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Sustainable Manufacturing: The Driving Force for Innovative Products, Processesand Systems for Next Generation Manufacturing
I. S. Jawahir
James F. Hardymon Chair in Manufacturing Systems,
Professor of Mechanical Engineering, and
Director, Institute for Sustainable Manufacturing (ISM)
College of Engineering
University of Kentucky
Lexington, KY
Phone: (859) 257-6262 ext. 207 Fax: (859) 257-1071
E-mail: [email protected] Website: www.ism.uky.edu
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Sustainable Growth: Example of a Tree Planted
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SocietyEnvironment
Economy
Technology
and
Human Resources
Education & Training
CreativityInnovation
The Foundation of Sustainable Development
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The creation of manufactured products that use processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and consumers and are economically sound
(US Department of Commerce, 2009)
Sustainable manufacturing includes:
(a) manufacturing of “sustainable” products, and
(b) sustainable manufacturing of all products.
The former includes:
manufacturing of renewable energy, energy efficiency, green building, and other “green” & social equity-related products,
and, the latter emphasizes:
sustainable manufacturing of all products taking into account the full sustainability/total life-cycle issues related to the products manufactured
(National Council for Advanced Manufacturing (NACFAM), 2009)
Sustainable Manufacturing: Definition
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Sustainability is the driver for innovation
Innovation promotes accelerated growth in manufacturing
Manufacturing is the engine for wealth generation and
societal well-being
Societal well-being and economic growth heavily depend on
the level and quality of education and training
Innovation-based Sustainable Manufacturing
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Sustainable
Manufacturing
Products Processes
Systems
Integral Elements of Sustainable Manufacturing
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Emphasis on all four product life-cycle stages
Manufacturing
Pre-manufacturing
Use
Post-use
Holistic and Total Life-cycle Approach
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Closed-loop Material Flow – The 6R Approach
3RCONCEPT
6RCONCEPT
Source: Jawahir et al. (2006)
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Sustainable Manufacturing(Innovative, 6R-based)
Innovation Elements
Remanufacture
Redesign
Recover
Recycle
Reuse
Reduce
Evolution of Sustainable Manufacturing
Lean Manufacturing(Waste Reduction-based)
Green Manufacturing(Environmentally-benign, 3R-based)
Traditional Manufacturing(Substitution-based)
Time1990 2000 20101980 2020 2030 2040 2050
Sta
keh
old
er V
alue,
$
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Design for Environmental
Impact
Design for Recyclability/
Remanufacturability
Design for Societal Impact
Design for Functionality
Design for Manufacturability
Design for Resource
Utilization and
Economy
Design for Sustainability
(DFS)
Regional and Global Impact
Energy Efficiency/Power Consumption
Ass
em
bly
Service Life/ Durability
Social Impact
Product Design for Sustainability
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Aerospace industry:
– 50 wt% of aero-engine alloys are
nickel-based alloys – continuous
efforts to substitute materials.
– Stationary and rotating
components in the hot end of jet
engines (e.g., turbine disk) –
Predictability of cracks comes
from the study of sustainability
science - allows reuse options at
a cost advantage of 16 times!!
– The reused disks are as safe as, or
even safer than newly machined
ones.
Product Reuse in Sustainable Manufacturing
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Personnel Health
Power Consumption
Environmental Friendliness
Operational Safety
Manufacturing Cost
Sustainable Manufacturing
Processes
Waste Management
Sustainability Elements of Manufacturing Processes
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Cryogenic Machining
Environmentally-friendly and safe coolant
Increased productivity
Better part surface quality
Cost-effective
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• Make innovation a continuous process for new and advanced products
and processes
• Integrate digital product and process models throughout the product
life cycle to ensure the success of the model based enterprise (MBE).
• Embrace and work to create interoperability throughout the
manufacturing enterprise.
• Develop and implement successful processes for information
management and ownership, including intellectual property (IP)
issues.
• Work to develop resilient supply chains that can accommodate natural
disasters and changes in players.
Extracts from the IMTI Benchmarking New Technology Workshop (February 2010)
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• New materials technologies for sustainable products
Molecular, microstructural and metallurgical transformation of materials;
self-healing materials and memory alloys
• Product innovation for sustainable manufacturing
Product sustainability metrics; product design for sustainability including
1R – 3R – 6R transformations
• Process innovation for sustainable manufacturing
Environmentally benign/responsible manufacturing process development –
toxic-free, hazardless, safe and secure technologies; minimal use of energy,
water, including metal working fluids, chemicals, and other resources
• Innovation and creativity in supply/value chain operations
Integrated manufacturing systems for sustainability; sustainable supply
chain operations; sustainable quality systems for manufacturing
Technological Challenges and Opportunities for Sustainable Manufacturing
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• Compliance with regulations (REACH, WEEE, RoHS, EuP, ELV, etc.)
• Economic analysis and business case for sustainable manufacturing
Marketing strategies and business economics for sustainable products
and processes
• Safety, health, public policy and regulatory issues in sustainable
manufacturing
Societal Impact studies; legislative and administrative issues; policy
implementation; product and process liability; ethics
• Education and training issues
Technological Challenges and Opportunities for Sustainable Manufacturing (Cont’d)
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• Sustainable manufacturing offers uniquely new kind of employment
opportunities:
- Innovative 6R applications
- Total life-cycle consideration
- Sustainable manufacturing processes
• Universities and colleges are well-positioned to provide educational and
training programs
- Undergraduate and graduate education
- Non-credit professional continuing educational programs
• Incentives must be provided to academic institutions and manufacturing
companies to educate, train and develop the workforce for next generation
manufacturing, and for conducting relevant fundamental and applied
research.
New Employment Opportunities
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• Richard Neal and Sam McSpadden, IMTI, Inc.
• Walter Roy, US Army
• Professor O.W. Dillon, Jr., University of Kentucky
Acknowledgments
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• 2010 Global Manufacturing Competitiveness Index, Deloitte and US Council on Competitiveness, June 2010.
• Ram Nidumolu et al., “Why Sustainability is now the Key Driver of Innovation”, Harvard Business Review, September 2009, pp. 1-10.
• Kenneth Arrow et al., Are We Consuming Too Much, Journal of Economic Perspectives, Volume 18, Number 3, Summer 2004, pp. 147-172.
• IMTI Report, Managing Aerospace Materials for Continuity and Sustainability, Document No.: IMTI10017, IMTI, Inc., August 4-5, 2009.
• IMTI Report, Benchmarking New Technology Applications, Document No.: IMTI10006-FINAL, IMTI, Inc., February 8, 2010.
• IMTI Report, DoD Sustainable Chemical and Material Management, IMTI Workshop, June 10-11, 2009, IMTI, Inc.,
• IMTI Report, Materials Lifecycle and Environmental Considerations at NASA, Document No.: IMTI10010-D2, February 23-24, 2010.
• I.S. Jawahir and O.W. Dillon, Jr., “Sustainable Manufacturing Processes: New Challenges for Developing Predictive Models and Optimization Techniques”, (Keynote Paper), Proc. 1st International Conference on Sustainable Manufacturing (SM1), Montreal, Canada, October 18-19, 2007, pp. 1-19.
• I.S. Jawahir et al., “Total Life-cycle Considerations in Product Design for Manufacture: A Framework for Comprehensive Evaluation”, (Keynote Paper), Proc. TMT 2006, Lloret de Mar, Barcelona, Spain, September 2006, pp. 1-10.
• I.S. Jawahir, O.W. Dillon, Jr., A. Jayal, F. Badurdeen and K.E. Rouch, “Developing Next Generation Products and Processes using Innovative Sustainable Manufacturing Principles, (Keynote Paper), 4th Int. Conf. on Sustainable Energy and Environmental Protection (SEEP 2010), Bari, Italy, June 30 – July 2, 2010.
Key References