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Analyze a real world problem Design a software solution for that problem

Zhen Chen

Solano Community College

Sustainable Manufacturing

Source: David Dornfeld, Ph.D. Will C. Hall Family Professor of Engineering, Director, Laboratory for Manufacturing and Sustainability (LMAS), University of California, Berkeley

Sustainability – everyone has a role to play

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Source: The University of Toledo – SEED Initiative, http://www.utoledo.edu/sustainability/; accessed 6.9.14

First, what is sustainability? Sustainable? Green?

Sustainability – everyone has a role to play

+Who … what … where …?

+ How you design and produce things matters a lot

+ There are concrete impactful actions that manufacturers can take

How it is made … ?

Technology

MaterialEnergy

Green manufacturingsystem triangle

Improve energy

efficiency

Improve materialefficiency

Reduceembedded energy

Improve manufacturing process

Use lower impact materials

Use clean energy

sources

Cost issue

Costissue

Cost issue

1

2 3

Source: Chris Yingchun Yuan, A System Approach for Reducing the Environmental Impact of Manufacturing and Sustainability Improvement of Nano-scale Manufacturing, PhD. Thesis, UC-Berkeley, 2009

Manufacturing and energy mix

Material yield,supply chain/source and haz, chemistry/chemical effects

Energy reduction, harvesting, combined processes, optimization, sustainability budget

+ There are concrete impactful actions that manufacturers can take

Example … line level

Process 1

Process 2

Process 3 Process n…

Energy Water Consumables

Waste Heat

Air Emission

s

Waste Water

Solid Waste

s

Process 1 Part / Product

Material / Part

Process 1

Source: Robinson, S. “An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability,” (December 2013), Doctoral Dissertation, UC-Berkeley.

+ There are concrete impactful actions that manufacturers can take

Optimize over the system

Source: Robinson, S., Dornfeld, D. “Leveraging Advanced Manufacturing for Sustainable Production,”Proc. 2014 International Symposium on Flexible Automation, Awaji-Island, Hyogo, Japan, July 14 – 16, 2014.

Savings/Value

Envir

onm

enta

lB

enefit

Current

Improved

Process 2

Process 4

Process 3

Process N

Process 1

Cost and environmental

impact

$

And extends to tooling and operations also …

+Example of process optimizationReal-time data processing is used to collect

and process data in parallel to a machine’s operationto save time and data storage

There are concrete impactful actions that manufacturers can take

+Data Mining and

Data Mining in Manufacturing What is data mining?

The process of the "Knowledge Discovery in Databases“

Enabled by improved computing power, increasing internet availability and decreasing of data storage cost

Data mining is a fast growing technology in many areas with great potential

Data mining effort in business, e-commerce and more

+Data Mining in Manufacturing cont.

Vast amounts of data are available to be collected from manufacturing systems at different levels From system-level to the operation-level with varying

degrees of complexity Data analysis can lead to

System and process optimization Informed decision making

Data driven accurate predictions on many aspects: Power consumption Resource usage Tool wear …

+Example of Data Mining in Manufacturing

Image source: http://www.qualitydigest.com/sept06/articles/04_article.shtml

+A real world data mining problem A machine shop has two automatic milling machines.

Machines’ operation output data is in XML format. To improve the energy efficiency of the machines, operation data of power consumption and time stamps for each operation need to be extracted from the XML file. The extracted data will be calculated and then saved for analysis and comparison.

Find a solution in software for this problem

Save extracted data into a data file

Calculate the average power consumption of each operation

Display and write to an output file the elapsed time and the average power consumption of each operation