1. Sustainable Design and Manufacturing Bert Bras Sustainable Design & Manufacturing George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta, GA 30332-0405 www.sdm.gatech.edu

2. Sustainability: Common Definition Copyright Georgia Institute of Technology, 2009 “development that meets the needs of the present generation without compromising the needs of future generations.” United Nations’ World Commission on Environment and Development in their report “Our Common Future”, 1987

3. Copyright Georgia Institute of Technology, 2009 Sustainability: Working within the Physical Limits Earth Ecosystems Urban Regions Industry Sourcing Material Production Distribution Use Waste (land, water, air emissions Product Re-X Extraction Power Sources (Sun, Moon, Earth) Society Nature Bottom-line: The extractive capability of humanity (and its industrial system) must be balanced with the regenerative capacity of the Earth.

4. Copyright Georgia Institute of Technology, 2009 Sustainability’s “Triple Bottom Line” Sustainability is defined in three dimensions: Environmental –Destroying our resources will hurt us long term –Some materials already getting scarce Financial –Being bankrupt helps nobody Social –Quality of Life should go up –Workforce education and retention Goal is to have win-win-win technologies and solutions “Green Economy” “People-Planet-Profit”

5. Some Business Drivers Legislation: –Clean Air Act has limited use of a number of materials. –(European) take-back legislation is driving Design for Recycling efforts. Risk & Liability –Using hazardous materials can be risky and create many liabilities Customers: –Awareness of environmental issues is increasing among customers. In Europe, some customers will already pay more for a product if it is green. –Industrial customers (e.g., Original Equipment Manufacturers) do not want (future) environmental liability for your product. Image: –Being “green” is good. ISO 14000: –ISO 14000 (environmental management standards) certification has become an important element in doing business, like ISO 9000 (quality management standards). In addition, many have noted that DFE makes good business sense and has many other positive effects. –Reduction of waste, driver for new creative solutions, etc. Copyright Georgia Institute of Technology, 2010

6. Image is Everything Copyright Georgia Institute of Technology, 2010

7. Sustainability Challenges Overseas China, India, etc., are all facing severe environmental, health, and quality of life problems as a result of their industrial growth As a US designer and firm, you are contributing to their problems Copyright Georgia Institute of Technology, 2010

8. Copyright Georgia Institute of Technology, 2008 Life Cycle Assessment (ISO 14040) LCA is one means to try to investigate some of the issues for these systems LCA examines the environmental burdens and impact of a product over its entire life-cycle (see ISO 14040) Bras, B. (1997). "Incorporating Environmental Issues in Product Realization." United Nations Industry and Environment 20(1-2): 7-13. Schematic of Product Life-Cycle Takes a lot of work

9. Materials Copyright Georgia Institute of Technology, 2010

10. Materials Issues Many materials are subject to legislations/regulations, e.g.: US: EPA “list of lists” –The “Title III List of Lists” is the key to EPCRA and is available from: http://www.epa.gov/ceppo/pubs/title3.pdf EU: Restriction of Hazardous Substances (RoHS) REACH Industry: GADSL (Global Automotive Declarable Substance List) http://www.americanchemistry.com/s_plastics/doc.asp?CID=1106&DID=9293 Copyright Georgia Institute of Technology, 2010

11. RoHS RoHS is often referred to as the lead-free directive, but it restricts the use of the following six substances: –Lead (Pb) –Mercury (Hg) –Cadmium (Cd) –Hexavalent chromium (Cr6+) –Polybrominated biphenyls (PBB) –Polybrominated diphenyl ether (PBDE) PBB and PBDE are flame retardants used in several plastics. Lots of companies want suppliers to certify that they are “RoHS compliant” If one part is not compliant, the whole product is not either Copyright Georgia Institute of Technology, 2010

12. EPA and Toxic Release Inventory (TRI) You have to fill in a TRI (like a tax report) if you use certain hazardous chemicals in manufacturing and it is posted online: –www.epa.gov/triexplorer/ In the US, look at the EPA “list of lists” to see when you should worry about permits and special rules –www.epa.gov/ceppo/pubs/title3.pdf Best thing is not to use any of these chemicals or let somebody else (your supplier) deal with it Biggest air polluters: coal fired power plants Biggest land polluters: mines Copyright Georgia Institute of Technology, 2010

13. Material Safety Data Sheets (MSDS) Check MSDS of materials if you want to be safe w.r.t. any health risks from a material you want to use in your design –Also think about worker safety (OSHA) MSDS can be obtained from material providers –Should be available upon request or onlinE GREAT list of online MSDS and related databases is at: –http://www.ilpi.com/msds/ Quick and easy online (free) MSDS database: –http://hazard.com/msds/ Copyright Georgia Institute of Technology, 2010

14. Energy & GHG Copyright Georgia Institute of Technology, 2010

15. Example - Two Automotive Parts Simple question: What is better? –Virgin manufacturing & disposal –Recycling –Remanufacturing Aluminum transfer case Steel pinion gear … and by how much? NSF Grant # 0522116 Copyright Georgia Institute of Technology, 2010

16. Al Process Energy Consumption (kWh/ton) Refining processes have the highest energy consumption Machining processes energy consumption is low NSF Grant # 0522116 De-Materialization should be higher priority from an energy point of view → product design Copyright Georgia Institute of Technology, 2010

17. Steel Processing Energy Consumption Refining processes have the highest energy consumption Machining processes energy consumption is low NSF Grant # 0522116 De-Materialization again will result in higher gains from an energy point of view Copyright Georgia Institute of Technology, 2010

18. Energy Consumption in Manufacturing Sectors MECS Survey Years NAICSSubsector and Industry19982002 311Food1,0441,123 312Beverage and Tobacco Products108105 313Textile Mills256207 314Textile Product Mills5060 315Apparel4830 316Leather and Allied Products87 321Wood Products509377 322Paper2,7472,363 323Printing and Related Support98 324Petroleum and Coal Products7,3206,799 325Chemicals6,0646,465 326Plastics and Rubber Products328351 327Nonmetallic Mineral Products9791,059 331Primary Metals2,5602,120 332Fabricated Metal Products445388 333Machinery217177 334Computer and Electronic Products205201 335 Electrical Equip., Appliances, and Components 143172 336Transportation Equipment492429 337Furniture and Related Products8864 339Miscellaneous8971 Manufacturing23,79622,666 Manufacturing process energy savings are small when majority is embodied in upfront material production/refining Relocating a manufacturing facility to a locality with renewable power often has a larger carbon footprint effect than any process efficiency improvement GA Power Plant Bowen (Cartersville): –CO2 emission: 0.9 kg/kWh –H2O evaporation: 0.4 gallons/kWh Copyright Georgia Institute of Technology, 2009 Consumption of Energy (Site Energy) for All Purposes (First Use) for Selected Industries, 1998 and 2002 (Trillion Btu) Source: Energy Information Administration, Form EIA-846, Manufacturing Energy Consumption Surveys, 1998 and 2002, http://www.eia.doe.gov/emeu/efficiency/mecs_trend_9802/mecs9802_table1a.html

19. DoE Energy information Agency One of the best sites to find all kind of info on energy: –http://www.eia.doe.gov/ For checking how much greenhouse gas emissions are created by burning gasoline, coal, methane, etc, see: –http://www.eia.doe.gov/oiaf/1605/coefficients.html –http://www.eia.doe.gov/oiaf/1605/emission_factors.html –Example: gasoline => 19.564 lbs CO2/gallon Copyright Georgia Institute of Technology, 2010

20. Regional Variation in CO 2 Emissions Copyright Georgia Institute of Technology, 2010 http://www.eia.doe.gov/oiaf/1605/emission_factors.html

21. Copyright Georgia Institute of Technology, 2008 Refining metal requires large amount of water specially for cooling and rinsing systems High water consumption related to the geometry of the transfer case part and the material This does not include water use from electricity generation (about 0.4-0.7 gallons/kWh for thermo-electric plants) Water Copyright Georgia Institute of Technology, 2010

22. Use Phase Typically, any energy consuming product has the largest environmental in its use phase –Exceptions always exist Conservation is good! –Every kWh or Joule saved by the product saves another 2-3 upstream Beware of “rebound effect” –You created a more efficient product, but it is going to be used more Copyright Georgia Institute of Technology, 2010

23. End Of Life Copyright Georgia Institute of Technology, 2010 Linear Production: “Take, make, waste” (our current system) Closed Loop Production (future system)

24. WEEE Directive The Waste Electrical and Electronic Equipment Directive (WEEE Directive) is the European Community directive 2002/96/EC on waste electrical and electronic equipment (WEEE) which sets collection, recycling and recovery targets for all types of electrical goods. Original Equipment Manufacturers are responsible for appropriate collection and treatment. Each country can have different implementation Think about how you will ensure that your (electronic) product will not end up on a landfill and can be recycled Copyright Georgia Institute of Technology, 2010

25. Design for Environment Guidelines & Scoring Copyright Georgia Institute of Technology, 2010 1 Selection of low-impact materials Non-hazardous materials Non-exhaustable materials Low energy content materials Recycled materials Recyclable materials 0 New Concept Development Dematerialisation Shared use of the product Integration of functions Functional optimization of product (components) 2 Reduction of material Reduction in weight Reduction in (transport) volume 3 Optimization of production techniques Alternative production techniques Fewer production processes Low/clean energy consumption Low generation of waste Few/clean production consumables 4 Efficient distribution system Less/clean packaging Efficient transport mode Efficient logistics 5 Reduction of the environmental impact in the user stage Low energy consumption Clean energy source Few consumables needed during use Clean consumables during use No energy/auxiliary material use 6 Optimization of initial life-time Reliability and durability Easy maintenance and repair Modular product structure Classic design User taking care of product 7 Optimization of end-of-life system Reuse of product Remanufacturing/refurbishing Recycling of materials Clean incineration Brezet, J. C. and al., e., 1994, PROMISE Handleiding voor Milieugerichte Produkt Ontwikkeling (PROMISE Manual for Environmentally Focused Product Development), SDU Uitgeverij, The Hague, The Netherlands.

26. Opportunities Think “holistically” about your product. Your product is part of a bigger system Thinking bigger may actually reduce cost –Can you reuse parts? –Can you lease instead of sell/buy? –Is the product really the end, or is it just a provider of a function? Copyright Georgia Institute of Technology, 2010

27. Copyright Georgia Institute of Technology, 2008 Importance of Sound Engineering Many systems are over- engineered Appropriate technology and sound engineering can go a long way towards sustainability Switching from Class 8 High Duty Diesel trucks to Ford F750 can provide significant savings. Ideas were triggered by quest for fuel savings.

28. Human Rights: Think about the social consequences of your products - Image is Everything Copyright Georgia Institute of Technology, 2010

29. In Closing In your project, you can –Calculate energy consumption and corresponding CO2 emissions –Check for RoHS compliance –Check and include MSDS sheets for potential problem materials –Increase recyclability by reducing number of different materials –Use recycled materials and/or reused parts –Etc. Achieving sustainability problems is a very complex, multi-scale problem requiring multi-disciplinary teams and approaches Think about the social and environmental consequences of your products But don’t forget the basics – good engineering & decision making is good for people-planet-profit! Copyright Georgia Institute of Technology, 2009