Post on 23-Dec-2015
transcript
© 2007 Dornfeld/UC Berkeley DRAFT
Sustainable Design and Manufacturing: Can we “Engineer our way” to a
Sustainable Future?
David DornfeldWill C. Hall Family Professor of Engineering
University of CaliforniaMechanical Engineering Department
Berkeley CA 94720-1740
Laboratory for Manufacturing And Sustainability (LMAS)
© 2007 Dornfeld/UC Berkeley DRAFT
Outline
• Defining sustainability• Sustainability in an engineering context• Sustainability in a manufacturing context• Summary and tasks
© 2007 Dornfeld/UC Berkeley DRAFT
So…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.
© 2007 Dornfeld/UC Berkeley DRAFT
Then…what does sustainable require?If you are presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands ofthe future. This is a net zero impact.
If you are NOT presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands ofthe future by reducing the environmental load/unit of commerce to offset any increase in unit production so as to achieve a sustainable state overtime.
That is, in the words of Hawken, 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 at a rate greater than the normal growth in consumption would require. Business must have a “net positive impact.”
© 2007 Dornfeld/UC Berkeley DRAFT
Sustainability Frame of Reference
Required Consumption Rateto reach Sustainability
Today Future
Rat
e of
Con
sum
ptio
n*
Sustainable rate
Consumption with
increased efficiency
Consumption at
“today’s rate”
How do we achieve this “slope change”?
•Any resource: energy, material, water,air …
© 2007 Dornfeld/UC Berkeley DRAFT
Mind the gap!Responses to the situation
Time Scale Response Drivers
Short regulations (green buildings gov’t/EU marketEnergy Star, CAFÉ, etc.) driven
Medium alternate energy, hybrids, H2, resource limits andphotovoltaic long range market
Long tools to engineer sustainable change of approach,systems, life cycle env costs holistic view of effectsincluded in product cost
© 2007 Dornfeld/UC Berkeley DRAFT
Think Global - Act Local
Design and Manufacturing - think supply chain…act process
Is the process - coupled? - decoupled?
with respect to environmental impacts (materials, energy required, consumables, waste generated)
© 2007 Dornfeld/UC Berkeley DRAFT
Think supply chain…act process
Questions:
- Can you improve the process/product withoutaffecting up/down stream processes/products?
- If you cannot…what is the impact on adjacent elements?- What are the “closed loop” parts of the design or process?
Process1 Process2 Process3 ProcessN…
© 2007 Dornfeld/UC Berkeley DRAFT
More details
Let’s define the terms more specifically wrt manufacturing…
© 2007 Dornfeld/UC Berkeley DRAFT
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.
© 2007 Dornfeld/UC Berkeley DRAFT
Closed Loop Manufacturing: Renewing Functions while Circulating Material
Source: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655
• Each orbit in the figure corresponds to a life cycle option, such as prolonged use by means maintenance, product reuse, part reuse,recycling, and energy recovery.
• To realize “closed-loop manufacturing” the product life cycle should be managed by selecting proper life cycle options.
• In selecting life cycle options, need to consider the environmentalperformance or “eco-efficiency” of the option…defined as the ratioof provided value to environmental load.
• The closer the “loop” is to the user…the lower the load on the environment.
© 2007 Dornfeld/UC Berkeley DRAFT
After Ishii, K., "Incorporating End-of-Life Strategy in Product Definition," Invited paper, Eco Design '99: First International Symposium on Environmentally Conscious Design and Inverse Manufacturing, February 1999, Tokyo, Japan.
Product design, manufacturing and recovery
Detail design
ManufacturingProductdefinition
End-of-life
Recycling organizations
Process selection/development
DFE
LCA
DFA
All includedin Sustainability
© 2007 Dornfeld/UC Berkeley DRAFT
Green Machines
Clean PowerGreen
ManufacturingProcesses
Green Products
“Ecofacturing*” or “Ecomanufacturing**”
Source: * TM Taiheiyo Cement, Japan**IGPA Newsletter, Dec. 2003
Closer Focus on Manufacturing
© 2007 Dornfeld/UC Berkeley DRAFT
Evolution of Production Paradigms
Source: F. Jovane, et al, “Present and Future of Flexible Automation: Towards New Paradigms, CIRP Annals, 52, 2, 2003, 543.
Green…yes…but…isthis really sustainable?
© 2007 Dornfeld/UC Berkeley DRAFT
Key transitionsWhat’s needed to make the last transition?
Automation“F. W. Taylor”
Computer Aided Manufacturing (CAM)
“M. E. Merchant”
Lean Manufacturing“Toyoda, et al”
Positive Impact Manufacturing
© 2007 Dornfeld/UC Berkeley DRAFT
Key to each transition- the enabler
Break complex tasks into elements;
organization and control
Move non-essentialelements outsideproductive time
Minimize working capital(cost of lack of quality)
Include whole life cycle cost of environmental impact
© 2007 Dornfeld/UC Berkeley DRAFT
Dimensions of design, manufacturing and environment
design(functionality,complexity,life)
production/distribution(quality, yield, throughput, flexibility/lean)
environment
(energy, consumables, waste, hazards, end-of-life)
co$t
© 2007 Dornfeld/UC Berkeley DRAFT
So….what do we learn from all this?• Think globally…act locally!
think corporate…..act departmentally!think department…act system!think system…act process!think process….act machine!think machine…act tool! (ok…ok…point made)
• Waste, of any resource (time, money, energy, space,consumables, etc.) costs…..eliminate waste (followDeming!)
• Make the business case for sustainable manufacturingby including life cycle cost of environmental impact
• Include your suppliers/distributers in this through the design process
• Need analytical/engineering tools (design/process plan) to enable decisions/tradeoffs
© 2007 Dornfeld/UC Berkeley DRAFT
How do we respond as engineers?• Make sure we evaluate the “real” impact of our technical solutions
in terms of how much of the “gap” we are removing (i.e. howmuch is a particular technology “wedge” going to reduce the gap?*) OR design our technical solutions to have the largest impact on the gap.
• Make the business case for sustainable manufacturingby including life cycle cost of environmental impact (the “true cost” of the product including the ‘environmental capital’)
• Include the supply chain in this through the design process• Develop analytical/engineering tools (design/process plan) to
enable decisions/tradeoffs based on life cycle costs…ie EnviroCAD
• Make sure to include our social science/policy friends in the discussion as there will be “side effects”
• Capitalize on the technology innovations as entrepreneurs• Educate…educate…educate
•Ref. S. Pacala and R. Socolow, "Stabilization Wedges: Solving the Climate Problem for the next 50 •Years with Current Technologies," Science, August 2004, Vol. 305, pp. 968-972.