1. © 2007 Dornfeld/UC Berkeley DRAFT Sustainable Design and Manufacturing: Can we “Engineer our way” to a Sustainable Future? David Dornfeld Will C. Hall Family Professor of Engineering University of California Mechanical Engineering Department Berkeley CA 94720-1740 Laboratory for Manufacturing And Sustainability (LMAS)

2. © 2007 Dornfeld/UC Berkeley DRAFT Outline Defining sustainability Sustainability in an engineering context Sustainability in a manufacturing context Summary and tasks

3. © 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.

4. © 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 of the 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 of the future by reducing the environmental load/unit of commerce to offset any increase in unit production so as to achieve a sustainable state over time. 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.”

5. © 2007 Dornfeld/UC Berkeley DRAFT Sustainability Frame of Reference Required Consumption Rate to reach Sustainability TodayFuture Rate of Consumption* Sustainable rate Consumption with increased efficiency Consumption at “today’s rate” How do we achieve this “slope change”? Any resource: energy, material, water,air …

6. © 2007 Dornfeld/UC Berkeley DRAFT Mind the gap! Responses to the situation Time ScaleResponseDrivers Short regulations (green buildingsgov’t/EU market Energy Star, CAFÉ, etc.)driven Mediumalternate energy, hybrids, H 2,resource limits and photovoltaiclong range market Long tools to engineer sustainablechange of approach, systems, life cycle env costsholistic view of effects included in product cost

7. © 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)

8. © 2007 Dornfeld/UC Berkeley DRAFT Think supply chain…act process Questions: - Can you improve the process/product without affecting 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? Process1Process2Process3ProcessN …

9. © 2007 Dornfeld/UC Berkeley DRAFT More details Let’s define the terms more specifically wrt manufacturing…

10. © 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.

11. © 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 environmental performance or “eco-efficiency” of the option…defined as the ratio of provided value to environmental load. The closer the “loop” is to the user…the lower the load on the environment.

12. © 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 Manufacturing Product definition End-of-life Recycling organizations Process selection/ development DFE LCA DFA All included in Sustainability

13. © 2007 Dornfeld/UC Berkeley DRAFT 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

14. © 2007 Dornfeld/UC Berkeley DRAFT Evolution of Production Paradigms Source: F. Jovane, et al, “Present and Future of Flexible Automation: To wards New Paradigms, CIRP Annals, 52, 2, 2003, 543. Green…yes… but…is this really sustainable?

15. © 2007 Dornfeld/UC Berkeley DRAFT Key transitions What’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

16. © 2007 Dornfeld/UC Berkeley DRAFT Key to each transition- the enabler Break complex tasks into elements; organization and control Move non-essential elements outside productive time Minimize working capital (cost of lack of quality) Include whole life cycle cost of environmental impact

17. © 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

18. © 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 (follow Deming!) Make the business case for sustainable manufacturing by 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

19. © 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. how much 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 manufacturing by 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.