1. Analyze a real world problem Design a software solution for that problem
Zhen Chen
Solano Community College

2. Sustainable Manufacturing
Sustainability – everyone has a role to play
Source: David Dornfeld, Ph.D. Will C. Hall Family Professor of Engineering, Director, Laboratory for Manufacturing and Sustainability (LMAS), University of California, Berkeley

3. First, what is sustainability? Sustainable? Green?
Sustainability – everyone has a role to play
First, what is sustainability?
Sustainable? Green?
‪Source: The University of Toledo – SEED Initiative, accessed

4. Who … what … where …?

5. How you design and produce things matters a lot

6. There are concrete impactful actions that manufacturers can take
How it is made … ?
Technology
Material
Energy
Green
manufacturing
system triangle
Improve
energy efficiency
Improve material
efficiency
Reduce
embedded
energy
Improve manufacturing process
Use lower impact
materials
Use clean energy sources
Cost
issue
Cost issue 1 2 3
Energy reduction, harvesting, combined processes, optimization, sustainability budget
Material yield,
supply chain/source and haz, chemistry/chemical effects
Manufacturing and energy mix
Source: Chris Yingchun Yuan, A System Approach for Reducing the Environmental Impact of
Manufacturing and Sustainability Improvement of Nano-scale Manufacturing, PhD. Thesis,
UC-Berkeley, 2009

7. Example … line level Process 1
There are concrete impactful actions that manufacturers can take
Example … line level
Process 1
Process 2
Process 3
Process n
Process 1 …
Energy
Water
Consumables
Process 1
Material / Part
Part / Product
Waste Heat
Air Emissions
Waste Water
Solid Wastes
Source: Robinson, S. “An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to
Inform Decision Making for Sustainability,” (December 2013), Doctoral Dissertation, UC-Berkeley.

8. Optimize over the system
There are concrete impactful actions that manufacturers can take
Optimize over the system
Process 4
Improved
Process 2
Cost and
environmental
impact
Process N
Environmental
Benefit
Process 3
Process 1 $
Current
And extends to tooling
and operations also …
Savings/Value
Source: Robinson, S., Dornfeld, D. “Leveraging Advanced Manufacturing for Sustainable Production,”
Proc International Symposium on Flexible Automation, Awaji-Island, Hyogo, Japan, July 14 – 16, 2014.

9. Example of process optimization
There are concrete impactful actions that manufacturers can take
Example of process optimization
Real-time data processing is used to collect
and process data in parallel to a machine’s operation
to save time and data storage

10. Data Mining and Data Mining in Manufacturing
What is data mining?
The process of the "Knowledge Discovery in Databases“
Enabled by improved computing power, increasing internet availability and decreasing of data storage cost
Data mining is a fast growing technology in many areas with great potential
Data mining effort in business, e-commerce and more

11. Data Mining in Manufacturing cont.
Vast amounts of data are available to be collected from manufacturing systems at different levels
From system-level to the operation-level with varying degrees of complexity
Data analysis can lead to
System and process optimization
Informed decision making
Data driven accurate predictions on many aspects:
Power consumption
Resource usage
Tool wear …

12. Example of Data Mining in Manufacturing
Image source:

13. A real world data mining problem
A machine shop has two automatic milling machines. Machines’ operation output data is in XML format. To improve the energy efficiency of the machines, operation data of power consumption and time stamps for each operation need to be extracted from the XML file. The extracted data will be calculated and then saved for analysis and comparison.
Find a solution in software for this problem
Save extracted data into a data file
Calculate the average power consumption of each operation
Display and write to an output file the elapsed time and the average power consumption of each operation