sustainable manufacturing: a product, process and systems ......• demonstrate reduced negative...
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© 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
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• Resource Consumption – 90 billion tons in 2017
(Source: Measuring Progress Towards achieving the environmental dimension of the SDGs, UNEP, 2019)
Current Outlook
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• Growth in resource extraction
(Source: UNEP Global Environment Outlook, 2019)
Current Outlook (Contd.)
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• 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)
Current Outlook (Contd.)
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Current Outlook (Contd.)
• 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)
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Current Outlook (Contd.)
• 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)
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UN Sustainable Development Goals
(Source: UNEP, The 6th Global Environment Outlook, 2019)
Sustainable Manufacturing
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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!
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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
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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)
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Product, Process, System Integration
• 6R-based sustainable manufacturing requires emphasis across different domains
Systems
Products
Processes
Sustainable Manufacturing
( Source: Badurdeen et al., 2011)
Coordinating Product and Process Design
Coordinating Product and Supply Chain Design
Coordinating Process and Supply Chain Design
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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)
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(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
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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
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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)
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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
Sustainable Manufacturing
Processes
Waste Management
(Source: Wanigarathne et al., 2004)
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Process Sustainability Clusters and Sub-clusters
(Source: Lu, , Shuaib, Rotella, Badurdeen, Dillon, Jr., Rouch, and Jawahir , 2020 - Forthcoming)
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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
(Source: Lu, , Shuaib, Rotella, Badurdeen, Dillon, Jr., Rouch, and Jawahir , 2020 - Forthcoming)
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ProcSI Example
Near-dry (MQL) machining Dry machining Cryogenic machining
Scores for the six process sustainability clusters
(Source: Lu, , Shuaib, Rotella, Badurdeen, Dillon, Jr., Rouch, and Jawahir , 2020 - Forthcoming)
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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)
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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
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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)
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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)
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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 …
…
(Source: Huang and Badurdeen, 2016)
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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
(Source: Huang and Badurdeen, 2016)
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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
(Source: Huang and Badurdeen, 2016)
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Science-based Targets Initiative
(Source: World Resources Institute, Apparel and Footwear Sector Science-based Targets Guidance)
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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)
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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
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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)
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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
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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)
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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)
Sustainable Manufacturing
Principles
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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)
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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)
“ “
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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
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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
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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
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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
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Thank you!
Questions?