A comprehensive presentation on Green Manufacturing

1. 应聘人：曹华军 教授/中共党员
Challenges and Opportunities
of Green manufacturing
Presented to: Professor Huanjun Cao
Prsented by: salman jafar

2.  Environmental impact of manufacturing
 What does sustainable mean
 Sustainable and green manufacturing
 Sustainability frame of reference
 Closed loop manufacturing
 Evolution of sustainable manufacturing
 Evolution of production paradigm
 Closer focus on manufacturing
 Motivations for green manufacturing
 Efficiency- relevance for production
technology
 Elements of sustainability
 Challenges for china’s manufacturing
 Green trade barriers
 Technological challenges and opportunities
for sustainable manufacturing
 New employment opportunities
 Cooperation initiative “students going
green network”

3. Environmental Impact of Manufacturing
Manufacturing
Processes
Input materials
• Working materials
• Auxiliary materials
Output emissions
• Greenhouse gases
• Various pollutants
• Toxicants/solid wastes
Input energy
• Electricity
• Fossil fuels
•Global
warming
•Acidification
•Human toxicity
•Eco-toxicity
•Etc.
Output materials
• Products
• By-products
Ref: Chris Yingchun Yuan, LMAS Presentation, 2009
Laboratory for Manufacturing and Sustainability © 2009

4. Environmental Impact of Manufacturing
Carbon Emissions:
Green house gas emissions are serious
concerns of global society. Industrial
production is a heavy consumer of fossils
fuels directly or indirectly which induces
global warming problems and serious
anthropogenic interference with climate
system.

5. Source: National Oceanic and Atmospheric Administration (NOAA Annual Greenhouse Gas Index )
Global trend of green house gasses:
Environmental Impact of Manufacturing

6. Environmental Impact of Manufacturing
Waste generation:
Manufacturing industry generates a huge
amount of waste , mainly in the form of solid
waste and water waste , which causes
significant environmental concerns and
impacts. The non-biodegradable and non-
compostable biodegradable wastes that are
capable of emitting greenhouse gases, toxic
fumes, contamination of ground, health
hazards and the spread of infections. Jardim Gramacho landfill in Rio de Janeiro, Brazil, received
more than 10,000 tones of waste per day.
1004.28
1200.3
1344.49
1515.41
1756.32
1901.27
2039.43
2409.44
3262.14
3325.09
3308.59
1000
1500
2000
2500
3000
3500
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
solidwasteinmillionmetrictons
Industrial solid waste generation trend
in China(2003-2013)
88.1
104.4
121.1
127.8
151.6
166.3
208.3
217.3
243.5
253.7
250.6
254.1
50
100
150
200
250
300
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
MSWgeneration(milliontons)
Municipal solid waste generation trend
in US (1960-2013)

7. What does Sustainable Mean?
One good definition of sustainability:
"an economic state where the demands placed upon the environment by
people and commerce can be met without reducing the capacity of the
environment to provide for future generations.....your business must
deliver clothing, objects, food or services to the customer in a way that
reduces consumption, energy use, distribution costs, economic
concentration, soil erosion, atmospheric pollution, and other forms of
environmental damage. Leave the world better than you found it.“ (From
Paul Hawken, The Ecology of Commerce, Collins, 1993, p. 139.)

8. Sustainable & Green Manufacturing
Sustainable Manufacturing: U.S. Department of Commerce has sustainable manufacturing as “the
creation of manufacturing products that use materials and processes that minimize negative
environmental impacts, conserve energy and natural resources, are safe for employees, communities,
and consumers and are economically sounds”
Green: it is concerned with or supporting environmentalism and tending to preserve environment
quality (as by being recyclable, biodegradable, or nonpolluting) or process of reducing the
environmental impact of a manufacturing process or system when compared to previous state.
Green Manufacturing: is a process or system which has a minimal, nonexistent, or negative impact on
the environment.
Greening of manufacturing system is reducing the volume of hazardous wastes, cutting down coolant
consumed, changing the energy mix to include renewable energy resources etc.

9. Today Future
Rateof
Consumption*
Sustainable rate
How do we achieve this
“slope change”?
Sustainability Frame of Reference

10. Closed Loop Manufacturing: Renewing Functions
while Circulating Material
Ref: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655
Source: T. Tani, “Product Development and Recycle System for Closed Substance Cycle Society,”
Proc. Environmentally Conscious Design and Inverse Manufacturing, 1999, 294-299.

11. Closed-Material Flow-The 6R Approach

12. Evolution of Sustainable Manufacturing

13. Evolution of Production Paradigms
Source: F. Jovane, et al, “Present and Future of Flexible Automation: Towards New Paradigms,
CIRP Annals, 52, 2, 2003, 543.

14. Green Machines
Clean Power
Green
Manufacturing
Processes
Green Products
“Ecofacturing*”
or “Ecomanufacturing**”
Source: * TM Taiheiyo Cement, Japan
**IGPA Newsletter, Dec. 2003
Closer Focus on Manufacturing

15. Motivations for Green Manufacturing
• Impact on the Environment
• Pressure Government (Regulations, Penalties, and Tax benefits)
• Interest in Efficiency
• Scarcity of Resources/Risk
• Continuous Improvement
• Pressure from Society/Consumers/Customers and other competitors
• Desire to Maintain Market Leadership

16. Efficiency – Relevance for Production Technology
demography (1) : 2011: 7 billion people
1,5 billion in prosperity
5,5 billion „on the move“
2050: > 9 billion people ...
 production – increase tenfold!?
 resource use – decrease to a tenth!?
 environmental impact – significant reduction!!
challenge:
(1) sources: United Nations, 2008
Dt. Stiftung Weltbevölkerung, 2010
conclusion: Paradigm Change Required
from „maximum profit realized by minimum funds“
to „maximum added value from minimum resources“
Cognitive Innovations!

17. Resource Stringency  Example: Fossil Fuels
Efficiency – Relevance for Production Technology
11 Mio. t mineral oil year 2040
9 Mio. t coal year 2180
8 Bn. m3 natural gas year 2070
!
Daily World Consumption Range up to
effects on  energy and resource availability
 energy and resource prizes

18. Elements of Sustainability
Source: H. Komiyama and K. Takeuchi, “Sustainability science: building a new discipline,”
Sustainability Science (2006) 1:1–6
“we are here”
We may not know exactly what sustainability
means…but we know what green is!

19. Challenges for China’s Manufacturing
China's manufacturing industry faces environmental challenges:
• International "green trade barriers": ROHS, WEEE, ErP, REACH ..., food, electrical
and mechanical, textile, leather, ceramics, tobacco and other industries export
trade is limited.
• Environmental issues: Since the 1980s, with the economic development,
environmental problems with global impact have become increasingly prominent.
Regional environmental pollution and large-scale ecological destruction;
greenhouse effect, global climate change, marine pollution and so on.
• Resource problems: resource shortage, resource efficiency is low, increasing the
cost of resources; a large number of products are facing scrapped, urgent high
efficiency and high value-added recycling.

20. Developed countries, especially the EU countries attach great importance to the development of
green standards and norms, guide and standardize the green behavior of enterprises and
consumers, the formation of green trade barriers, such as:.
Use the product instructions,
Energy related Products
(ErP )2009/125/EC
"Instructions for restricting the
use of certain harmful
ingredients in electrical and
electronic equipment -
ROHS》
Scrapped electrical and electronic
equipment recovery instructions
WEEE Directive (2002/96/EC)
Green Machine International Standard
（ISO 14955）
Green Trade Barriers

21. • Molecular, micro structural and metallurgical
transformation of materials
• self-healing materials
• memory alloys
New materials technologies for sustainable products
Technological Challenges and Opportunities
for Sustainable Manufacturing

22. Product sustainability metrics; product design for sustainability
including 1R –3R –6R transformations
Product innovation for sustainable manufacturing
Technological Challenges and Opportunities
for Sustainable Manufacturing

23. • Environmentally benign/responsible manufacturing
process development
• toxic-free, hazardless, safe and secure technologies
• efficient use of energy
• minimal use of water , including metal working fluids,
chemicals, and other resources
Process innovation for sustainable manufacturing
Technological Challenges and Opportunities
for Sustainable Manufacturing

24. Integrated manufacturing systems for sustainability
sustainable supply chain operations
sustainable quality systems for manufacturing
Innovation and creativity in supply/value chain
operations
Technological Challenges and Opportunities
for Sustainable Manufacturing

25. Compliance with regulations (REACH, WEEE, RoHS, EuP, ELV, etc.)
Marketing strategies and business
economics for sustainable products
and processes
Economic analysis and business
case for sustainable manufacturing
Technological Challenges and Opportunities
for Sustainable Manufacturing

26. Societal Impact studies
legislative and administrative issues
policy implementation
product and process liability
ethics
Safety, health, public policy and regulatory
issues in sustainable manufacturing
Education and training issues
Technological Challenges and Opportunities
for Sustainable Manufacturing

27. New Employment Opportunities
Sustainable manufacturing offers uniquely new
kind of employment opportunities:
-Innovative 6R applications
-Total life-cycle consideration
-Sustainable manufacturing processes
Universities and colleges are well-positioned to
provide educational and training programs
-Undergraduate and graduate education
-Non-credit professional continuing educational
program
Incentives must be provided to academic
institutions and manufacturing companies to
educate, train and develop the workforce for next
generation manufacturing, and for conducting
relevant fundamental and applied research.

28. Cooperation Initiative
“Students Going Green Network”
Vision:
It is proposed to form a platform to initiate the collaboration between the students
of China and UK to :
o promote critical thinking , problem solving
and global participation
o improve understanding
o build relationship
o reduce communication barrier
o enhance collaboration
o increase exposure
o awareness to multi disciplinary research areas
o interchange thoughts
o initiate multidisciplinary research projects
o familiarize current research trends
o find assistance in educational matters by posting, sharing ideas
o open study gateways especially for Chinese students in English countries