presentation will help students and researchers to learn and explore the concepts and details of sustainable manufacturing.

3. Sustainable Development and Sustainability
Sustainability in Manufacturing
Sustainable Manufacturing
Performance Indicators for SM
1
2
3
4

4. Dr. Gro Harlem Brundtland, from Norway is known as
Mother of Sustainable Development Philosophy

5. Prof. Dr. David A. Dornfeld,
Laboratory of Manufacturing And Sustainability (LMAS),
University of California, Berkely

6. Environmental
(Planet)
Economic
(Profit)
Social
(People)
Sustainability

8. Courtesy: google.com

9. Courtesy: google.com

11. 25
From 13% in 2010 to
16% in 2016, india
targeting 25% by 2025

12. https://www.nist.gov/sites/default/files/documents/mep/data/Manufacturing-the-Future.pdf
India
2016 2025
India

13. Report on Global Risk, 2012; Seventh edition

14. What is Sustainable Manufacturing?

17. Institute for Sustainable Manufacturing
Sustainable Manufacturing
(Innovative, 6R-based)
Innovation Elements
Remanufacture
Redesign
Recover
Recycle
Reuse
Reduce
Evolution of Sustainable Manufacturing
Lean Manufacturing
(Waste Reduction-based)
Green Manufacturing
(Environmentally-benign, 3R-based)
Traditional Manufacturing
(Substitution-based)
Time
1990 2000 20101980 2020 2030 2040 2050
StakeholderValue,$
17

18. https://www.uschamberfoundation.org/blog/post/manufacturing-s-declining-share-gdp-global-phenomenon-and-it-s-
something-celebrate/34261
Innovative, 6R based SM practices and 4th
Industrial Revolution i.e. Industry 4, Known as
Cyber Physical System

19. Sustainability of a manufacturing process is to be defined, measured
and evaluated using six sustainability criterion.
Courtesy By: Prof. I. S. Jawahir, University of Kentucky, USA

21. Performance Indicators for Sustainable Manufacturing
Economic Performance
Manufacturing cost
Energy Cost
Quality of products
Production Efficiency,
Productivity
Technology
Supply chain network
Environmental Performance
Material and Water usage
Energy Consumption
Water, Land and Air
pollution
Restricted Waste
generated
Emissions released
Social Performance
Health
Happiness
Education
Poverty
Standard of living

23. • GHG emissions from energy
consumption from line
(Ton Co2 Equivalent/ unit )
• Total water consumption
(Kgs/unit )
• Mass of restricted waste
generated ( Kgs/unit )
• Noise level inside/ outside
factory (dB)
• Ration of renewable energy
used (%)
• In line energy consumption
(KWh/Unit)
• Energy consumption on
maintaining facility
environment (KWh/Unit)
• Energy consumption in
transportation in/out of
line (KWh/Unit)
• Ratio of use of renewable
energy (%)
• Labour Cost (Rs./unit)
• Cost of consumables
(Rs./unit)
• Cost of energy (Rs./unit)
• Maintenance Cost
(Rs./unit)
• Cost of by product treatment
(Rs./unit)
• Indirect labour cost
(Rs./unit)

25. Emphasis is on develop technologies and
methodologies to,
• Reducing emission of greenhouse gas
• Use of clean energy
• Improve energy usage
• Reduce use of non renewable or toxic materials
• Reduce waste by products

26. Raw Material
Substitution
Shifting to more
environmentally
sound inputs
1 “Government Strategies and Policies for Cleaner Production.” United Nations Environmental Programme and
“Eco-Innovation in Industry: Enabling Green Growth” OECD
Generally easier More Difficult

27. Designing your
product to be
reusable,
remanufacturable,
recyclable, or
biodegradable
Working with
stakeholders like
customers and retailers
to reduce the
environmental impact of
sales and distribution
Expanding the life of
the product, making it
easier to repair or
designing it to use
fewer resources during
use
Using less
packaging,
lowering product
weight, using
more efficient
transportation
and logistics
Modifying
production
processes to use
less energy, water,
and materials and
to produce less
waste
Using fewer
materials and
inputs and
materials that
are non-
hazardous or
recycled
Using
renewable
materials that
don’t deplete
the natural
environment

29. Life cycle Assessment (LCA)
Sustainability in Machine Tool Systems
Metal Cutting Fluids
Research Opportunities in SM
1
2
3
4

31. Azapagic, A. (1999). Life cycle assessment and its application to process selection, design and optimisation. Chemical
engineering journal, 73(1), 1-21.

34. https://sftool.gov/learn/about/402/lca-example-light-emitting-diodes-leds

35. LCA
Example of
cloth

37. Manufacturing is dominant in its environmental impacts in toxic chemical release, waste
generations, energy consumptions and greenhouse gas emissions (Gutowski, 2001).

38. Input-Process-Output diagram for EDM process

39. Kellens K, Dewulf W and Duflou JR. Preliminary environmental assessment of electrical discharge machining
(glocalized solutions for sustainability in manufacturing).In: Proceedings of the 18th CIRP international conference
on life cycle engineering, Technische Universita ¨ tBraunschweig, Braunschweig, 2–4 May 2011, pp.377–382. Berlin,
Heidelberg: Springer.
Distribution of the
environmental impact
during 1 hour of EDM
roughing (copper electrode,
hard metal workpiece).

40. Linke, B., Dornfeld, D., Huang, Y.: Establishing Greener Products and Manufacturing Processes, Proceedings of the
International Symposium on Green Manufacturing and Applications (ISGMA 2011), October 6-7, 2011, Seoul,
South Korea

41. These include…
 Design For Sustainability,
 Environmental Impact Assessment
 Cleaner Production Programs,
 Supply Chain Management,
 End-of-life Management,
 Integrated Materials Management,
 Environmental Management Systems,
 Design For Environment/Eco-design,
 Environmental Labeling,
Other Life Cycle Approaches for Sustainable Manufacturing

42. Life Cycle Assessment (LCA) Tools
To evaluate the potential environmental impact of a product, process or activity throughout its entire life cycle
by quantifying the use of resources ("inputs" such as energy, raw materials, water) and environmental
emissions ("outputs" to air, water and soil) associated with the system that is being evaluated.
Sr. No. Name of software Developed by
1 GaBi PE International
2 SimaPro PRé Consultants
3 Quantis SUITE 2.0 Quantis International
4 Umberto Ifu Hamburg GmbH
5 Earthster Web based
6 LinkCycle.( Web based) Alex Loijos, Sahil Sahni
a) Solid works CAD software (Dassault Systems) provides LCA-based environmental information to the user through an
add-on called Sustainability Xpress.
a)PTC’s Windchill Product Analytics makes LCA results an integral part of product development systems.
Common reasons for the application of LCA are for internal purposes, like product improvement, support for strategic
choices and benchmarking - [Frankl and Rubik 2000 , Survey on how LCA is used]

44. Use of innovative concept like HYBRID machine tools,
i.e use of battery for initial operations and direct electric supply for cutting
HYBRID machine tools
HYBRID car
In case of FMS:- Machining power – 14.8 % & Constant power – 85.2 %
(Gutowski, 2005)
(A) Machine Design/Manufacturing

45. • Minimum embedded energy materials, resources per unit of
performance (positioning accuracy, speed, thermal stability, etc.
in machine tool frame and components)
• Minimum operating energy (hydraulics, spindles, tables/axes,
idle, energy recovery)
• Basic machine elements with less energy consumption, e.g. In
Machine lightening use CFL bulbs
• Design using sustainability metrics (GHGROI, etc.)
• Design for re-use/re-manufacturing/component upgrade
• Low maintenance
(A) Machine Design/Manufacturing

46. One machine with extended capability to replace several individual machines,
e.g milling + drilling + turning → “mill-turn”
(B) Manufacturing process planning
Use of one is better than number of machine tool from an
energy point of view
Drill + Turn + Vertical mill + Horizontal mill

47. Keep the database of actual power consumption of each machine tool when cutting instead of
specific energy. And consider the same while process planning
(C) Micro Process Planning
• Feeds/speed for minimum energy machining
• Rough/finish plan for minimum energy, consumables,
finishing, etc.
• Tooling design
• Optimized tool path for high productivity and minimum
energy
• Minimized environmental requirements

48. (D) Optimum selection of Cutting Parameters
Ref: Narita, H., et al, “Development of Prediction System
for Environmental Burden for Machine Tool Operation (1st
Report,Proposal of Calculation Method for Environmental
Burden),”JSME International, Vol. 49, No. 4, 2006, pp. 1188-
1195.
Source: Stefan Tönissen, “Power Demand of
Precision Machine Tools”,MS Report, UC-
Berkeley, 2009
Higher spindle RPM reduces cutting power requirement

49. Machine tools give signal when machine consumes more power than average.
One of the reason for more power may be wear of cutting
(E) Energy monitoring of machine tools
Real time power consumption database helps in identifying the sources through any abrupt
change in power consumption curve patterns.
Energy “load balancing” over line/system
• Energy “load balancing” over plant
• Resource/consumable optimization

50. MORI-NET BY MORI SEIKI (2008).
Sustainability in Manufacturing
(E) Online Energy monitoring of machine tools

51. (F) Use of coolant
Minimum Quantity lubrication or Dry machining or Cryogenic cooling
- Reduces Toxic Emissions
- Minimize the power requirement
Use of water based coolants
- problem is disposal of waste coolant
- Coolant pump consumes additional power

54. Sutherland J.: Design and manufacturing for sustainability, 2015, ASME

57. Petroleum
Based Metal
working fluids
Minimum
Quantity
Lubrication
(MQL)
Vegetable oil
based MWF
Use Nano Particle
based MWF and
Coatings
Dry
Cutting

58. Raw Material
Substitution
Shifting to more
environmentally
sound inputs
Generally easier More Difficult
Better handling
of MWF
Use
MQL
Use vegetable oil
cutting fluids Use Nano
cutting fluids
MQL with Nano particle
added cutting fluids

59. MQL cooling Flood cooling Courtesy: Google.com

62. SHASHIDHARA, Y., & JAYARAM, S. (2010). Vegetable oils as a potential cutting fluid—An evolution. Tribology
international, 43(5-6), 1073-1081.