1. Challenges and Opportunities for Sustainable Manufacturing Pusan National University Prof. Haedo Jeong

2. Outline Drivers for sustainable manufacturing How do we define sustainability? What is sustainable manufacturing? Examples of opportunities and strategies What can we accomplish working together on this? Agenda

3. Today: One Big Issue Energy/Environment/Sustainability as user as manufacturer as good citizen as market/industry growth driver as risk reducer as cost reducer as parent as researcher as educator This should be seen as good for all manufacturing and a driver for our research This should be seen as good for all manufacturing and a driver for our research

4. From 2007 to 2057 consumption is Projected to Double World Energy Consumption Source: International Energy Outlook 2001, March 2001, U.S. Department of Energy World Energy Consumption by Region, 1970-2020

5. Korea Is this where we want to be? Source: G. Fleming, LBNL, 2007 GDP vs Energy Efficiency Top 40 economies by GDP

6. To allow surface temperature stabilization, the UK and EU have adopted a target of a 60% absolute cut in yearly carbon emissions by 2050 compared to 1990 levels. Actual emissions adjusted for “off- shore” effects Kyoto target of 5% cut by 2012 from 1990 agreed Gradient is 1.6% cut per year for 60 years The 2050 Carbon Target

7. If demand for steel doubles then stabilizes, and every efficiency known to the EU ULCOS project is perfectly implemented, the carbon target requires that two thirds of all steel is re-used without re-smelting, and the energy of all forming processes is halved. 2050 2006 Scope of Change Required The future of iron and steel

8. Why does industry care? Pressure from Government –Regulations –Penalties –Tax benefits Interest in Efficiency/Reduced CoO Continuous Improvement Pressure from Society/Consumers/Customers Pressure from Competitors

9. Environment or Economy? “Today, we need a shift in how we think about the relationship between the earth and the economy. This shift is no less fundamental than the one proposed by Copernicus back in 1575. This time, the issue is not which celestial sphere revolves around the other -- but whether the environment is part of the economy -- or the economy is part of the environment.” Source: Lester Brown, “The Second Coming of Copernicus” The Globalist, 2001:

10. Everyone wants to be green!

11. http://www.airbus.com/en/aircraftfamilies/a380/index2.html#greener (accessed 1/28/08) Airbus A380

12. So…what does sustainable mean? United Nations: Sustainable Development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs. Brundtland Commission Report, UN, 1987

13. How do we define sustainability? Global warming gases emission (CO 2, methane CH 4, N 2 O, CFC’s) per capita per GDP per area/nation Recyclability Reuse of materials Energy consumption Pollution (air, water, land) Ecological footprint - “fair share”

14. Rethinking Business “The best solutions are based not on tradeoffs or “balance” between these objectives [economic, environmental and social policy] but on design integration achieving all of them together - at every level, from technical devices to production systems to companies to economic sectors to entire cities and societies.” Source: P. Hawken, A. Lovins and L. Lovins, Natural Capitalism, Little, Brown, 1999, pp. x-xi.

15. Sustainability Frame of Reference Required Consumption Rate to reach Sustainability How do we achieve this? TodayFuture Rate of Consumption Sustainable rate Consumption with increased efficiency Consumption at “today’s rate” or Impact

16. Basis for assessing the impact

17. societyeconomyenvironment -economic “capital” -environmental “capital” -social “capital” -economic “capital” -environmental “capital” -social “capital” Sustainable Business

18. Mining, harvesting & extraction ConversionMfg Transport & distribution UseEnd of life All part of manufacturing/processing Phases of production and use (don’t just focus on use!)

19. Sustainable manufacturing is … Source: J. Allwood, “What is Sustainable Manufacturing?,” Lecture, Cambridge University, February 2005

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

21. Key transitions in manufacturing Break complex tasks into elements; control Move non-essential elements outside productive time Minimize working capital Include whole life cycle cost of environmental impact Automation “F. W. Taylor” Computer Aided Manufacturing (CAM) “M. E. Merchant” Lean Manufacturing “Toyoda, et al” Positive Impact Manufacturing Environmental Externalities Metrics

22. Source: J. Pearson, Design and Sustainability-Opportunities for Systematic Transformation, Greenblue Institute, p.16, 2006; www.greenblue.org.www.greenblue.org “Internalize All Costs”

23. Change of Manufacturing Boundaries Detail design Manufacturing Product definition End-of-life Recycling organizations Process selection/ development DFE LCA DFA All included in Sustainability After Ishii, K., "Incorporating End-of-Life Strategy in Product Definition," EcoDesign '99: First Int’l Symp. on Environmentally Conscious Design and Inverse Manufacturing, February 1999, Tokyo, Japan.

24. Green Machines Clean Power Green Manufacturing Processes Green Products “Ecofacturing*” or “Ecomanufacturing**” Source: * TM Taiheiyo Cement, Japan **IGPA Newsletter, Dec. 2003 Sustainable Mfg. Components

25. Levels of design & manufacturing flexibility Level 1 Feature prediction, control, and optimization in an iterative design and process planning environment Design: High Manufacturing: High Finishing: Low Level 2 Feature prediction, control, and optimization through the selection of a manufacturing plan in an “over-the-wall” design-to-manufacturing environment Design: Low Manufacturing: High Finishing: Low Level 3 Feature prediction and control through limited adjustments to a pre established manufacturing process Design: Low Manufacturing: Limited Finishing: Low ➔ High Level 4 Feature prediction for finishing process planning, finishing tool trajectories, and sensor-feedback strategies Design: Low Manufacturing: Low Finishing: High Software Driven Hardware Driven

26. Metrics of Sustainable Manufacturing Energy payback time Water (or materials, consumables) payback time Greenhouse gas return on investment (GROI) Carbon footprint Link to traditional design and manufacturing parameters

27. MRR (production time) energy (sp. energy x vol) waste mass/materials/resources Green process “trade-offs”

28. design (functionality, complexity, life) production/distribution (quality, yield, throughput, flexibility/lean) environment (energy, consumables, waste, hazards, end-of-life) co$t Dimensions of design, manufacturing and environment

29. Question: How do you do this for a process ……not a product? Is there a value to product-based analysis? First…we need to understand what we are working with…meaning what influences product quality/performance from process side Environmental Assessment

30. www.remmele.com/flash/contractManu/pca.html www.caranddriver.com/features/7207/virtual-tour-of-vws-transparent-factory.html Factory/enterprise Process/detail Effects at different scales

31. complexity of manufacturing automobiles/aircraft/components environmental “impacts” increasingly important must “holistically” consider components, tooling and machinery and system design when addressing these challenges (and must include the whole supply chain) engineers/designers need “tools” to assist in this as part of the design process for plants/production systems What’s the challenge?

32. To reduce the environmental impact of manufacturing processes Reduce Utilization of Scarce Resources Reduce waste generated Increasingly stringent US/Int’l standards and regulations Applications (especially important to) –Transfer Line, Job Shop (complex fluid interactions and worker assignment) Environmental Planning Objectives

33. Social - Quality of Life - Pay Rates - Working Conditions - Health Care Economic - Part Quality - Resource Availability - Lead Times & Inventory - Risk Environmental - Electricity Mix - Resource Availability - Electricity Demand - Emissions Fate - Regulations TRANSPORTATION SUPPLIER - Location Economic - Accessibility - Availability - Lead Times - Risk Environmental - Emissions - Resource Use - Distance Supply Chain Considerations

34. Minimum cost/CoO Maximum production Maximum flexibility Maximum quality Minimum environmental & social impact Broadest integration * Through software Functional Model Feedback (validation) Integration with CAD Feedback (validation) Feedback (validation) Include “islands of automation” and existing models) Include supply chain with constraints (e.g. “quality gates” ) Prototype based on model Feedback (validation) Extend to “social impact” constraints (green, sustainability, health, safety, etc.) Feedback (validation) Feedback (validation) Interoperability Enables Manufacturing Pipeline

35. Software Driven Process Planning Optimize process as one of a sequence of operations Design process individually for each component Integrate sophisticated models for various process outcomes Maintain software focus at each stage for easy integration Insure overall performance specs met (quality, throughput, cost) Face Milling: Interface Tool path planning Burr predictionSurface finish prediction Process Database Cleaning & Inspection Sustainable production

36. A Product “Life-cycle” - focus on manufacturing - Manufacturing

37. Sustainability…effects at different scales Machine (Build/Run) Machine (Build/Run) Process (Microplan) Process (Microplan) System (Factory) System (Factory) Operation (Macroplan) Operation (Macroplan)

38. Sustainability…machine tool level Machine (Build/Run) Machine (Build/Run) 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) Alternate energy sources for operation (fuel cell, etc.) and energy storage/recovery capability; variable motors energy req’ts Minimized environmental requirements Machine work envelope/machine footprint minimization Design using sustainability metrics (GHGROI, etc.) Design for re-use/re-manufacturing/component upgrade Low maintenance ? 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) Alternate energy sources for operation (fuel cell, etc.) and energy storage/recovery capability; variable motors energy req’ts Minimized environmental requirements Machine work envelope/machine footprint minimization Design using sustainability metrics (GHGROI, etc.) Design for re-use/re-manufacturing/component upgrade Low maintenance ?

39. Sustainability…machine operation level Operation (Macroplan) Operation (Macroplan) Workholding/work orientation for minimum energy machining Process sequencing for minimum energy, consumables, finishing, etc. Combined tooling “mill-turn” type processing Minimized environmental requirements ? Workholding/work orientation for minimum energy machining Process sequencing for minimum energy, consumables, finishing, etc. Combined tooling “mill-turn” type processing Minimized environmental requirements ?

40. Sustainability…process level Process (Microplan) Process (Microplan) Feeds/speed for minimum energy machining Rough/finish plan for minimum energy, consumables, finishing, etc. Spindle/tooling design Optimized tool path for high productivity and minimum energy Minimized environmental requirements ? Feeds/speed for minimum energy machining Rough/finish plan for minimum energy, consumables, finishing, etc. Spindle/tooling design Optimized tool path for high productivity and minimum energy Minimized environmental requirements ?

41. Sustainability…system/factory level System (Factory) System (Factory) Energy “load balancing” over line/system Energy “load balancing” over plant Resource/consumable optimization Factory/line alternate energy supply and network/grid Minimized environmental impact over line/system and plant ? Energy “load balancing” over line/system Energy “load balancing” over plant Resource/consumable optimization Factory/line alternate energy supply and network/grid Minimized environmental impact over line/system and plant ?

42. Sustainability…system performance tracking and optimization Energy “load balancing” over line/system Energy “load balancing” over plant Resource/consumable optimization Energy “load balancing” over line/system Energy “load balancing” over plant Resource/consumable optimization 1 2 34567N time Power Synchronous cycles Asynchronous cycles

43. Other considerations? How to handle rest of supply chain? Machine tool/power as part of power grid? Manufacture of machine tool vs use of machine Tool? Material Machine Tool Machine Tool Tooling

44. Conclusions Sustainability and surrounding issues are a big opportunity for manufacturing researchers This requires careful analysis and development of metrics and analytical tools Must consider entire “pipeline” of the design to process with integrated CAD and CAM tools based on process modeling Including sustainable manufacturing considerations can be part of a successful business strategy The problem is too large for individual countries/researchers or individual companies to solve - must be a cooperative effort among experts