Industrial Sustainability h t IfM &research at IfM &

Introduction to the Centre

PRESENTED TO PRESENTED BYIfM Open Day SE 15/05/2012

Purpose of presentation

To briefly explain the topic of Industrial SustainabilityTo explain our plansp p

What we are doingHow we are doing itWho withWho with

To present some early results

Manufacturing & Efficiency

300% improvement in productivity since 1979We make more today than ever

We belie e that s stainabilitWe believe that sustainability –environmental, social and economic –will be at the heart of our next changewill be at the heart of our next change

What is Industrial Sustainability?

The Challenge:

To double output, To emit 80% less GHGs, To halve resource use

All by 2050

The challenge requires new approaches an d d hnew understanding that we term 

Industrial Sustainability, which is nothing less than a new industrial

“Manufacturing’s contribution to a more sustainable society” which is nothing less than a new industrial 

revolution 

Case Study:

Who is this?

TMM Europe Targets Actual (2001-2006)TMM Europe Targets1. Energy usage2. Water usage3. Volatile Organic Compounds (VOCs)

Actual (2001 2006)1. - 44%2. - 37%3. - 32%g p ( )

released from painting operations4. Waste to landfill5. Degree of compliance with

4. - 99%5. All plants ISO14001g

environmental regulations6. Number of complaints from external(neighbourhood) parties

Sustainability in ManufacturingSustainability in Manufacturing- Towards Zero Emissions

Steve HopeGeneral Manager Plant Engineering and SafetyToyota Motor Europe

Key environmental priorities y p

Energy use (C02) Water consumptionp

Waste generated

Waste sent to landfill

Volatile Organic Compound emissions

Waste sent to landfill

Aim:-Zero

Emissions

l i

Toyota Motor Europe

Green Lean and Clean World No.1Regional No.1

World No.1Regional No.1

Toyota Motor EuropeEnvironment and FacilityPlant Engineering Division

Ultimate ECOFactory

Green, Lean and CleanTowards the Ultimate

ECO FactoryOC

No 1 Performance by 2010T O Y O T A

g

Improvementof

EnvironmentalPerformance

T O Y O T A

g

Improvementof

EnvironmentalPerformance

Zero CO2Zero Incineration

VOC Free

Plant Minimum Requirements

New Plant Design Criteria

E M SLaw

Adherence

Compliance/no-complaint Environmental

Risk

Prior Prevention

Minimizationof

E M SLaw

Adherence

Compliance/no-complaintCompliance/no-complaint Environmental

Risk

Prior Prevention

Minimizationof

Integrated Approach

Zero LandfillRenewable Energy Recover RainwaterSubstance of Concern Free

Toyota EnvironmentManagement System

Organisational LearningProblem Solving, Root Cause Analysis, Kaizen (Continuous Improvement) and Yokoten (Sharing)

ECO AuditControl Criteria

Prior PreventionISO 14001

Risk AuditInternal Control Limits Apply 5R’s Hierarchy

Refine, Reduce, Reuse. Recycle, Recovery to Energy

Risk Air Land WaterZero Non Compliance

Energy

Optimised Environmental Performance

ReductionCompliance & Complaint Toyota Production System

S.B. Hope 1st August 2006

…..dramatic reductions achieved in EU…..dramatic reductions achieved in EU

2000

2500

3

3.5Energy kWh/Veh Water m3/Veh

1000

1500

2000

1.5

2

2.5

~40% ~44%

0

500

2001 2003 2005 2007 20090

0.5

1

2001 2003 2005 2007 2009EU Consolidated KPI results

25

30

35

303540Waste kg/Veh Air Emission (VOC) g/m2

~38% ~51%

EU Consolidated KPI results– 2001 - 2009

10

15

20

25

10152025~38% ~51%

Zero Waste to

0

5

2001 2003 2005 2007 200905

2001 2003 2005 2007 2009+ VE factor - Increasing vehicle production volume-VE factor - Increasing vertical integration (2 x engine / transmission plant introduced)

Landfill (8/9 sites)

Environmental KPI Results (TMUK) ( )

WATERWater usage per vehicle (m3)ENERGYEnergy usage per vehicle (KWh)

56789

10

/Car

Over 75% Reduction4000

5000

6000

7000

h/C

ar

Over 70% Reduction

012345

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

m3/

0

1000

2000

3000

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

Kw

h

YearsYears

VOLATILE ORGANIC COMPOUNDS

90

VOC emissions per vehicle (g/m2)WASTE

40

Waste produced per vehicle (kg)

30405060708090

g/m

2

Over 70% Reduction

10152025303540

Kg/

Car

Over 60% Reduction

01020

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

Years

05

10

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

Years

Examples of Leadershipp pEnergy reductionInter shift shutdown focusInter-shift shutdown focus

Burnaston Plant site electrical loading

Between shifts Oct 06 (no production)Oct 06

May 08

Day shift (production)

Night shift (production)

MW

• Employees responsible for switch off

• Energy switch observation points

06:30

07:00

07:30

08:00

08:30

09:00

09:30

10:00

10:30

11:00

11:30

12:00

12:30

13:00

13:30

14:00

14:30

15:00

15:30

16:00

16:30

17:00

17:30

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18:30

19:00

19:30

20:00

20:30

21:00

21:30

22:00

22:30

23:00

23:30

00:00

00:30

01:00

01:30

02:00

02:30

03:00

03:30

04:00

04:30

05:00

05:30

Time Energy switch observation points

• Clear instructions for switch off times

• Local ownership of energy control

TimeTime

Target: no production = no energy use

Further Develop the Manufacturing “Vision”Further Develop the Manufacturing Vision

Established 20062006

Ultimate ECO Car Ultimate ECO Factory

Compliance Energy (CO2) Water Waste Air Emissions

Equipping & inspiring our members (employees)q pp g p g ( p y )

Consistent & Strong Leadershipeg Board-led environmental forums

Environment trainingEnvironment trainingeg general awareness, technical skills

Member involvement eg – “window” role, quality circleseg window role, quality circles

Consistent / Frequent Communicationseg – Green Month, Open days, shop level events

Develop Specialised Energy Saving Teamsp p gy gTrain the Trainers

In House Training - The 6 Attitudes Then developEU Wide Teams

Detailed Measurement and Analysis Skills

Beyond benchmarking –Determine concepts of “Minimum Requirement”

Renewable PowerRenewable PowerExample

•Large Scale PV Installation at TMUK•17,000 panels, 4.1MW Peak, 4,600,000 kWh / ann•Joint Venture with British GasJoint Venture with British Gas•All power is used on site

Collaboration ProjectjCurrent Method Future Image Collaborative Project

Separate energy studiesB ildi

Integrated energy studyB ildi•Building

•Process group•Individual process

•Building•Process group•Individual process Integrated modelling tool

Incorporating 6 attitudes

Eco‐Efficiency at Toyota Europe

/Energy in manufacturing (kWh/vehicle)2001 ‐ 2006 = 44% reduction 2006 on new programmes2006 ‐ on = new programmes2010 = investigation of paint plant refrigeration?2011 = investigation of paint drying?g p y g

When will they reach a limit?yWhat is that upper limit?What is your upper

limit & how close are you?

Themes and practiceECO EFFICIENCY ECO TECHNOLOGY INDUSTRIAL SYSTEMECO‐EFFICIENCY, ECO‐TECHNOLOGY, INDUSTRIAL SYSTEM

3 themes align with short, medium and long term changes to th i d t i l tthe industrial system

Areas of activity in manufacturing

U b t ti

material material

Use best practiceUse best technologyUse best systems

energywater

(higher value)

Includes: monitoring, measurement,

d lli

materialtoxicity

modelling, process technology, control technology, waste processing, energy harvesting material

energywater

yquantitypurity (mix)

energy harvesting, energy creation, material substitution, etc

Research Themes

Use best practice

Use best technology

Use best systems

What are we planning to p gdo about it?

A new national research tcentre

PRESENTED TO PRESENTED BYSE 15/05/2012

Vision

We will create a transparent, collaborative community for practical research into ways to enable industry to become more sustainableenable industry to become more sustainable.

We are global in outlook open & pro‐activeWe are global in outlook, open & pro active in working with others, and transparent about our successes & failures.Challenge-led

20 Grand Challengesg200+ manufacturers88 PhDsInternational co-

tioperation

Current Members

Across sectors, large to small, & network members

Centre Investigators

Professor Steve EvansProfessor Steve EvansCentre Director, Institute for Manufacturing (fM), University of Cambridge. 

Professor Sir Mike GregoryHead of the IfM, University of Cambridge.

Professor Shahin RahimifardProfessor Shahin RahimifardDeputy Director, Professor of Sustainable Engineering, Loughborough University.

Executive Group are:Toyota

Dr Peter BallSenior Lecturer in Manufacturing Operations, Cranfield University

yGMRiversimpleUnilever

Dr Mike TennantLecturer in Business and Environment, Imperial College London

ES-KTN

Outputs

Tools and t h i th t

Large cohort of f t i d t techniques that 

improve current performance

future industry and research 

leaders

A strong Envision the 

20 Grand Challenges200+ manufacturers88 PhDs

A strong membership 

that uses results

Direct policy influence

potential future shape of the 

industrial system

Research Themes WHAT ARE TODAY’S KEY CHALLENGES?WHAT ARE TODAY’S KEY CHALLENGES?

From ‘why do factories vary?’ to ‘’which business

d l h l ?’models help?’

PRESENTED TO PRESENTED BY

Projected Centre Funding Source

TechnologyTechnology Integration & Application

TSBIndustrialFunding

Technology EPSRC

EU £1.0M 

£1.3Mg

£2.1M

Base

EPSRC Core Grant

£4 77M

EPSRC BusinessInnovation£1.7M

Univ’£1.0M

Knowledge Base

£4.77M

EPSRC Frontier£1.7MUniversity  PhDs £0.96M

M

y

Research Focus 2012

Research Focus 2016

Grand Challenge

2011 2012 2013 2014 2015 2016

Eco‐efficiency performance variation 1 1

learning systems 1.2Ex 7Ex 7Ex 10Ex 10

Keyefficiency performance variation 1.1SAKE I

Ex 11Ex 11Ex 12

KeyProjects:GC 

Explore

Learning  1.2Learning  1.2

Eco

sustainable value creation 2.4

i lli f 2 313

Explore

PhD

Funding:

Ex 11Ex 11

Eco‐Factory

resource efficient manufacturing 2.1zero waste factories 2.2eco‐intelligent factory 2.3Ex 13 Funding:

Agreed

Proposedg

scenarios for resilience 3.2

Explores 1‐6

External

Sustainable Industrial

responsible Innovation 3.?Ex 8Ex 8

Industrial Systems SIS configurations 3.1

Ex 9

Year 1 priorities

Set up admin & back office

Recruit best  Key resourcesStart projectsMember start

staff & researchers

Projects active with members Policy plan

International Explore newProgress on plan except for:Delayed

Cohort buildingPublic LaunchGovernance operating

International developmentExternal UKOther Centres

Explore new project ideasNew members

administration operating

Early resultsy

Sustainability Assessment & Knowledge Exchange (SAKE ) 

Investigate sustainability metrics and KPIs, and how these may are being used Help members address areas of concern and identifyHelp members address areas of concern and identify future research directionsEncourage knowledge exchange between members

An example Explore project driven by Members short term

dneeds

Some initial outputs of SAKE

We identified specific research needs for our members (e.g. energy analysis for buildings)We helped some of our members with short‐term needs (e.g. feedback on their sustainability reports)We identified some generic issues related to KPIs and We identified some generic issues related to KPIs and sustainability performance improvement to drive the future research agenda, e.g.:

Companies are not sure whether sustainability KPIs areCompanies are not sure whether sustainability KPIs are leading to performance improvement. Choosing appropriate boundaries and metrics will greatly influence improvementinfluence improvement. Learning within the company between different sites is important but may be difficult because of differences in energy management systems geographical areasin energy management systems, geographical areas, age of equipment, personnel expertise etc. Also, the politics of inter‐site competition may be a barrier.

‐

SAKE: OUTCOMES (1)

1. Members are not sure whether KPIs are leading to the right behaviour or to desired performance. pSetting the boundaries, and choosing metrics (absolute or per product) will greatly influence improvement. 

2 How can we make trade‐offs between social economic and2. How can we make trade‐offs between social, economic and environmental metrics, because all are important? Should we consider one metric more than the others and how do we go about this? Social metrics are not widely used yet butdo we go about this? Social metrics are not widely used yet, but are of increasing interest to governments and some companies. 

3. Measurement and control of impacts outside of direct scope (customer suppliers) are of concern(customer, suppliers) are of concern.How can we best engage our suppliers and downstream stakeholders?

SAKE: OUTCOMES (2)

4. Leaders are finding ways to move beyond the metrics they have used in the past Wh t th d h d th d t i ?What are these and how do we prove they are good metrics?

5. There may be tension between internal and external sustainability reportingAre we measuring what we want and need, and are we broadcasting what we do well? 

6. Learning within the company is important but challengingLearning within a company ‐ between different sites ‐ is important but may be difficult.

7. Emissions to air in factories are not regularly measured and are7. Emissions to air in factories are not regularly measured and are of concern to some members.Some companies do measure emissions to air but not on a regular basis Others do not know exactly how to measure this.regular basis. Others do not know exactly how to measure this. 

Vision

I t t t lid i h b t SAKEI want to put some slides in here about SAKE findings, especially key challenges (KPIs, supply chain)

Show we are reacting to membersShow we are reacting to membersWant to put some in about value

How it is being squandered…Want to say something about SIS

Maybe Resilience emphasis, what gets made where, howFuture factory scenarios

Emphasis in this section should be on what we are learning from industry, We just need 1 picture or maybe 2 slides per section…

SustainValue Grand Challenge ProjectBUSINESS MODEL INNOVATION FINDINGS TO DATE

Business model innovation is seen to offer the

BUSINESS MODEL INNOVATION – FINDINGS TO DATE

Business model innovation is seen to offer theopportunity for fundamental shiftA good conceptual understanding in the literature butlimited practicalOur Industrial case studies demonstrate:

Leading firms are exploring business model innovation

Providing f t ith

Leading firms are exploring business model innovationsuccessfullyThe business modelling process is ad‐hoc and largelydependent on visionary leadershipmanufacturers with a

business modelling process and accompanying tools to

b d t i bilit

dependent on visionary leadership

There is a lack of systematic tools and methods to help manufacturers innovate their business models for 

embed sustainability into everyday business operations

sustainability

Better Business Modelling needs:

A Multiple stakeholder view of valuecurrent tools focus largely on customerscurrent tools focus largely on customers

A Comprehensive view of value:Value proposition is not just value exchangesp p j gExisting value opportunities are being missed in thecurrent modell i b i ti l d t dvalue is being actively destroyed

A systematic approach to shifting value isneeded:

Systematic and practical process for reconceptualising the business model for

needed:using existing industrial knowledge on businessmodel innovation

business model for sustainability

Tool for value innovation

Customers

Investors and

New Stakeholder

Investors and ShareholdersAcademia

EmployeesMedia

Systematic and practical tool for preconceptualising the business model for sustainability

Suppliers and Partners

External Agencies

Environment

Community

Government

Grand Challenge Project Sustainable Industrial SystemsHOW DOWE PREPARE FOR A CHANGING FUTURE?

There are a number of weak signals for future changes to

HOW DO WE PREPARE FOR A CHANGING FUTURE?

There are a number of weak signals for future changes to the industrial system: 

Pressures from energy cost, resource availability, policies… Suggested solutions from Cradle to Cradle, The Natural Step, gg , p,Industrial Ecology, Industrial Symbiosis, Product Service Systems, Green Chemistry, Bio‐mimicry…

How will we make decisions about what gets made whereHow will we make decisions about what gets made where and how?

There are a number of tools and techniquesRoad‐mapping, foresight, scenario planning , PEST, forecasting, backcasting, systems modeling. . . .systems modeling. . . . 

These techniques do not deal with the growing challenge of coping with uncertainty, resilience, unintended system 

t

There are many approaches to planning – how do we

f t consequences, etcWe would like to understand the shaping forces and cope with weak signals, black swans, interconnectedness,  etc.

prepare for a step change?

Project aims

H l f d d h l fHelp manufacturers understand how to plan for futures, that may need to be radically different, from today's business as usual trajectory. . .  y j y

What gets made whereWhat needs to change

System parametersGovernance business modelsGovernance, business modelsRelationships At the system level (policy, conditions)

What is different about planning for sustainability at the

t l l?system level?

Likely activities1 2 3Year

Opportunities to share• Planning processes.• Paradigm intelligence.Paradigm intelligence.• Experience to date.• Resilience & Efficiency.• Learning by doing.

Integrating insights• Observing Knowledge andg y g

• Strangers & frogs.g

reactions.• What people feel, think, do

Knowledge and tools• What are the dimensions of theand say.

• Integration of ideas.

dimensions of the problem?• Experimentation.

Research questionsHOW OUR INTERACTIONS WILL BE FRAMED

What possible configurations are there for future

HOW OUR INTERACTIONS WILL BE FRAMED

What possible configurations are there for future industrial systems? How might manufacturers develop their own planning processes?processes?What dimensions of performance are of importance to such planning?What is the role for system thinking?How might the concept of value change and what business models offer the greatest value and resilience?What processes work to improve the value of such planning?

What might the role of ubiquitous information be?

What thought and planning processes help us move forward

? g q

How does an emphasis on resilience change our process?. . .?

Join us!

Thank you

Thank youy

Projects already agreed in Yr 1 funding:j y g gGrand Challenge Projects

Project Proposals - Expressions of Interest

Company / University Name:

Project Lists Theme

Interested to be

involved in

Keep me updated on

Not interested CommentsProject Lists Theme involved in

the research

pthe research progression

in the project

Comments

Grand Challenge ProjectsGC 1.1: 1 agreedEco-EfficiencyyGC 2.1: 2 agreed – plan to run concurrentlyResource Efficient Manufacturing GC 2.2: 2 agreed – plan to run concurrentlyZero Waste Zero EmissionsGC 2.3: 2 agreed – plan to run concurrentlyE I t lli t F t i g p yEco-Intelligent FactoriesGC 3.1:

3 agreedConfiguring the Sustainable Industrial System

GC 2.4: 2 agreed – funded by EUSustain Value

Explore Projects: Proposed as yet un‐fundedProject Proposals - Expressions of Interest

Company / University Name:

Project Lists Theme

Interested to be

involved in

Keep me updated on

Not interested CommentsProject Lists Theme involved in

the research

the research progression

in the project

Comments

Explore Projects

EX 1 Sustainability Performance of 2EX 1 Nanotechnology 2

EX 2 Sustainable Design of Production Systems 2

EX 3 Non-invasive Monitoring of Water Quantity and Quality 2

Flexible and Reconfigurable 2EX 4 Flexible and Reconfigurable Manufacturing for 3Rs 2

EX 5 Artificial Intelligence in Sustainable Manufacturing 2

EX 6 Eco-innovation for Sustainable Manufacturing 2

L d iEX13 Low energy production system design 2

j l i f

Projects already agreed in Yr 1 funding: Explore Projects

Project Proposals - Expressions of Interest

Company / University Name:

Project Lists Theme

Interested to be

involved in

Keep me updated on the

Not interested CommentsProject Lists Theme involved in

the research

research progressi

on

in the project

Comments

Explore Projects

EX 7 Sustainable Practices Library 1 agreed

EX 8 Responsible Innovation 3 agreed

EX 9 Closed Loop Business Models 3 agreed

EX 10 O S i 1 dEX 10 Open Science 1 agreed

EX 11 Sustainability Assessment and Knowledge Exchange II 1 agreed

EX 12 Sustainability Assessment and Knowledge Exchange III 1 agreed

Original Draft Project Development Plan