TRENDS IN SUSTAINABLE

MANUFACTURING

Dr. Juanjo Zulaika

TECNALIA R&D

Pro-Factory Plus 2011San Sebastian, 6th October

Approach for Sustainable Manufacturing:

REDUCE:REDUCE:

ECONOMIC ECONOMIC

++

SOCIAL SOCIAL

++

ENVIRONMENTALENVIRONMENTAL

COSTSCOSTS

IN THE LIFECYCLE OF IN THE LIFECYCLE OF MANUFACTURING MANUFACTURING PROCESSES AND PROCESSES AND SYSTEMSSYSTEMS……

…WHILE MAXIMIZING THE ADDED VALUE TO THE USER

Sustainable Manufacturing:

REDUCE ECONOMIC COSTS:REDUCE ECONOMIC COSTS:

The exploitation cost (use stage) of a The exploitation cost (use stage) of a manufacturing system may become manufacturing system may become

much higher than its acquisition costmuch higher than its acquisition cost

Key issues:Key issues:

High ReliabilityHigh Reliability

Low energy Low energy consumptionconsumption

Sustainable Manufacturing:

REDUCE ENVIRONMENTAL COSTS:REDUCE ENVIRONMENTAL COSTS:

In an average manufacturing system, In an average manufacturing system, the energy consumption represents the energy consumption represents

above 90% of total environmental costsabove 90% of total environmental costs

Key issue:Key issue:

Low energy Low energy consumptionconsumption

5

End of life (recycling)

1

Material production

2

Manufacture & assembly

3

Transport

4

Use

Energy consumption (95% of use impact)

Phase CO2 Tons %

1 100.65 6.7%

2 5.64 0.4%

3 4.14 0.3%

4 1,124.24 95%

5 -34.39 -2.4%

Total 1,500.2 100%

General view for Sustainable Manufacturing:

Closely related to reducing the consumption of Closely related to reducing the consumption of resources resources -- especially energy resourcesespecially energy resources -- in reliable in reliable

and high valueand high value --adding manufacturing systems.adding manufacturing systems.

Main Trends in Sustainable Manufacturing:

1)1) Integrated productIntegrated product --processprocess --machine approachesmachine approaches

2)2) Reduce the use of material and energy resourcesReduce the use of material and energy resources

3)3) Improve the energyImprove the energy --efficiency by energy efficiency by energy management systemsmanagement systems

4)4) Reusing and recovering energy implemented in Reusing and recovering energy implemented in production systemsproduction systems

5)5) Using renewable resourcesUsing renewable resourcesEnvironmental impact

(2)(3)

(4)(5)

(1)

Main Trends in Sustainable Manufacturing:1)1) Integrated productIntegrated product --processprocess --machine approachesmachine approaches

-- CO2PECO2PE! Initiative! Initiative

-- Aimed at analyzing and Aimed at analyzing and documenting the documenting the environmental impact environmental impact --especially energy especially energy consumptionconsumption -- of different of different manufacturing processes, manufacturing processes, including innovative and new including innovative and new sustainable processes such sustainable processes such as as additive manufacturingadditive manufacturing and and near net shape near net shape techniques.techniques.

-- Coordinated by KU Leuven Coordinated by KU Leuven

Main Trends in Sustainable Manufacturing:2)2) Reduce the use of material and energy resources Reduce the use of material and energy resources

-- DEMATDEMAT Project (Project ( NMPNMP--VII FP), VII FP), coordinated by Tecnaliacoordinated by Tecnalia

-- Goal : To reduce the use of Goal : To reduce the use of mass in the conception stage mass in the conception stage as means for reducing the as means for reducing the energy consumption in the energy consumption in the use stage.use stage.

-- Technologies involved: new Technologies involved: new machine architectures, new machine architectures, new structural concepts, structural concepts, lightweight materials, active lightweight materials, active damping devices, etc.damping devices, etc.

Main Trends in Sustainable Manufacturing:3)3) Improve the energyImprove the energy --efficiency by energy efficiency by energy

management systemsmanagement systems

-- ECOMATIONECOMATION Project.Project.

-- Goal: Goal: Control of Control of Energy Consumption in Energy Consumption in Production to Achieve Production to Achieve Energy Efficiency Energy Efficiency MaximisationMaximisation ..

-- German Project led by German Project led by the Univ. of Stuttgartthe Univ. of Stuttgart

Main Trends in Sustainable Manufacturing:4)4) Reusing and recovering energy implemented in Reusing and recovering energy implemented in

production systemsproduction systems

-- eniPRODeniPROD Project: Project: towards towards almost almost emissionemission --free free production processes.production processes.

-- German Project led German Project led by by FraunhFraunh . . IWUIWU

-- KERSKERS in machine in machine tools: recover energy tools: recover energy from spindle; analysed from spindle; analysed strategies: strategies: supercapacitorssupercapacitors , , motormotor --generatorsgenerators

Main Trends in Sustainable Manufacturing:5)5) Using renewable resources: material and energy. Using renewable resources: material and energy.

Clean energy sources + low impact materials Clean energy sources + low impact materials

Not covered well Not covered well enough at research enough at research and industrial level: and industrial level: One of the topics One of the topics identified by identified by ManufutureManufuture Platform Platform for upcoming for upcoming FoFFoF Calls Calls in in NMPNMP

I.I. The lifecycle of manufacturing systems and their The lifecycle of manufacturing systems and their components will trend to be increasingly longer components will trend to be increasingly longer for reducing lifecycle impacts & costs in for reducing lifecycle impacts & costs in manufacturing processes:manufacturing processes:

-- Scarce and expensive natural resourcesScarce and expensive natural resources

-- Reuse of components with lifecycles longer Reuse of components with lifecycles longer than manufacturing systemsthan manufacturing systems

-- Maintenance for higher reliabilityMaintenance for higher reliability

-- Modular conception for easy reconfigurationModular conception for easy reconfiguration

-- Market opportunity for Market opportunity for demanufacturingdemanufacturingsystemssystems

Some Conclusions from these Main Trends in Sustainable Manufacturing:

Some Conclusions from these Main Trends in Sustainable Manufacturing:

II.II. There is a need to integrate economic There is a need to integrate economic sustainability and environmental sustainability:sustainability and environmental sustainability:

-- Despite benefits of sustainability are general, Despite benefits of sustainability are general, costs of polluting are low and costs of costs of polluting are low and costs of implementing environmentallyimplementing environmentally --friendly friendly processes may be high: processes may be high: EcoEco--efficiency is not efficiency is not sustainable per se.sustainable per se.

-- Future need/trend: monetise the Future need/trend: monetise the environmental costs of manufacturing environmental costs of manufacturing processes: processes: sum the monetised environmental sum the monetised environmental costs of manufacturing processes to the costs of manufacturing processes to the actual costs of manufacturing systemsactual costs of manufacturing systems

Some Conclusions from these Main Trends in Sustainable Manufacturing:

II.II. There is a need to integrate economic There is a need to integrate economic sustainability and environmental sustainability:sustainability and environmental sustainability:

-- Future need/trend: monetise the Future need/trend: monetise the environmental costs of manufacturing environmental costs of manufacturing processes: processes: sum the monetised environmental sum the monetised environmental costs of manufacturing processes to the costs of manufacturing processes to the actual costs of manufacturing systemsactual costs of manufacturing systems

““ EU should address taxes and subsidies that do not r eflect EU should address taxes and subsidies that do not r eflect the real costs of resource usethe real costs of resource use …”…” ""

““ Environmental taxation [Environmental taxation [ ……] can facilitate the restructuring ] can facilitate the restructuring towards a resourcetowards a resource --efficient economyefficient economy ””Communication from the Commission to the European Parliament. Communication from the Commission to the European Parliament. Roadmap to a Resource Efficient Europe, Brussels, 2011/09/20Roadmap to a Resource Efficient Europe, Brussels, 2011/09/20

Thanks for your attention.Thanks for your attention.

Contact: Contact:

juanjo.zulaika@tecnalia.comjuanjo.zulaika@tecnalia.com