), Pressurized systems (P) , High-speed components (S)]

Environmental Metrics Societal Metrics

(Source: Faulkner and Badurdeen, 2014)

© Copyright University of Kentucky (Source: Faulkner and Badurdeen, 2014)

Pad PrintingWorkers: 4C/T: 24 secC/O: 30 minUptime: 100%PLI: 8.3/8.3Noise: 84 dbA

Cure OvenWorkers: 1C/T: 1,230 secC/O: --Uptime: 100%PLI: 17.2/17.2Noise: 83 dbA

MRPCustomer

Supplier

Supplier

Customer

1-2x Weekly

6-7x Weekly

Weekly Shop Orders

Shipping

I

2,875 dishes

I

25,424 dishes

I

Receiving

Raw Material Usage

-

+

Original: 8.25 lbs.

0.192.91

Final: 5.53 lbs

Added: 0.19 lbs

Removed: 2.91 lbs

Energy Consumption

N/A 1,084 BTU 10 BTU N/A6,849 BTU Transport: 3,340 BTU

Process: 8,154 BTU8 BTU

Process Water -- -- -- -- -- --.01 gall .01 gall .01 gall 160 gall 231 gall 64 gall -- -- -- -- -- -- 160 gall 231 gall 64 gall

Needed Used Lost

Time

Lead Time: 12.64 days

Value Added: 1,952 sec5.08 days

13 sec

2.16 days

469 sec

Steel LT = 8-10 weeks

StampingWorkers: 3C/T: 13 secC/O I: 12 minC/O II:261 minUptime: 66%PLI: 21.2/34.3Noise: 89 dbA

WashWorkers: 1C/T: 469 secC/O: --Uptime: 100%PLI: 16.9/16.9Noise: 83 dbA

PaintWorkers: 2C/T: 126 secC/O: --Uptime: 100%PLI: 8.0/8.0Noise: 83 dbA

KittingWorkers: 12C/T: 90 secC/O: 45 minUptime: 100%PLI: 17.4/35.4Noise: N/A

TransportTruck to

Warehouse

.03 days

126 sec

.01 days

1,230 sec

211 BTU 3,284 BTU N/A

I I I I I

2,875 dishes

2.75 days

24 sec 90 sec

1.45 days0.58 days 2 min 0.58 days

10 BTU 13 BTU4 BTU 11 BTU 4 BTU6 BTU

10,780 dishes

13,750 dishes 7,232

dishes

128 dishes

30 dishes

Highlands Diversified Services: Satellite Dish Sus-VSM

Evaluating Production Lines with Sus-VSM

E:-- H:--P:2 S:2

E:-- H:3P:-- S:--

E:-- H:3P:--S:--

E:--H:--P:-- S:--

E:--H:--P:--S:--

E:--H:--P:--S:--

PLI 10.2/12.0

PLI 17.0/17.0

PLI N/A

PLI N/A

PLI 14.9/14.9

PLI 2.0/2.0

PLI 31.7/31.7

PLI 31.7/31.7


Production Lines with Sus-VSM (Contd.),

2%

60%

0%

9% 0% 0%

0% 29%

Energy Consumption Stamping

Wash

Paint

Cure Oven

Pad Printing

KPI Value

Total Leadtime 12.64 days

Value Added time 1,952 Secs % Value Added Time < 1% Process Water Consumption 231 gal/unit

(64 gal/unit lost) Raw Material Usage 8.25 lbs/unit Material Utilization Rate 67% Energy Consumption 3.78 KWh/unit

0

20

40PL

I Sco

re

Process

Physical Load Index (PLI)

PLI Avg.

PLI Max.

(Source: Faulkner and Badurdeen, 2014)


Sustainable Total Productive Maintenance (Sus-TPM)

• Total Productive Maintenance (TPM) A systematic method to ensure equipment is able to function at required performance to meet customer demand

Sus-TPM Economic Metrics

Environ. Metrics

Societal Metrics

(Source: Brett and Badurdeen, 2020 - Forthcoming)


Principles


1. Process Analysis

2. Identify Sustainability Impact

3. Inventory Weighting

4. Assessment Criteria

5. Equipment Assessment

6. Impact Assessment Tree Generation

7. Develop/Refine Maintenance Plan

Refine Maintenance Plan 7

Impact Tree Y0 Impact Tree P1 ……………… Impact Tree Pn

Injection Molding Machine

Sus-TPM (Contd.),

(Source: Brett and Badurdeen, 2020 - Forthcoming)


Industry 4.0 and Smart Manufacturing

(Source: McKinsey, “Operations 4.0 Turning digital analytics into 20 percent higher productivity”, 2017)

Manufacturing technologies

Advanced sensing

Ubiquitous computing

Big Data

Artificial Intelligence

Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0

Mechanization Stream power (1776)

Mass Production Assembly line (1913)

Automation Industrial robots (1970)

Cyber-physical system (2010)

Smart Manufacturing: fully-integrated, collaborative manufacturing systems that respond in real time to meet changing demands and conditions in factory, in supply network, and in customer needs.

- National Institute of Standards and Technology (NIST)

“ “


Industry 4.0 Value Drivers for Sustainable Manufacturing

Enhanced capability for product recovery, reuse and

remanufacturing

Improved lifecycle risk assessment

Improved product – process integration

Enhanced capability for product customization

Real-time resource monitoring

Increased supply chain visibility

Improved predictive maintenance

Enhanced process quality control

Better EoL/EoU product quantity prediction

(Source: Enyoghasi and Badurdeen, 2020 - Forthcoming)

Improved supply chain robustness

Better EoL/EoU product quality prediction

In-situ process monitoring

Adaptive production control

Flexible and dynamically reconfigurable systems


Benefits of Digitally-integrated Tools

Item No. Component - variant Cost Savings ($) GWP

Saving (kg CO2eq) Water

Savings (m^3)

1 Toner Housing – PC/ABS 244,790 2,977,705 1,237,842 2 Developer Roll – Urethane 867,706 1,739,127 428,260 3 Doctor Blade – Spring 55,000 753,981 0 4 Toner Paddle – Mixed 27,500 156,126 0 5 Toner Bushings – Plastic 0 13,090 0 6 Auger – POM 40,427 80,469 39,874 7 Waste Toner Housing – PC/ABS 334,397 1,337,643 678,858 8 PC Drum Diameter – 20 mm 291,075 1,498,796 12,391,868 9 PC Drum Bushings – Plastic 0 19,617 0

10 Charge Roll - Contact 603,607 845,484 246,847 11 Toner Adder Roll 55,000 297,000 0 12 Cleaner Blade 30,250 708,116 0

Total Savings 2,549,753 10,427,153 15,023,549

Percentage Total Savings 21.6% 25.4% 23.2%

(Source: Badurdeen, Aydin, and Brown, 2019)

Digital integration allows better access to total lifecycle data for more sustainable product design


Concluding Remarks

• Significant advances are necessary to minimize the adverse impacts due to manufacturing operations

• Sustainability manufacturing requires: – Product, process and system integration – 6R-based approach for closed-loop material flow – Multi-lifecycle emphasis

• Factories of the future equipped with Industry 4.0

technologies can enhance capability to improve sustainable manufacturing performance


Institute for Sustainable Manufacturing @ UKY

Edward (Peng) Wang, Ph.D. Assistant Professor, Dept. of Electrical and Computer Engineering and Mechanical Engineering Research Areas: Smart Manufacturing, Predictive Maintenance, Human-Robot Collaboration


Thank you!

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Sustainable Manufacturing: A Product, Process and Systems ......• demonstrate reduced negative environmental impact, • offer improved energy and resource efficiency, • generate