1.0
DEFINITION
The Brundtland Commission's report (1987) defined sustainable development as "development which meets the needs of current enerations without compromisin the abilit! of future enerations to meet their own needs" #lthouh this didn$t spea% to manufacturin& but the %e! words that reuire for sustainabilit! is do not harm *anufacturin has traditionall! been associated with undesirable environmental side effects such as pollutions +t is necessar! for the manufacturers to implement a manufacturin strate! that interates environmental and social considerations in addition to the technoloical and economic ,r -awahir& +. (/008) define sustainable manufacturin is design and manufacture of high quality/perf quality/performanc ormancee products products with improved improved/enha /enhanced nced functional functionality ity using energy-e energy-efficien fficient, t, toxic-free, hazardless, safe and secure technologies and manufacturing methods utilizing optimal resou resourc rces es and energ energyy by prod produci ucing ng minimu minimum m wastes wastes and emissio emissions, ns, and provid providing ing maximu maximum m recovery recovery,, recyclabi recyclability lity,, reusabil reusability, ity, remanufacturab remanufacturability ility,, with redesign redesign features, features, and all aimed at enhanced societal benefits and economic impact impact .ustain .ustainabl ablee manufa manufactu cturin rin is an inter interate ated d field field of stud! stud! that that combin combines es techni technical cal feasibilit! with environmental responsibilit! and economic viabilit! (,epartment of *echanical and *echatronic nineerin and .ustainable *anufacturin& /012) .ustainable manufacturin is the pathwa! to re3establishin manufacturin as the main activit! in the future clean econom!& built on the principles of sustainabilit! sustainabilit ! .ustainable manufacturin includes two main products4 manufacturin of sustainable products& and sustainable manufacturin of all products (5#C6#*& /009) The field cover the manufacturin of renewable ener!& ener! efficienc!& reen buildin& and other reen social euit!3related products .ustainable manufacturin of all products ta%in into account the full sustainabilit!total life3c!cle issues related to the products manufactured The main obective of sustainable manufacturin is to reduce the environmental impact related related to manufactur manufacturin in 6or e:ample& e:ample& ;. 5ational 5ational +nstitute +nstitute for .tandards .tandards and Techno Technolo! lo! (nd) states that sustainable manufacturin is a s!stems approach for the creation and distribution (suppl! chain) of innovative products and services that4 minimi
1
2.0
INNOVATION BASED MANUFACTURING ENGINEERING
+n the manufacturin sector& innovation usuall! refers to4 product innovation& the introduction of innovative processes and euipment& often +T driven& and reen technoloies which reduce waste and use consumables more efficientl! (5+B+.& /012) The benefits of innovation can comprise4 reater responsiveness to customer demands& faster turnaround times& reduced waste levels and downtime& improv improved ed produ product ct desin desin and ualit! ualit!&& reate reaterr potent potential ial for a wider wider produc productt rane& rane& streaml streamline ined d relationships with suppliers and customers (5+B+.& /012) There are man! areas with opportunities for manufacturers to innovate +t can divide into two maor cateories4 strate! thin%in and mar%etin strate! 6or strate! thin%in& it includes4 competent competent sourcin& sourcin& materials materials technolo! technolo!&& factor! factor! process process control& control& euipment euipment maintenance maintenance&& stoc% control and order processin& and loistics and warehousin (5+B+.& /012) Component sourcin involves new components& new suppliers or an improved deal with current suppliers could improve the profits and product ualit! (5+B+.& /012) *aterials technolo! involve new materials that could improve the products or their pac%ain and presentation (5+B+.& /012) 6actor! process control depends how to automate process control& includin ualit! control& to ive better efficienc! and products (5+B+.& /012) 6or euipment maintenance& an automatic schedulin of maintenance will ensure ensure that that euipm euipment ent is %ept %ept runnin runnin smooth smoothl! l! and compl! compl! with with health health and safet! safet! reula reulatio tions ns (5+B+. (5+B+.&& /012) /012) .toc% .toc% contro controll and order order proces processin sin which which is consta constantl! ntl! loo% for better better wa!s wa!s to streamline the order processin and stoc% control to ensure the riht amount of stoc% (5+B+.& /012) >oistics and warehousin involves how to deliver the products to the customers b! ta%in advantae of new transport opportunities and %eep warehousin costs to a minimum (5+B+.& /012) 6or mar%etin strate!& it involves the +T s!stems& accountin procedures& customer and supplier relationship manaement& mar%etin& and desin +T s!stems must alwa!s %eep up to date with developments in the +T s!stems used b! manufacturer (5+B+.& /012) #ccountin procedures include accountin& invoicin and pa!ments procedures should be streamlined with the stoc% control and order processin and must updated reularl! (5+B+.& /012) Customer and supplier relationship manaement is a valuable insihts is ain into how to improve the products and their deliver! from the customers and suppliers (5+B+.& /012) +nnovative mar%etin strateies are also an important wa! to set the products that manufacture apart from those produced b! competitors (5+B+.& /012) ,esin is another process for desiners help to develop new products and services& or redesin the e:istin products to improve their functionalit! and client appeal (5+B+.& /012)
2
2.1
Hard and Soft Tecno!o"#e$
.wamidass (/000) classif! manufacturin technoloies into hard and soft technoloies ?ard technoloies are hardware and software intensive whereas soft technoloies are manufacturin and production %now3how& techniues and procedures The maor difference between soft and hard technoloies is soft technoloies are not necessaril! hardware or software dependent (.wamidass& /000& p 2) The e:ample of soft technoloies include concurrent enineerin& bar codes& manufacturin cells& -+T manufacturin& *@A& .C& simulation and modellin& T*& TA*& and so on (.wamidass& /000& p 32) The e:ample of hard technoloies are C#,& C#*& C5C machines& C+*& 6*.& automated inspection& robots& >#5& D#5& and so on (.wamidass& /000& p ) .ome of the innovation manufacturin technoloies are e:plained for further understandin
2.1.1
Conc%rrent En"#neer#n"
Concurrent enineerin& also %nown as simultaneous enineerin& is a lon term business strate!& with lon term benefits to business (ATC& /012) Concurrent enineerin is a method of desinin and developin products& in which the different staes run simultaneousl!& rather than consecutivel! (ATC& /012) +t decreases product development time and also the time to mar%et& leadin to improved productivit! and reduced costs (ATC& /012) Concurrent enineerin can lead to three %ind of business benefits4 competitive advantae& enhance productivit!& decrease desin and development time (ATC& /012)
2.1.2
&%$t'#n't#(e )&IT* +rod%ct#on
-ust3in3time (-+T) production& also %nown as lean production& a t!pe of innovation based manufacturin& turns traditional manufacturin thin%in be!ond its limit -+T processes focus on producin e:actl! the amount reuire b! manufacturer at e:actl! the time the customers reuire& rather than producin oods and suppl!in customers from stoc% (5+B+.& /012) The main advantaes of -+T is can improve production efficienc! and therefore competitiveness The other benefits b! -+T are4 preventin over3production& savin resources b! streamlinin the production s!stems& dispensin with the need for inventor! operations& minimisin waitin times and transport costs& reducin the capital that have tied up in stoc%& and decreasin product defects ?owever& implementin thorouh -+T procedures can involve a maor renovate of the business s!stems& hence it ma! be difficult and e:pensive to introduce Besides& -+T manufacturin also opens businesses to a number of ris%s& especiall! those toether with the suppl! chain Dith no stoc%s to fall bac% on& a minor disruption in supplies to the business from ust one supplier could force production to terminate at ver! short notice 3
2.1.,
A"#!e'- %#c/ Re$+on$e' and V#rt%a! Man%fact%r#n"
#nother t!pe of fle:ible and responsive manufacturin is aile manufacturin& uic% response manufacturin& and virtual manufacturin #ile manufacturin is a term that has been coined to indicate the use of the principles of lean production on a broad scale (Ealpa%ian& /001) 6or an e:ample& it has been predicted that the automotive industr! could confiure and build a car within three da!s& and that eventuall!& the traditional assembl! line will be replaced b! a s!stem in which a nearl! custom F made car will be produced b! connectin individual modules (Ealpa%ian& /001) Girtual manufacturin refers to new manufacturin entities created throuh ver! rapid interation of scattered resources in one or several firms (.wamidass& /000& p 10) The rise of information technoloies and +nternet fuels the rowth of virtual manufacturin (.wamidass& /000& p 10)
2.1.
Tota! %a!#t Mana"e(ent )TM*
# core definition of total ualit! manaement (T*) describes a manaement approach to lonFterm success throuh customer satisfaction (#.& nd) There are 8 primar! elements of T*& are customer3focused& total emplo!ee involvement& process3centred& interated s!stem& strateic and s!stematic approach& continual improvement& fact3based decision ma%in& and communications (#.& nd) Total ualit! manaement can be summari
2.1.
Stat#$t#ca! %a!#t Contro! )SC*
.tatistical ualit! Control (.C) is the term used to describe the set of statistical tools used b! ualit! professionals (+mpros!s& /010) .C is used to anal!se the ualit! problems and solve them .tatistical ualit! control refers to the use of statistical methods in the monitorin and maintainin of the ualit! of products and services (+mpros!s& /010) SQC provides a means of detectin error at inspection& leads to more uniform ualit! of production& improves the relationship with the customer& reduces inspection costs& reduces the number of reects and saves the cost of material& provides a basis for attainable specifications& points out the bottlenec%s and trouble spots& provides a means of determinin the capabilit! of the manufacturin process& promotes the understandin and appreciation of ualit! control (+mpros!s& /010)
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2.1.3
Mater#a! Re4%#re(ent$ 5!ann#n" )MR5* and Man%fact%r#n" Re$o%rce 5!ann#n" )MR5 II*
*aterial reuirements plannin (*@A) and manufacturin resource plannin (*@A++) are both incremental information interation business process strateies that are implemented usin hardware and modular software applications lin%ed to a central database that stores and delivers business data and information (*on%& et al& /00H) *@A is concerned primaril! with manufacturin materials while *@A++ is concerned with the coordination of the entire manufacturin production& includin materials& finance& and human relations (*on%& et al& /00H) The oal of *@A++ is to provide consistent data to all pla!ers in the manufacturin process as the product moves throuh the production line (*on%& et al& /00H) *@A++ s!stems bein with *@A& material reuirements plannin *@A allows for the input of sales forecasts from sales and mar%etin These forecasts determine the raw materials demand (*on%& et al& /00H) *@A and *@A++ s!stems draw on a master production schedule& the brea%down of specific plans for each product on a line (*on%& et al& /00H) Dhile *@A allows for the coordination of raw materials purchasin& *@A++ facilitates the development of a detailed production schedule that accounts for machine and labour capacit!& schedulin the production runs accordin to the arrival of materials (*on%& et al& /00H) #n *@A++ output is a final labour and machine schedule ,ata about the cost of production& includin machine time& labour time and materials used& as well as final production numbers& is provided from the *@A++ s!stem to accountin and finance (*on%& et al& /00H)
2.1.6
CAD- CAE- and CAM
The constructin and stud!in anal!tical models is simplified throuh the use of computer3aided desin (C#,)& computer3aided enineerin (C#) and computer3aided manufacturin (C#*) techniues C#, allows the desiner to conceptualise obects more easil! without havin to ma%e costl! illustrations& models& or protot!pes (Ealpa%ian& /001& p 11) ;sin C#& the performance of structures subected to static or fluctuatin loads ad to var!in temperatures can now be simulated& anal!sed& and tested more efficientl!& accuratel! and uic%l! than ever (Ealpa%ian& /001& p 1/) C#* involves all phases of manufacturin b! utilisin and processin further the lare amount of information on materials and processes collected and stored in the oranisation$s database (Ealpa%ian& /001& p 1/)
2.1.7
CNC Mac#ne$
5
The C5C in C5C *achinin means Computer 5umerical Control C5C *achinin is a process used in the manufacturin sector that involves the use of computers to control machine tools Tools that can be controlled in this manner include mills& lathes& routers and rinders In the surface& it ma! loo% li%e a normal AC controls the machines& however there is a uniue software and control console are inside the computer to set the s!stem apart for use in C5C machinin ;nder C5C *achinin& machine tools function throuh numerical control # computer proram is customi
#dvantaes C5C machines can be operated continuousl! / hours a da!& KH2 da!s a !ear and onl! turn off for irreular maintenance C5C machines are prorammed with a desin and
C5C
,isadvantaes machines are
more
e:pensive than manuall! operated machines&
althouh
costs
are
can then be manufactured hundreds or even thousands
slowl! comin down The C5C machine operator onl!
of times ach manufactured product will be e:actl!
needs basic trainin and s%ills&
the same with hih precision and e:act match >ess traineds%illed people can operate C5Cs unli%e manual lathes millin machines which reuire 6
enouh
to
machines +n
supervise
several
!ears one
b!&
enineers needed !ears of trainin
s%illed enineers C5C machines can be updated b! improvin the software used to drive the machines Trainin in the use of C5Cs is available throuh the use of Lvirtual software$ that allows the operator to
to operate centre lathes& millin machines and
other
manuall!
operated machines This means man! of the old s%ills are been
practice usin the C5C machine on the screen of a
lost >ess wor%ers are reuired to
computer C5C machines can be prorammed b! advanced
operate C5C machines compared
desin software such as Aro,.ETIAM& enablin the manufacture of products that cannot be made b!
to manuall! operated machines +nvestment in C5C machines can
manual machines& even those used b! s%illed
lead to unemplo!ment *an! countries no loner teach
desiners enineers *odern desin software allows the desiner to
pupils students how to use
simulate the manufacture of hisher idea There is no need to ma%e a protot!pe or a model This saves time and mone! # s%illed enineer can ma%e the same component
manuall! operated lathes millin machines etc Aupils students no loner develop the detailed s%ills reuired b! enineers of the
man! times ?owever& if each component is carefull!
past These include mathematical
studied& each one will var! slihtl! # C5C machine
and enineerin s%ills
will manufacture each component as an e:act match
2.1.;
Co(+%ter'Inte"rated Man%fact%r#n" )CIM*
Computer3interated manufacturin (C+*) is the use of computer techniues to interate manufacturin activities #ccordin to the ;. 5ational @esearch Council& C+* improves production productivit! b! 0 to 70 percent& as well as enhances enineerin productivit! and ualit! (#dvame& /012) C+* can also decrease desin costs b! 12 to K0 percent& reduce overall lead time b! /0 to H0 percent& and cut wor%3in3process inventor! b ! K0 to H0 percent (#dvame& /012) C+* is particularl! effective because of its capabilit! and responsiveness to rapid chanes in mar%et demand and product modification& better use of materials& machiner!& and personnel& and reduction in inventor! (Ealpa%ian& /001& p /)
+t also has a better control of production and manaement of total
manufacturin operation and hih ualit! products at low cost (Ealpa%ian& /001& p /) C+* pla! a maor role in manufacturin in application of Computer 5umerical Control (C5C) machines& #daptive control (#C)& +ndustries robots and so on Besides& it is a maor tool use in -+T& 6*.& and automated s!stems
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,.0
E
There are man! basic elements for sustainable manufacturin ?owever& all these basic elements must wor% interall! to form the sustainable manufacturin 6ull! interated sustainable manufacturin will become an effective platform for developin sustainable products from sustainable processes and with related s!stem interation ,evelopin the products& processes and s!stems is a sinificant aspect of sustainable manufacturin to promote interated sustainable manufacturin
,.1
Ba$#c E!e(ent$ of S%$ta#na8!e Man%fact%r#n"
The e:pectations of sustainable manufacturin (-awahir& /008& p K)43 • • • • • • • • • •
,.2
@educin ener! consumption @educin waste @educin material utili
Inte"ra! E!e(ent of S%$ta#na8!e Man%fact%r#n"
,evelopin innovative products& processes and s!stems is a sinificant aspect of sustainable manufacturin& and it involves a holistic approach to manufacturin different from the traditional manufacturin practices where the ualit! and performance characteristics are measured and uantified independentl!& often without consideration of the effects of other interal elements The emerin holistic and interated approach reuires all sta%eholders to wor% toether on common obectives with total commitment To enable innovation in sustainable manufacturin& innovation must be embraced at the product& process and s!stems levels with cl ose interactions amon each other
8
6iure K14 .ustainable manufacturin at interated product& process and s!stem levels 5rod%ct $%$ta#na8#!#t9 Consideration of a total and comprehensive evaluation of
product sustainabilit! can lead to reduced consumer costs over the entire life3c!cle of the product& while the initial product cost could be slihtl! hiher in some cases (-awahir& /01K) This benefit is compounded when a multiple life3c!cle approach is adopted on the basis of continuous material flow (-awahir& /01K) The overall economic benefits and the technoloical advances involvin reater functionalit! and sustained ualit! enhancement are far too reat to outscore with the current practice (-awahir& /01K) The technoloical and societal impacts are also sinificant @ecent research on product sustainabilit! evaluation shows a consistent trend towards the lon3rane development of a product sustainabilit! ratin s!stem for all manufactured products (-awahir& /01K) This ratin would be e:pected to represent thelevel of sustainabilit! built in a product b! ta%in into account all maor contributin sustainabilit! elements and their sub3elements (-awahir& /01K) arl! wor% shows the followin si: product sustainabilit! elements (-awahir& /01K)4 • • • • • •
nvironmental +mpact .ocietal +mpact (.afet!& ?ealth& thics& etc) 6unctionalit! @esource ;tili
product sustainabilit! Ither influencin elements and sub3elements will be identified as appropriate This s!stematic stud! should provide a solid foundation for involvin relevant priorit! roles and trade3offs& when this proect is e:tended to the ne:t level (-awahir& /01K) The preliminar! wor% in this area also considered ratins at all three levels (s ub3element& element and overall)
9
5roce$$ $%$ta#na8#!#t9 *anufacturin processes are man!& and each of them depend on
the product bein manufactured& method of manufacture& and their %e! characteristics& these processes differ ver! widel! (-awahir& /01K) This ma%es the identification of the factorselements involved in process sustainabilit! and the demarcation of their boundaries comple: (-awahir& /01K) The primar! obective of identif!in and definin the various contributin elements and sub elements of manufacturin process sustainabilit! is to establish a unified& standard scientific methodolo! to evaluate the deree of sustainabilit! of a iven manufacturin process (-awahir& /01K) This evaluation can be performed irrespective of product life3c!cle issues& rec!clin& remanufacturabilit!& etc& of the manufactured product (-awahir& /01K) 6or e:ample& if the production process of a simple component is considered& it oes throuh a few clearl! defined production staes= component desin& toolwor% material selection& metal removalformin& finishin& pac%ain& transportin& storae& dispatchin& etc (-awahir& /01K) +t is e:tremel! hard to consider all of these staes in evaluatin manufacturin process sustainabilit! althouh the! ma! directl! or indirectl! contribute to the manufacturin process sustainabilit! Besides& the processin cost larel! depends on the method used to produce the partcomponent and the wor% material selected (-awahir& /01K) +n a never3endin effort to minimi
ner! consumption *anufacturin cost nvironmental impact Iperational safet! Aersonnel health Daste reduction The motivation for recent sustainabilit! studies of manufacturin processes comes from
recent efforts in developin a manufacturin process sustainabilit! inde: (-awahir& /01K) The idea in developin this concept is to isolate the manufacturin process from the lobal picture of sustainabilit!& and to develop it up to the level of acceptance for common practice in industr! (-awahir& /01K) The observations and the e:istin modellin capabilities can be used to model the impact of the manufacturin process on contributin maor sustainabilit! parameters (-awahir& /01K) *odels developed for manufacturin variables can be interated for achievin optimi
10
(-awahir& /01K) 6inall!& the optimi
6iure K/4 :amples of innovative aspects in sustainable manufacturin at product& process and s!stem levels .ource4 -awahir (/01K) Innovation in sustainable manufacturing education.
,.2.1
S%$ta#na8!e 5rod%ct$ fro( S%$ta#na8!e 5roce$$e$
#s efforts continue to develop sustainable products and sustainable manufacturin processes& a recent trend observed is to develop sustainable products from sustainable processes& thus enablin& potentiall!& doublin environmental& economic and societal values of product manufacture (-awahir& /01K) Case studies involvin the use of sustainable machinin methods such as dr!& cr!oenic and minimum uantit! lubrication (*>) machinin have been shown for producin functionall! superior machined products with sinificantl! improved& product sustainabilit!& in terms of
11
performance& ualit! and life (-awahir& /01K) 6iure 2 shows a schematic of activities involved in producin sustainable products from sustainable processes
6iure KK4 Aroposed methodolo! for producin sustainable products from sustainable processes .ource4 -awahir (/01K) Innovation in sustainable manufacturing education.
,.2.2
S%$ta#na8#!#t I$$%e$ at te S$te($
The transformation of raw materials into more sustainable products throuh sustainable manufacturin processes reuires careful coordination of various activities across and within the orani
Besides&
s!stems are adaptive and emerent entities characterised b! various feedbac% and reinforcin loops without a proper understandin of which can lead to catastrophic behaviours of these s!stems iven the comple: conte:ts in which the! operate (-awahir& /01K) Thus& sustainable manufacturin s!stems and suppl! chains must be desined and manaed as interated socio3techno3environmental s!stems from a total life3c!cle perspective b! considerin the interfaces and interactions amon the different sub3s!stems (-awahir& /01K) #lso& iven the intractable nature of s!stems for sustainabilit!& the abilit! to thin% and communicate s!stematicall!& or s!stems thin%in& becomes an important capabilit!
12
that must be developed to increase the capabilit! to desin and manae such s!stems (-awahir& /01K)The desin protocol for desinin such sustainable s!stems is shown in 6iure K
6iure K4 Arotocol for .ustainable .!stem ,esin .ource4 -awahir (/01K) Innovation in sustainable manufacturing education. @ecent advances in sustainable suppl! chain desin that follows some aspects of the approach have addressed coordinatin the desin of sustainable products and s!stems b! considerin the social& economic and environmental implications of a variet! of sta%eholders= the time3variant& adaptive behaviour of suppl! chains and implications on sustainabilit! performance is also considered (-awahir& /01K) ,evelopin tools such as sustainable value stream mappin (.us3G.*) to assess the socio3techno environmental aspects at the manufacturin s!stems level have also been presented (-awahir& /01K) The modellin ris%s due to neative and unintended influences of economic& environmental and social implications from and on other interdependent s!stems (6iure K) throuh probabilistic Ba!esian Belief 5etwor%s can provide methods to develop mitiationsinterventions to improve sustainabilit! of manufacturin s!stems and suppl! chains (-awahir& /01K)
.0
3R=$ A55ROACH 13
The H@ name was inspired b! wor% done at the ;niversit! of Eentuc%!& Center for .ustainable *anufacturin (H@B+I& /01) The H@$s are the innovative elements whose additive implementation achieves sustainable manufacturin H@ *anufacturin can be thouht of as environmentall! benin& closed3loop manufacturin s!stem that creates durable oods without neativel! impactin the environment The H@ B+I product line is applicable to man! industries& not ust manufacturin& and has the potential to be used effectivel! b! man! orani
6iure 14 Closed F loop *aterial 6low F The H@ #pproach .ource4 +. -awahir ;niversit! of Eentuc%! Sustainable anufacturing! "he #riving $orce for Innovative %roducts, %rocessesand Systems for &ext 'eneration anufacturing. The K$@$s is promoted throuh Jreen *anufacturin are (Eiritsis et al& /011) are @educe& @euse& and @ec!cle Red%ce primaril! focuses on the first three staes of the product life F c!cle and refers to the reduced use of resources or Lsource reduction$ in pre F manufacturin& reduced 14
use of ener! and materials durin manufacturin and the reduction of waster durin the use stae (Eiritsis et al& /011& pae K09) Re%$e is referrin to the reuse of products or its components& after usae in its first life F c!cle& for subseuent life F c!cles to reduce the usae of new raw materials to produce such products and components (Eiritsis et al& /011& pae K09) Recc!e involves the process of convertin material (such as paper& lass& and metal) that are considered waste into new materials or products Eiritsis et al& /011& pae K09) The additional K L@$s in H@ #pproach are recover& redesin& and remanufacture Reco:er involves the process of collectin products at the end of the use stae& disassembl! into components& sortin and cleanin for utilisation in subseuent lifeFc!cles of the product (Eiritsis et al& /011& pae K09) Rede$#"n is the act of redesinin products for better resource utilisation durin manufacture& use and to simplif! future postFuse processes throuh the application of techniues such as ,esin for nvironment (,f) to ma%e the product more sustainable (Eiritsis et al& /011& pae K09) Re(an%fact%r#n" involves the re3processin of alread! used products for restoration to its oriinal
state or a li%e F new form throuh the reuse of as much components and parts without loss of functionalit! (Eiritsis et al& /011& pae K09) The H@$s approach provide the framewor% to implement sustainable manufacturin& where the performance in all life F c!cle staes must be considered in ma%in decision at an! lifec!cle stae The application of the H@$s across the four staes for multiple life F c!cles& where the frustum depicts the reduced resource footprint (for subseuent life F c!cle) is illustrated in 6iure /
6iure /4 #pplication of H@$s #cross Aroduct >ife F c !cle .taes .ource4 Eiritsis et al (/011) (ngineering )sset anagement. .0
EVO
15
There are four staes activities involved in the life F c!cle of a product4 pre F manufacturin& manufacturin& use& and post F use (Eiritsis et al& /011& pae K09) #ll four product life F c!cle staes and impacts (economic& environmental& and social) must be clearl! stated and interated to ensure sustainabilit! in the suppl! chain .ince manufacturin is the core operation in a suppl! chain (limitin the focus to ph!sical products)& desinin the s!stem and promotin sustainabilit! in its operations must centre on a sustainable manufacturin approach (Eiritsis et al& /011& pae K09) This %ind of approach reuires two important considerations4 a tool lifeFc!cle emphasis and multiF lifec!cle emphasis (Eiritsis et al& /011& pae K09) # tool lifeFc!cle emphasis is reuired to that manufacturin is pursued while e:plicitl! considerin activities across all four life3c!cle staes and the impacts (Eiritsis et al& /011& pae K09) *ultiFlifec!cle emphasis is needed to ensure closed3loop material flow from the post3use stae of one life3c!cle to the pre3manufacturin of the ne:t& which is mandator! for sustainable manufacturin (Eiritsis et al& /011& pae K09) Besides& current more advance thin%in also emphasises on the need for active interation of business partners who contribute to the sustainabilit! sta%es of a product (Eiritsis et al& /011& pae K09) The evolution of manufacturin strateies over the !ears and their impact on the sta%eholder value (much broader than shareholder value) is shown in 6iure 21 (Eiritsis et al& /011& pae K09) 6rom 6iure 21& traditional manufacturin was substitutionFbased and relied upon relentless resource consumption to deliver value to customers= the value addition to the wider roup of sta%eholders was ver! limited (Eiritsis et al& /011& pae K09) .ubseuent practice of lean manufacturin b! To!ota$s Aroduction .!stem& focused on waste F reduction (one L@$) and was able to deliver more value to customers while also appreciatin the role of team members (Eiritsis et al& /011& pae K09) Jreen manufacturin practices& advocates environmentall!3benin practices throuh the K@ approach of @educe& @euse& and @ec!cle& ained sinificant popularit! over the last several !ears (Eiritsis et al& /011& pae K09)
6iure 214 The e:ponential shareholdin rowth of innovation3based sustainabilit ! 16
.ource4 -awahir ;niversit! of Eentuc%! Sustainable anufacturing! "he #riving $orce for Innovative %roducts, %rocessesand Systems for &ext 'eneration anufacturing. # sinificant effort has been underta%en b! various roups from a rane of disciplines to characteri
3.0
DESIGN OF SUSTAINABI
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.ustainabilit! can be included into desin& durin all phases of the desin process& and also man! tools ma! use to support such effort have been developed and applied There are ten desins of sustainabilit! proposed b! -awahir (nd)4 ,esinin for @epair& @euse and @ec!clin& ,esinin for Daste *inimi
The desin practices for sustainable manufacturin s!stem and suppl! chain desin must consider a variet! of interactions between the methods and technical models& all the sta%eholders who have an influence on the s!stem or can be influenced b! the s!stem as well as the comple: dependencies between these aspects and the natural environment valuatin the s!stem performance from these aspects therefore will reuire comprehensive sustainabilit! metrics at the plant& enterprise and suppl! chain levels= the adaptive and emerent behaviour of the s!stem desined with all other interactive s!stems& must be assessed throuh predictive models
3.1
De$#"n for En:#ron(ent and <#fe Cc!e A$$e$$(ent )
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,esin for environment involves the consideration of environmental impact throuhout the desin process& and forms an interal component of desinin for sustainabilit! To develop a holistic and comprehensive understandin of environmental impacts& the full life c!cle of a product or process normall! is needed (@osen& /01/) #ll these observations contribute to the development of life c!cle assessment (>C#) >C# is a tool for improvin the environmental performance of processes and s!stems& and is often used in sustainabilit! wor% (@osen& /01/) +n >C#& the environmental impacts of a product or service are anal!sed throuh all phases of its life& with the obective of reducin environmental damae& in part b! enhancin resources conservation and efficienc! # life c!cle assessment consists of four steps4 oal and scope definition& life3c!cle inventor! anal!sis& impact assessment and interpretation (@osen& /01/) Consumption of ener! and other resources and environmental dischares of material and ener! wastes are e:amined in >C# for e:istin process and desin alternatives (@osen& /01/) .trateies for the desinselection of products& materials& processes& reuse& rec!clin& and final disposal can be obtained with >C# >C# is also used in pollution prevention and reen desin efforts (@osen& /01/) >C# is incorporated into the +.I series 100 standards and is often used in conunction with evaluation of to:icit! and ris% potential to promote manufacturin sustainabilit! (@osen& /01/)
3.2
Re$o%rce and Ener" S%$ta#na8#!#t
.ustainabilit! has been applied to man! fields related to manufacturin& includin ener! and resource use 6rom the perspective of resource utili
3.,
De$#"n for S%$ta#na8#!#t
19
,esin for sustainabilit! involves the incorporation of sustainabilit! obectives in desin activities #lthouh in its infanc!& interest in desin for sustainabilit! is rowin .everal approaches aimed at desin for sustainabilit! have been reported& includin the followin4
# triple bottom line approach to desin for sustainabilit! is described b! *c,onouh and Braunart (/00/)& in which firms balance traditional economic obectives with social and
environmental concerns #n co,esin approach (6iure H1) is described b! Earlsson and >uttropp (/00H) co3efficient strateies& which focus on maintainin or increasin the value of economic output while decreasin the impact on ecoloical s!stems& are e:amined b! Braunart et al (/007) The relationship between ualit! function deplo!ment& life c!cle anal!sis and continent valuation is investiated b! Borea and Dan (/007)& and these factors are compared with customer willinness to pa! for environmentall! benin products # product development approach usin desin for O (,6O) tools& such as life c!cle anal!sis and theor! of inventive problem solvin (T@+P) is discussed b! Jrote et al This approach see%s to assist the desin enineer in emplo!in eco3desin principles without sinificant economic trade3 offs (/008) +nteration of ualit! function deplo!ment& life c!cle anal!sis and T@+P into a methodolo! for environmentall! conscious desin is described b! .a%ao
6iure H14 co,esin approach for desinin for sustainabilit! .ource4 @osen et al (/01/) Sustainable anufacturing and #esign! *oncepts, %ractices and &eeds.
3.
Need$ for Enanced De$#"n for S%$ta#na8#!#t
*an! feel that methodoloies for desin for sustainabilit! are not advanced& and that numerous improvements are needed .ome e:amples follow4 *oran and >i%er (/00H) suest an enineerin approach within lean product development s!stems for manain product development& notin that companies li%e ?onda and To!ota use such an approach This approach permits desin alternatives to be e:amined throuhout the product development process& and allows the costs and benefits of desin for sustainabilit! issues to be
20
evaluated These benefits in part stem from the fact that lean product development focuses on %e! customer needs and manufacturin capabilities& and tends to avoids errors and improve ualit! -ohnson and .rivastava (/008) indicate that enineerin tools for desin for sustainabilit! need better capabilities to evaluate the comple: trade3offs between process parameters& customer needs& as well as environmental and other constraints& and that these tools must be usable in a straihtforward manner b! desin teams -ohnson and .rivastava (/0080 also suest that a more sophisticated inclusion of environmental and sustainabilit! issues in constraints and desin parameters is needed to !ield a broader rane of desin alternatives& and to permit evaluation of the effect of sustainabilit! on product cost& proect comple:it! and process desin in a more holistic and data driven manner -ohnson and .rivastava Q9R feel sustainabilit! is not suitabl! considered usin enineerin desin tools& or modified versions of them& such as desin for manufacturin and assembl!& desin for .i: .ima& ualit! function deplo!ment and desin structure matri:
3.
Ste+$ to #(+ro:e and de$#"n S%$ta#na8!e 5rod%ct
There are nine simple steps to improvin the products and desin it to be more sustainable 6irst of all& it is ver! li%el! to have a taret product in mind& presumabl! because mar%et intellience suest that there are environmental and social characteristics of that product that are becomin critical to its future success #ware of societal or mar%et pressures which could impact the reputation of compan! :perience has shown that selection of the first test product should be made carefull! Jenerall! the product should fit the followin characteristics in that it should be in a mar%et where it$s environmental or social characteristics are under scrutin!& or where there is competition from products claimin to be more sustainable The second step is to prepare a product dossier The product and its usae need to be understand in term of its histor!& the mar%et information& the distribution and t!pical transport information& t!pical product life and end of life path The information will lead to desin and manufacturin of the products The %e! components and sourcin of the components can be determined and come out with a material list # simplified diaram of the manufacturin process can be orani
21
chec% what priorities are e:pressed Consult compan! personnel about standards and reulations in the mar%et 6ourth steps is reflect the product in liht of simple desin for sustainabilit! assessment ;se it as a wa! to start thin%in criticall! and creativel! about possible product improvements +t is useful to identif! an! missin information for in the dossier ;se the two blan% sections of the dossier to collect observations and ideas about the product characteristics and possible areas of improvement @eturn to this list later when bein to select appropriate improvement option for the product
.tep 2 is to develop a uic% picture of the product$s impact profile b! ta%in social and ethical issues into account # desin for sustainabilit! methodolo! relates the different desin approaches to the environmental and social impacts of the particular product& providin a wa! to select those that will be relevant and fruitful .tep H is to define the product$s improvement tarets and desin approaches b! a simplified desin brief *ost of the information needed is collected and proceed to identif!in desin for sustainabilit! strateies and desin responses that address the life c!cle phases and product characteristics reuirin focus .tep 7 is a redesin option which is focus on the creativit! of the desin #fter redesin the product& step 8 is prioriti
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6.0
TECHNO
@esearch has shown that companies that adopt sustainable practices are able to achieve increased product ualit!& increased mar%et3share and increased profits ?owever& there is a eneral misconception about the true meanin of sustainabilit! and companies often end up focusin onl! on sinle aspect especiall! in ener! consumption The factors motivatin companies to embar% upon sustainable development include social responsibilit! and investor demands& overnment reulations and international standards& and increased customer consciousness @esearchers also have tended to focus more on the environmental aspects of sustainable development The challenes for ener! consumption associated with reducin the carbon footprint >imited attention has been ranted to the social dimension of sustainabilit! as visualised b! ;nited 5ations ,ivision for .ustainable ,evelopment (;5,.,) such as fosterin euit! both economic and ender3related& improvin health3care and sanitation facilities& and raisin literac! levels amon other indicators Ine of the technoloical challenes for sustainable manufacturin is where it reuires new materials technoloies for sustainable products to reduce material waste and optimi
23
.%ill of innovation and creativit! in suppl! or value chain operations also is one of the challenes that sustainable manufacturin face The interated manufacturin s!stems for sustainabilit!& sustainable suppl! chain operations and sustainable ualit! s!stems for manufacturin need to be considered time b! time (-awahir& /008) Besides that& the production of sustainable manufacturin need to compliance with reulations such as @#C?& D& @o?s& uA& >G and etc (-awahir& /008) Ither than that& economic anal!sis and business case for sustainable manufacturin need to be determined time b! time This is because consumer$s need or trend are chanin time b! time Therefore without economic anal!sis and business care& the sta%eholder value will decrease (-awahir& /008) ,urin sustainable manufacturin& safet!& health& public polic! and reulator! issues need to be considered as alwa!s This is important challenes faced b! sustainable manufacturin .afet! is ver! important This is to remain the reputation of the manufacturin compan! Besides that education and trainin issues need to be considered as well (-awahir& /008) 6or e:ample& trainin courses in a manufacture compan! need to be carried out as alwa!s to maintain wor%er$s capabilit! to produce sustainabilit! products (-awahir& /008)
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7.0
REFERENCES
*anufacturin :tension Aartnership (/012) &ational *ouncil for )dvanced anufacturing! 'reen +obs in anufacturing @etrieved on /0 th *a! /012& from http4wwwmassmacor newsline090/article0Hhtm IC, (nd) )bout sustainable manufacturing and the toolit @etrieved on /0 th *a! /012& from http4wwwoecdorinnovationreentool%itaboutsustainablemanufacturinandthetool %ithtm ,epartment of *echanical and *echatronic nineerin and .ustainable *anufacturin& California& .tate ;niversit!& Chico S Sustainable anufacturing @etrieved on /0 th *a! /012& from
http4wwwcsuchicoedummemproramsbsmanufacturinStechnolo!inde:shtml
5+.T (nd) verview of sustainable manufacturing @etrieved on /0th *a! /012& from http4wwwmelnistovmsid..Aintroductionmanufacturinhtml @ochester +nstitute of Technolo! (@+T) hat is Sustainable anufacturing0 @etrieved on /0 th *a! /012& from http4wwwriteduiscesmwhatisphp ATC Channel #dvantae (/012) Concurrent nineerin @etrieved on /0 th *a! /012& from http4wwwconcurrent3enineerincou%what3is3concurrent3enineerin .wamidass& A* (/000) Innovations in *ompetitive anufacturing ;nited .tates of #merica #merican *anaement #ssociation Ealpa%ian& . (/000) anufacturing (ngineering and "echnology ;nited .tates of #merica Arentice
?all& +nc
#merican .ociet! for ualit! (#.) (nd) "otal 1uality anagement 2"13. @etrieved on /0 th *a!
/012&
from
http4asorlearn3about3ualit!total3ualit!3manaementoverview
overviewhtml +mpros!s
(/010)
Statistical
1uality
*ontrol
@etrieved
on
/0 th
*a!
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from
http4wwwimpros!sin.CStraininhtm *on%& and Daner& B (/00H) *oncepts in (nterprise 4esource %lanning ditor& *ac *endelsohn
Canada Thomson Course Technolo!
25
#dvame& (/012) *%5"(4-I&"('4)"(# )&5$)*"54I&' @etrieved on /0 th *a! /012& from
http4wwwreferenceforbusinesscommanaementBun3CompComputer3
+nterated3*anufacturinhtml ,r -awahir& +. (/008) eyond the 647s! 84 *oncepts for &ext 'eneration anufacturing! 4ecent "rends and *ase Studies ;niversit! of Eentuc%! @etrieved on /0 th *a! /012& from http4mmaeiitedus!mposiumdownloadspres-awahirpdf @!an& G (/009) )#9)&")'(S )&# #IS)#9)&")'(S $ *&* )*:I&(S @etrieved on /0 th *a! /012& from http4wwwtechnolo!studentcomcamcncmanhtm H@
B+I
(/01)
)bout
84
I
%*
@etrieved
on
/0 th
*a!
/012&
from
http4Hrbiocominde:phpabout3Hrsuppl! Eiritsis& ,& mmanouilidis& C& and Eoronios& # (/011) (ngineering )sset anagement %roceedings of the $ourth orld *ongress on (ngineering )sset anagement 2*()3
;<<= @etrieved on /0th *a! /012& from https4boo%soolecomm!boo%sidU 20VV@>#Eom-u#.rs+,+C#redirSescU!XvUonepaeUsustainableY/0manufactur inY/0HrfUfalse
5ambiar& #5 (/010) *hallenges in Sustainable anufacturing @etrieved on /0th *a! /012& from http4wwwiieomorpaper6inalY/0AaperY/0forY/0A,6/HHY/0#runY/05ambiar pdf
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