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Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:1
Environmentally Conscious Design & Manufacturing
Class 4: Life Cycle Analysis-Design
Prof. S. M. Pandit
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:2
Agenda:
- Motivation and Introduction
- Product Life Cycle
- Systems View
- Product Design
- Green Design Strategies
Life Cycle Analysis - Design
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:3
Motivation - 1
Steps in the life-cycle assessment of a product
Define Scope
RERPManufacture
Inventoryanalysis
Improvementanalysis
Impactanalysis
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:4
Motivation - 2
The elements of a life-cycle inventory analysis
Materials acquisition
Product distribution
Product use
Recycle:Products,components, materials
Waste management
Materials
Energy
Air
Water
Formulation, processing,and manufacturing
Principalproducts
Co-products
Watereffluents
Airborneemissions
SolidWaste
Other environmentalinteractions
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:5
Motivation - 3
• A life cycle inventory and impact assessment provides a snapshot of the environmental features of
- Products or - Processes
Discrete Products: - Machined shaft- Gearbox- Washing Machine
Milling operationOil refiningBeverage mixing and bottling
Hazards and Risks
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:6
Raw Material Extraction
Manufacturing
Use
Post Use“Waste”•Energy•Materials•Fluids
Power Generation
Material Handlingand Logistics
Product Life Cycle
Introduction -1
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:7
Introduction -2
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:8
Raw material extraction
Manufacturing
Use
Post Use
- Disposal- Recycling- Remanufacturing
Product Life Cycle - 1
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:9
- Design for disassembly methodologies
- Design for recycle and reuse methodologies
- Design for decommissioning of equipment
Environment
Product functionality and quality
Cost
Product Life Cycle - 2
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:10
Design factors
- Env.
- x
Product Life Cycle - 3
ComplianceAssembly Environment
Reliability
Orderability
TestabilityServiceability
Manufacturabiliy
Material Logisticsand Component
Applicability
Safety and Liability Prevention
Design for X
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:11
Material Handling and Logistics
Discrete Event Models - I/O response from simulation
Power Generation
Idealized models with empirical weights
Product Design
Process Models
‘Usage’ models
Recycling / Reuse / Biodegradation / Chemical degradation / Physical degradation & collection
• Environment• Cost• Function ..
Systems View - 1
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:12
Systems View - 2
Product attributes
•Weight
•Size
•Can be palletized?
•Handle with care?
•Cost
Material Handling and Logistics
Speed of movement?
Distance to be moved?
Sensor (vision?)
Control (fuzzy?)
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:13
Material Handling and Logistics
Discrete event Model
Simulation •Control•Movement•Queuing
Product attributes
TimeCostHandling capacitySuccess / Failure statistics
Systems View - 3
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:14
“Materials”
StrengthCreep resistanceThermal & Electrical properties
“Mechanical”
Power outputKinematicsVelocity ratios
“Functional Requirements”
(Does it do the job?)
“Aesthetic Requirements”
“Environmental Factors”
(Does it do the job?)
Product Design(Bridge between Design Islands)
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:15
Multidisciplinary research that would result in
validated models of physical processes that also
incorporate
• life cycle,
• environmental, and
• economic parameters-as well as
• traditional process control parameters.
Green Design - 1
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:16
Ideally these models would
• use the best computer technology-• but be adaptable to manufacturing
environments.
Tied directly to the modeling was the need for correlation of
• materials/chemical properties and • structure with processing parameters.
Green Design - 2
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:17
Closely related is instrumentation research that canenhance process monitoring, & control
The need for novelty and creativity in solving technicalproblems is stressed throughout.
To attain goals of total sustainability simple enhancements of traditional methodology will not usually be sufficient.
Green Design - 3
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:18
• New approaches to processing• Sensors that monitor phenomena that are unmonitorable
today • New materials that survive high temperatures and
corrosive environments and last "forever," • New technologies for energy efficiency and clean
combustion • New ways to separate effluents • New approaches to catalysis• Without basic research these leaps are unlikely to occur.
Green Design - 4
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:19
Every industry will need highly specific chemical sensors for applications such as process control, process monitoring, ambient monitoring, and leak detection.
These sensors must be fast, reliable, robust, inexpensive, sensitive, miniature, on-line capability, local, remote, for multicomponent analysis.
In addition, all these features must be available for sensing in gaseous and liquid environments (including air and water) where the conditions may be considered harsh or even hostile.
Green Design - 5
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:20
Given the fact that water quality concerns are prominent throughout industry, another common need is for improved water quality sensors with the same characteristics noted above for chemical sensors but focusing almost exclusively on those parameters measuredfor regulatory purposes including BOD, TOC, and particulates.
Similarly, there is a need for improved air quality sensors to accurately and rapidly measure extremely low quantities ofvolatile organic chemicals and particulates.
In particular, measurements of particle size distributions were identified as a specific need. It will be increasingly necessary to develop methodologies for multi-point as well as multi-species monitoring.
Green Design - 6
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:21
Another research need, common to all of the industries discussed, falls in the general category of physical sensors.
It was found that the need for fast, reliable, inexpensive physical sensors that can operate in harsh environments currently exists and that need will certainly increase in the future. Even a need for improved temperature sensors was identified.
Other specific sensing needs include (1) particle size distribution, (2) non-destructive evaluation (NDE) of near-net shape to reduce material waste, (3) structural integrity so as to avoid catastrophicsystem failure resulting in release of process fluids, (4) rheometry especially for complex fluids such as slurries, (5) multiphase flow parameter sensors, and (6) leak detection.
Green Design - 7
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 13, 2000 Slide:22
The final common element centered on the need for
improved data processing and management.
With the large scale increase in sensors and rapid
monitoring devices it is obvious that careful attention must
be paid to the collection and use of large amounts of data.
Error detection and identification, multiple sensor data
"fusion" (i.e., integration, interpretation), and robust
control methods must be enhanced.
Green Design - 8