1. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:1 Environmentally Conscious Design & Manufacturing Class 4: Life Cycle Analysis-Design Prof. S. M. Pandit

2. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:2 Agenda: -Motivation and Introduction -Product Life Cycle -Systems View -Product Design -Green Design Strategies Life Cycle Analysis - Design

3. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:3 Motivation - 1 Steps in the life-cycle assessment of a product Define Scope R ERP Manufacture Inventory analysis Improvement analysis Impact analysis

4. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:4 Motivation - 2 The elements of a life-cycle inventory analysis Materials acquisition Product distribution Product use Recycle:Products, components, materials Waste management Materials Energy Air Water Formulation, processing, and manufacturing Principal products Co-products Water effluents Airborne emissions Solid Waste Other environmental interactions

5. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:5 Motivation - 3 A life cycle inventory and impact assessment provides a snapshot of the environmental features of -Products or -Processes Discrete Products: - Machined shaft - Gearbox - Washing Machine Milling operation Oil refining Beverage mixing and bottling Hazards and Risks

6. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:6 Raw Material Extraction Manufacturing Use Post Use “Waste” Energy Materials Fluids Power Generation Material Handling and Logistics Product Life Cycle Introduction -1

7. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:7 Introduction -2

8. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:8 Raw material extraction Manufacturing Use Post Use - Disposal - Recycling - Remanufacturing Product Life Cycle - 1

9. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:9 - Design for disassembly methodologies -Design for recycle and reuse methodologies -Design for decommissioning of equipment Environment Product functionality and quality Cost Product Life Cycle - 2

10. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:10 Design factors - Env. - x Product Life Cycle - 3 Compliance Assembly Environment Reliability Orderability TestabilityServiceability Manufacturabiliy Material Logistics and Component Applicability Safety and Liability Prevention Design for X

11. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:11 Material Handling and Logistics Discrete Event Models - I/O response from simulation Power Generation Idealized models with empirical weights Product Design Process Models ‘Usage’ models Recycling / Reuse / Biodegradation / Chemical degradation / Physical degradation & collection Environment Cost Function.. Systems View - 1

12. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:12 Systems View - 2 Product attributes Weight Size Can be palletized? Handle with care? Cost Material Handling and Logistics Speed of movement? Distance to be moved? Sensor (vision?) Control (fuzzy?)

13. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:13 Material Handling and Logistics Discrete event Model Simulation Control Movement Queuing Product attributes Time Cost Handling capacity Success / Failure statistics Systems View - 3

14. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:14 “Materials” Strength Creep resistance Thermal & Electrical properties “Mechanical” Power output Kinematics Velocity ratios “Functional Requirements” (Does it do the job?) “Aesthetic Requirements” “Environmental Factors” (Does it do the job?) Product Design (Bridge between Design Islands)

15. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:15 Multidisciplinary research that would result in validated models of physical processes that also incorporate life cycle, environmental, and economic parameters-as well as traditional process control parameters. Green Design - 1

16. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:16 Ideally these models would use the best computer technology- but be adaptable to manufacturing environments. Tied directly to the modeling was the need for correlation of materials/chemical properties and structure with processing parameters. Green Design - 2

17. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:17 Closely related is instrumentation research that can enhance process monitoring, & control The need for novelty and creativity in solving technical problems is stressed throughout. To attain goals of total sustainability simple enhancements of traditional methodology will not usually be sufficient. Green Design - 3

18. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:18 New approaches to processing Sensors that monitor phenomena that are unmonitorable today New materials that survive high temperatures and corrosive environments and last "forever," New technologies for energy efficiency and clean combustion New ways to separate effluents New approaches to catalysis Without basic research these leaps are unlikely to occur. Green Design - 4

19. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:19 Every industry will need highly specific chemical sensors for applications such as process control, process monitoring, ambient monitoring, and leak detection. These sensors must be fast, reliable, robust, inexpensive, sensitive, miniature, on-line capability, local, remote, for multicomponent analysis. In addition, all these features must be available for sensing in gaseous and liquid environments (including air and water) where the conditions may be considered harsh or even hostile. Green Design - 5

20. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:20 Given the fact that water quality concerns are prominent throughout industry, another common need is for improved water quality sensors with the same characteristics noted above for chemical sensors but focusing almost exclusively on those parameters measured for regulatory purposes including BOD, TOC, and particulates. Similarly, there is a need for improved air quality sensors to accurately and rapidly measure extremely low quantities of volatile organic chemicals and particulates. In particular, measurements of particle size distributions were identified as a specific need. It will be increasingly necessary to develop methodologies for multi-point as well as multi-species monitoring. Green Design - 6

21. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:21 Another research need, common to all of the industries discussed, falls in the general category of physical sensors. It was found that the need for fast, reliable, inexpensive physical sensors that can operate in harsh environments currently exists and that need will certainly increase in the future. Even a need for improved temperature sensors was identified. Other specific sensing needs include (1) particle size distribution, (2) non-destructive evaluation (NDE) of near-net shape to reduce material waste, (3) structural integrity so as to avoid catastrophic system failure resulting in release of process fluids, (4) rheometry especially for complex fluids such as slurries, (5) multiphase flow parameter sensors, and (6) leak detection. Green Design - 7

22. Environmentally Conscious Design & Manufacturing (ME592) Date: March 13, 2000 Slide:22 The final common element centered on the need for improved data processing and management. With the large scale increase in sensors and rapid monitoring devices it is obvious that careful attention must be paid to the collection and use of large amounts of data. Error detection and identification, multiple sensor data "fusion" (i.e., integration, interpretation), and robust control methods must be enhanced. Green Design - 8