Basic concept of sustainable and green manufacturing

1. "If you are not part of solution, you are part of problem”.
(Elbridge Cleaver )
“Man has long forgotten that the earth was given to him for usufruct
alone, not for consumption, still less for profligate waste”.
(Marsh stated)
“A new way of thinking is essential if the mankind is to survive and
move towards higher level” Albert Einstein

2. Sustainable development – historical roots of the concept
• Plato in the 5th century BC, Strabo and Columella in the
1st century BC and Pliny Elder in the 1st century AD
discussed different types of environmental degradation
resulting from human activities such as farming, logging
and mining .These authors also recommended remedies
(sustainable practices) to maintain the everlasting youth
of earth. Varro (1st century AD) stated that ‘we can, by
care, lessen the evil effects’.
• The ancient Egyptian, Mesopotamian, Greek and Roman
civilizations faced environmental problems such as
deforestation and the salinization and loss of fertility of
soil (sustainability problems).
Salinization

3. • The term ‘sustainability’ was first used in
German forestry circles by Hans Carl von
Carlowitz (Mining Engineer) in “Sylvicultura
Oeconomica” in 1713.
• Carlowitz suggested nachhaltende Nutzung
(sustainable use) of forest resources, balance
between harvesting and implanting.
• ‘Sustainability’ and ‘Sustainable’ appeared for
the first time in the Oxford English Dictionary
during the second half of the 20th century.
• Sustainability problem moved from forest(18th
century)-coal(19th century)-oil(20th century)
and so on.
Sustainable development – historical roots of the concept

4. Sustainability
Meaning of sustainability
• Living within the limits
• Understanding the interconnections
among economy, society, and
environment
• Equitable distribution of resources
and opportunities

5. Sustainability Concept
• Sustainability is three legged stool.
• A product, system or service is said to be
sustainable if it promotes socialism,
environmentalism and economically sounds.
These three factors are also called three pillars
of sustainability or sustainability three pillars
concepts.
• The most important factor is environmental
factor. If this is not solved, then no matter how
hard we try the other pillars cannot be made
strong because they are dependent on the
greater system they live within, the
environment.

6. Sustainable Development
• In 1987 World Commission on
Environment and Development defined
sustainable development as “development
that meets the needs of the present
without compromising the ability of future
generation to meet their own needs.”
• "A process of change in which the
exploitation of resources, the direction of
investments, the orientation of
technological development and
institutional change are all in harmony and
enhance both current and future potential
to meet human needs and aspirations" The
World Commission on Environment and
Development

7. Sustainable Development
• "The environment must be protected… to preserve
essential ecosystem functions and to provide for the
wellbeing of future generations; environmental and
economic policy must be integrated; the goal of policy
should be an improvement in the overall quality of life,
not just income growth; poverty must be ended and
resources distributed more equally; and all sections of
society must be involved in decision making". (The Real
World Coalition 1996, a definition based on the work of
the World Commission on Environment and
Development)
• "We cannot just add sustainable development to our
current list of things to do but must learn to integrate the
concepts into everything that we do." (The Dorset
Education for Sustainability Network)

8. Ricoh’s Sustainability Concept
• Japanese copier company Ricoh stated that "We are aiming to create a society
whose environmental impact is below the level that the self-recovery capability of
the natural environment can deal with."
• Ricoh concept of sustainable society (LMAS,university of California). The Comet
Circle

9. What is Green
• “Green” is an adjective. It can be defined as
“concerned with or supporting environmentalism
and tending to preserve environment quality (as by
being recyclable, biodegradable, or nonpolluting)”.
• “Green” can also be implied as verb. It would be
referred as process of reducing the environmental
impact of a manufacturing process or system when
compared to previous state.
• Green is a subset of sustainability. Wood is
clearly a very green product, but it’s only
sustainable if the company that harvests the
wood has a sustainable forest plan that doesn’t
deplete the source forests over time and on
balance.

10. Sustainable & Green 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 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.

11. Environmental Impact of Manufacturing
Manufacturing is highly dependent on material and
energy. It usually consumes water also.
Environmental impact of manufacturing is due to
materials, energy and water consumed in
manufacturing systems.
Manufacturing’s dominant environmental impacts.
• Toxic chemicals
• Waste generation
• Energy consumption
• Carbon emissions

12. Toxic Chemical release
• Toxic chemicals are widely used in many
manufacturing industries for product
development and process operation.
• US EPA established the TRI program in 1987 to
collect data about the toxic chemical release of
chemical manufacturing and other sectors
including metal mining, coal mining, electric
utilities, petroleum bulk terminals, chemical
wholesalers, hazardous waste treatment, and
solvent recovery. This data is collected annually.
• TRI data is publicly available containing
information on toxic chemical releases and
other waste management activities in
the United States.

13. Toxic Chemical release
TRI statistics of 2001 about the release of toxic
chemicals in United States.
Manufacturing industry released about 1.99 billion
pounds
Metal mining 2.3 billion pounds.
Total air emissions are roughly 30%.
Land release 62%
Water discharge and underground injections 4%.
Many small scale manufacturing entities are not
required to report their toxic chemical emissions so,
the actual chemical release of manufacturing are
much more significant.
The U.S. toxic release inventory in 2001

14. Waste Generation
• Manufacturing industry generates a huge
amount of waste usually inform of solid
waste, waste water which causes significant
environmental concerns and impacts.
• Waste of manufacturing industry is much
more than other industries in US.
• The amount of manufacturing’s waste is even
larger then the sum of seven other industries.
• Reducing the waste of manufacturing industry
in one of the major objective of Green
Manufacturing.
Amount of waste generated in US

15. Energy Consumption
• Manufacturing consume enormous amount of
energy in different processes and operations.
• Manufacturing industry is very energy
extensive.
• According to 2003 statistics manufacturing
consumed 23% of total energy in US.
• Energy consumption in manufacturing is
ranked 2nd by transportation.
• But in many cases transportation is a major
element is manufacturing due to complex
supply chains employed.
U.S. energy consumption by sector

16. Energy Consumption
• Energy consumption causes environmental
impacts due to the fact that 71.4% of energy
is generated from fossil fuels (in 2006). Only
2.11% of energy is produced by clean energy
sources.
• Fossils fuels contain various polluting
elements such as carbon, nitrogen and sulfur.
• Energy generation from fossil fuels produces
carbon di-oxide, sulfur dioxide, and nitrogen
oxides which causes global warming,
acidification and smog.
U.S. electricity mix

17. 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.
• According to Intergovernmental Panel on Climate Change expected
average temperature rise on current emissions trends is 1.4-5.8OC
between 1990-2100.
• Kyoto protocol is established for making legally binding targets for
the reduction of green house gases including carbon dioxide,
methane, nitrous oxide, sulfur hexafluoride, hydro fluorocarbons,
and per fluorocarbons.
• Graph shows U.S. GHG emissions in economic sector between 1998-
2004.
• Industrial sector has the largest result, while manufacturing industry
produces 80% of industrial CO2 emissions.
• Major source of CO2 emissions in manufacturing are the use of
energies generated by fossil fuels (directly or indirectly).
• About 120GJ energy is consumed in the manufacturing of a car which
would generate 23 metric tons of CO2 and other pollutants.
• Petroleum industry has the largest CO2 emissions per $10,000 value
generated, followed by primary metals and chemicals industry.
Carbon emissions of manufacturing(ton CO2/$10,000)

18. 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

19. Strategies for Sustainble Manufacturing
• Inverse Manufacturing
The life of any product
can be extended by disassembly the original
product at the end of its original life into
components that could be reused, maintained
or up-graded. For example, Fuji Xerox is
making entire machines with 70% reused
parts, this reduces 75% of the CO2 emissions
associated with manufacturing.
Several strategies have been developed make efficient use of resources, minimize pollution and waste.
• Recycling
The proves of converting waste
material into useful material or objects. It is one of the
better known strategies for sustainable manufacturing.
It should be mandatory to every one to participate in
recycling programs. Coca Cola recycling program

20. • Re-Manufacturing
The process of rebuilding a unit/machinery
to restore it condition “as good as new”
after overhaul and replacement of some
component parts and it is ensured that
remanufactured product meet the
tolerance’s and capabilities of new
product. Re-manufacturing of typres
• Reverse Logistic
It requires that manufacturers take a “cradle to gave” for their products. The
manufacturer is forever responsible for the product. It is also referred as “
product stewardship” . Product stewardship is driven by public outcry about the
degradation of environment.
In 2004, Xerox supplies return initiatives prevented more than 13.8 million
pounds of waste from entering landfills worldwide. The Xerox Waste Toner
Return Program (since 1998) received more than13 million pounds of waste
toner and over 2 million pounds in 2004 alone. Customers worldwide returned
nearly 3.2 million cartridges to Xerox in 2004 for reuse and recycling.

21. Life Cycle Assessment (LCA)
LCA definition proposed by ISO “ a technique for assessing
environmental aspects and potential impacts associated (with
products and services) …. LCA can assist in identifying
opportunities to improve environmental aspects of products
and services at various points of their life cycle”. It is also
referred as “cradle to grave” approach. It emphasis
environmental impacts of product from concept stage (i.e. raw
material generation) to end life (i.e. recovery or disposal).
It involves three major activities
• Inventory Analysis: Identification and quantification of energy
and resources used, environmental discharge to air, water
and land.
• Impact Analysis: technical assessment of environmental risk
and degradation.
• Improvement Analysis: identify opportunities to improve
environmental performance.

22. Eco-Labelling
The aim of eco-labelling is to make consumers
well aware of the health and environmental
impact of the product they use. In this way
choices are provided to customers between
products (to identify green products) to force
the manufacturer toward environment
conscious manufacturing system. There are also
standards of ISO for supporting environment,
ISO 14000 Environment Management System
Design for the Environment
This strategy implies an efficient designing of
product for environment management. Products
are to be designed with ease of disassembly and
recovery of valuable part to conserve energy and
resources while minimizing waste.
Three main design strategies are
Design for recyclability: the ease with which a
product can be disassembled and components
parts are recovered.
Design for remanufacture: it identifies
different stages of equipment or product wear.
Design for disposal: it identifies the strategies
to design the product with of disposal to
minimize hazardous and unsafe effects.

23. Barriers to Green Manufacturing
• Although green manufacturing is driven
by a number of positive factors, the
manufacturing industry still faces some
barriers and challenges that hinder the
application of green manufacturing
strategies in practice.
• In order to mitigate these barriers, the
prioritization of barriers is essential as
high-priority barriers can be taken up first
to address the issue more effectively
within the available resources.
• In the given table major barriers are
prioritized by a quantitative approach
(fuzzy TOPSIS multi-criteria decision
model ) in descending vitality order.

24. Environmentally Benign Manufacturing
EBM research group is the part of Laboratory
for Manufacturing and Productivity headed by
Professor Timothy Gutowski at MIT.
Main Research contents:
• RAFFT(Rapid Free Form Sheet Metal Forming
Technolocy) Project: Modeling the benefits of
a new incremental sheet forming technology
• Additive manufacturing: Tracking the energy
use of emerging technology
• Single stream recycling: Modelling of
material, exergy and energy flows
• Automobile assembly plant: Energy used and
carbon emitted

25. National Institute of standards and Technology
NIST is awarding $ 7.4 to accelerate use and innovation with
additive manufacturing.
NIST's Engineering Laboratory, the Measurement Science for
Additive Manufacturing Program has four projects.
 Real-Time Control of Additive Manufacturing Processes:
Ensure process consistency, develop process metrology, in
process sensing methods and real time process control.
 Qualification for Additive Manufacturing Materials and
Processes:
For critical important parts (turbine blade, medical parts)
 Systems Integration for Additive Manufacturing:
Facilitate coordination of design and machine control softwares
to reduce design-to-product cycle time.
 Characterization of Additive Manufacturing Materials:
Develop measurements and standards for powder metal raw
materials in terms of particle size, shape, chemical consistency
and size consistency.
by the process.

26. Sustainability is a Journey, not a Destination
• Remember there is no such thing as a company with
no environmental impact. There is no sustainability
“destination”.
• Goal should be continuous improvement – making
constant advances in company’s overall sustainability
performance.

28. • http://www.okinternational.org/mining
• http://web.mit.edu/ebm/www/projects.htm
• http://lmas.berkeley.edu/research.html
• https://www.nist.gov/topics/additive-manufacturing
• https://www.nist.gov/news-events/news/2015/04/report-charts-research-
path-improving-printed-metal-parts
• http://link.springer.com/chapter/10.1007/978-3-642-40060-5_101
• http://www.treehugger.com/culture/recycling-is-cool-but-inverse-
manufacturing-is-hot.html
• http://www.xerox4u.net/recycle