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STUDY OF SUSTAINABILITY
IN A
MANUFACTURING SYSTEM
Prince Pal Singh
PG/ME/098307Mech. Dept.
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Plan of Presentation
Introduction Need Motivation
Literature review Research gaps Objectives Methodology
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Introduction
Manufacturing industries are facing tough competitiondue to increasing raw material cost and depletingnatural resources.
There is great pressure to produce environmentalfriendly products using environmental friendlyprocesses.
To address the above said issues modern
manufacturing industries are focusing on sustainablemanufacturing
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What is Sustainable Manufacturing?
Sustainable manufacturing is a systems approach forthe creation and distribution (supply chain) ofinnovative products and services that:
Minimizes resources (inputs such as materials, energy,water, and land)
Eliminates toxic substances
Produces zero waste that in effect reduces green house
gases e.g., carbon intensity, across the entire lifecycle ofproducts and services.
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Sustainable Vs Unsustainable
Lifecycle
Approximately 25% ofwhat goes in the pipe
comes out as goods and
services
Recycle
ReuseReduce
Fig: Unsustainable life cycle
Fig: Sustainable life cycle
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Indicators of Sustainability
Air Emissions indicators
Energy useindicators
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What are the effects?
Environmental imbalance
Floods,
glaciers melting ,
damage to habitat,
contaminated water etc.
Wastage ,depletion resources
In equilibrium all are related tohuman health
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Output Indicators: Green House
Gases
S.no gases sources
1. CO2 Fuel combustion, manufacturing processes
2. CH4 Waste (landfill activities)
3. HFCs Refrigerants, foams, aerosols
4. N2O Chemical manufacture, agriculture
5. PFCs Aluminum, electronic manufacture
6. SFO6 Magnesium smelting, electronics manufacturing
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Indicator measure: Carbon weight
Environmental indicators (energy use) can be quantified byknowing the gases causing green house gas effect (air
emission).
Green house gases are classified as direct ,indirect ,other
indirect emissions.
Carbon weight: a measure of exclusive total amount of carbondioxide emissions that are directly and indirectly caused by anactivity.
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Indicator Measuring Units
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Finalproduct
Raw barStep
turningdrilling grinding
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Litrature Review
Indicators of sustainable production ,Damjan krajnc,Peter Gavic(2003)
Attempt: Classification of indicators focused on environmental aspects of sustainableproduction
Issues addressed:
a)Explored measurable indicators
b)Dimensioned and classified indicators.
Methodology: researched for the simple measurable and can be expressed with theinput output relation in a manufacturing industry.
Achievements: provided strategic metric for assessing sustainability matrices andidentifying better option for future.
Limitations: formulation for the determination of environmental impact not assessed.
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Need
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Motivation
If a system is developed that could determine different productdesign alternatives at design stage for achieving sustainability inproduct life cycle it will be beneficial for industry, planet, and human
health.
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Literature Review
Electrical Energy Requirements for Manufacturing Processes, Timothy Gutowski et al.(2006)
Attempt:Analysis of the manufacturing processes and provides insight into howequipment can be redesigned in order to be more energy efficient.
Issues addressed:
a)Specific energy requirements for manufacturing processes
b) Process rate
c) Energy use by breakdown by type
Methodology: Specific energy consumption ,process rate computed using conceptualmodel for electrical energy requirements for manufacturing parts and plotted on a singleplot.
Achievements: Provide a simple conceptual model for estimating the electrical energyrequirements for a manufacturing process.
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Literature Review
Carbon emissions and CESTM in manufacturing, J. Jeswiet , S. Kara(2008)
Attempt:To calculate carbon emission using carbon emission signature(CES) andgreen house gas labeling
Issues addressed:
a)Energy source and its conversion
b) Energy usec) Conversion of energy use to carbon weight by usingCESTM
Methodology: Calculated the total energy including ancillary energy (energy neededto run the process i.e. pumps, cooling media etc.) then conversion of energy to CW
Achievements: CESTM Is used , this signature based on the carbon content of fossilfuels used for an electrical power grid.
Limitations: Limited manufacturing process were considered.
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Literature Review
Carbon weight analysis for machining operation and allocation for redesign, Gaurav Ametaaet al.(2009)
Attempt: Computing CW for machining operations, specifically turning and milling.
Issues addressed:
(a)Energy for different stages of product life cycle
(b)Carbon weight
(c)Conversion of energy to CW
Methodology: (a)Mechanical tolerance principles applied for computing worst case andstatistical case CW of a product.(CW tolerance approach (CWTA))
Achievements: (a)CW estimates can be utilized during the design evaluation stages of aproduct to make environmentally friendly decisions both regarding the product and themanufacturing process.
Limitations: (a) CW allocation carried out manually for machining processes only
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Literature Review
Linkage or power consumption to design feature on turning process , Zahari Taha et.
Al(2010)
Attempt:Analysis of environmental impact in machining process at the design stage. Issues addressed:
a)Power consumption during machining processes
b)Effect of design on power consumption
c)Calculation for CW
Methodology: Experimenting by varying some machining parameters(depth of cut,feed rate, cutting speed) on a predesigned part then compute specific energy thenmodify design and compared the CW change due to design change
Achievements: Linked the life cycle data of power consumption from machiningprocess to the design feature
Limitations: Manually done and for machining process only(turning)
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Comparison chart
Author(year) Title Objective Methodology Limitation
Damjan krajnc,PeterGavic(2003)
Indicators of sustainableproduction
Timothy Gutowski et
al. (2006)
Electrical Energy Requirements
for Manufacturing Processes
J. Jeswiet , S.Kara(2008)
Carbon emissions and CESTMin manufacturing
Gaurav Ametaa etal.(2009)
Carbon weight analysis formachining operation andallocation for redesign
Zahari Taha et.Al(2010)
Linkage or power consumptionto design feature on turningprocess
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Research Gaps
Primary manufacturing processes not taken intoconsideration
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Objectives
To purpose a methodology for determining carbonweight for a part manufacturing including primaryprocesses in addition to part machining.
To purpose a automated system for determination of
carbon weight from process plan of the part. To purpose a integrated framework for carbon
emission this would include manufacturing activities at
the micro-level.
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