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    The document discusses issues of sustainable manufacturing. It identifies key issues like greenhouse gas emissions, waste generation, and use of non-renewable materials. It then outlines five options to address these issues: using less material/energy, substituting inputs, reducing outputs, converting outputs to inputs through recycling, and changing production structures. Finally, it provides examples of research from Cambridge University on technologies that enable more sustainable manufacturing, like incremental sheet forming and flexible ring rolling.

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    Sus Man Power Point 1

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    37 views28 pages
    The document discusses issues of sustainable manufacturing. It identifies key issues like greenhouse gas emissions, waste generation, and use of non-renewable materials. It then outlines five options to address these issues: using less material/energy, substituting inputs, reducing outputs, converting outputs to inputs through recycling, and changing production structures. Finally, it provides examples of research from Cambridge University on technologies that enable more sustainable manufacturing, like incremental sheet forming and flexible ring rolling.

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    The document discusses issues of sustainable manufacturing. It identifies key issues like greenhouse gas emissions, waste generation, and use of non-renewable materials. It then outlines five options to address these issues: using less material/energy, substituting inputs, reducing outputs, converting outputs to inputs through recycling, and changing production structures. Finally, it provides examples of research from Cambridge University on technologies that enable more sustainable manufacturing, like incremental sheet forming and flexible ring rolling.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    37 views28 pages

    Sus Man Power Point 1

    Uploaded by

    Justice Rao
    The document discusses issues of sustainable manufacturing. It identifies key issues like greenhouse gas emissions, waste generation, and use of non-renewable materials. It then outlines five options to address these issues: using less material/energy, substituting inputs, reducing outputs, converting outputs to inputs through recycling, and changing production structures. Finally, it provides examples of research from Cambridge University on technologies that enable more sustainable manufacturing, like incremental sheet forming and flexible ring rolling.

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    Sustainable manufacturing

    Presentation for Cambridge University Horizon Day, 8th December 2004

    What are the issues? What are the responses? What are we doing in Cambridge?

    Julian Allwood Institute for Manufacturing University of Cambridge Mill Lane Cambridge CB2 1RX +44-1223-338181 jma42@cam.ac.uk 1

    Sustainable manufacturing

    Presentation for Cambridge University Horizon Day, 8th December 2004

    What are the issues? What are the responses? What are we doing in Cambridge?

    Julian Allwood Institute for Manufacturing University of Cambridge Mill Lane Cambridge CB2 1RX +44-1223-338181 jma42@cam.ac.uk 2

    Sustainability: what are the issues?


    United Nations indicators of sustainability:

    Greenhouse gas Ozone layer Air quality De-forestation Desert-ification


    Agricultural chemicals

    Poverty Gender equality Nutrition Child mortality Sanitation

    Anthropo-sphere Ecosphere

    Health Education Housing Crime Population (Employment)


    http://www.un.org/esa/sustdev 3

    Bio-diversity Urbanization
    Non-renewable material

    Hazardous waste Waste volume


    Energy consumption

    Sustainability: some issues will never be solved

    Poverty

    Utanapishtim spoke to Gilgamesh, saying: O man of Shuruppak, son of Ubartutu: Abandon wealth and seek living beings! Spurn possessions and keep alive living beings!
    Epic of Gilgamesh, tablet XI, ~2600BC

    Gender equality Nutrition Child mortality Sanitation Health Education Housing Crime Population

    Sustainability: some issues are already being addressed


    Where a local lobby can create pressure for change on bodies with local authority
    16 14 UK emissions (Mt) . 12 10 8 6 4 2 0
    Agricultural chemicals

    Carbon Monoxide Sulphur Dioxide Nitrogen Oxide

    Ozone layer Air quality

    1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 5 4 3 2 1 0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
    5

    Hazardous waste

    UK waste (Mt)

    Nickel Zinc Lead

    Sustainability: some issues are not solved but could be


    Where a local lobby cannot create effective pressure for change
    UK CO2 emissions (Mt)
    700 600 500 400 300 200 100 0 1990 700 600 (Billion tonnes) 500 400 300 200 100 0 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
    40 35 30 25 20 15 10 5 0 1996/97 1997/98 1998/99 1999/00 2000/01 2001/02

    Greenhouse gas
    (energy consumption) Non-renewable material (material consumption)

    Waste volume (Employment)

    UK Municipal waste (Mt)

    Global pig iron production

    1991

    1992

    1993

    1994

    1995

    1996

    1997

    1998

    1999

    2000

    Incineration with energy recovery Recycled/composted Landfill

    Sustainable manufacturing is ...


    Developing technologies to transform materials without emission of greenhouse gases, use of non-renewable materials or generation of waste.
    Assembly
    Components

    Retail Use

    Materials Extraction

    Anthropo-sphere

    Disposal

    Ecosphere

    Sustainable manufacturing is ...


    Developing technologies to transform materials without emission of greenhouse gases, use of non-renewable materials or generation of waste.

    Sustainable manufacturing

    What are the issues? What are the responses? What are we doing in Cambridge?
    9

    Five options for sustainable manufacturing:


    1. Use less material and energy

    Assembly
    Components

    Retail Use

    Materials Extraction

    Anthropo-sphere

    Disposal

    Developing technologies to transmit power with reduced emission of greenhouse gases: 50% of US industrial
    electricity is used by electric motors, most of which could be reduced to around 20% of the current power
    10

    Five options for sustainable manufacturing:


    2. Substitute input materials: non-toxic for toxic, renewable for non-renewable

    Assembly
    Components

    Retail Use

    Materials Extraction

    Anthropo-sphere

    Disposal

    Developing technologies to join electrical components without lead:


    WEEE directive likely to outlaw lead in solder by 2006
    11

    Five options for sustainable manufacturing:


    3. Reduce unwanted outputs: Cleaner production, Industrial symbiosis

    Assembly
    Components

    Retail Use

    Materials Extraction

    Anthropo-sphere

    Disposal

    Developing technologies to manufacture PCBs without water pollution: Anglia Circuits cleans its effluent
    water to drinking quality standards
    12

    Five options for sustainable manufacturing:


    4. Convert outputs to inputs: recycling and all its variants

    Assembly
    Components

    Retail Use

    Materials Extraction

    Anthropo-sphere

    Disposal

    Developing technologies to take photographs with reduced use of materials:


    Kodaks single use camera changed from an environmental problem to an example of good practice, once the used cameras were accepted back for renewal
    13

    Five options for sustainable manufacturing:


    5. Changed structures of ownership and production: product service systems, supply chain structure

    Disposal Use Retail Assembly


    Components

    Extraction Materials

    Developing technologies to wash clothes with reduced end of life waste: Electrolux pay-per-wash system, means that the company retains
    ownership of the material embedded in the product
    14

    Sustainable manufacturing

    What are the issues? What are the responses? What are we doing in Cambridge?
    15

    Changed structures of production :


    Environment & structures of production:
    10% of World energy use is in freight
    Disposal Use Retail Assembly Componen ts

    Extraction Materials

    16

    Trillion BTu

    10% of World energy use is in freight

    Changed structures of production :

    Environment & structures of production:

    Most energy use in manufacturing is in primary materials production

    P Pu etro lp l & an c o C d p al he ap p m er rod ic ( u a p c Pr ls ( rim ts im pr a r Pr ary ima y) im m ry ar e t ) y a Pr Fe wo ls Tr i m rt o an ar iliz d sp y er or te s ta xt tio ile n s N eq on M uip Fa me ac m br tal hi en ic m ne t Pl a in as ted e ry C tic m ral om & e p pu ru tal rod te bb pro uc r, er d ts El ec W elec pro uct tri o . du s ca od pr c l a p od ts p p ro uc lia du ts nc cts Pr es e i M Fu ntin tc i Te sce rnit g xt lla ure ile ne pr ou od s uc ts D rin k F & oo to d ba cc o

    4000 3500 3000 2500 2000 1500 1000 500 0

    Primary Secondary

    1998 US manufacturing energy use


    (source eia.doe.gov)

    17

    Changed structures of production :


    Environment & structures of production:
    10% of World energy use is in freight Most energy use in manufacturing is in primary materials production 10 tons of material make 1 ton of products
    Materials Disposal Use Retail Assembly Componen ts

    Extraction

    Globalisation results in disposal far from production, so inhibits recycling

    18

    Changed structures of production :


    Environment & structures of production:
    10% of World energy use is in freight Most energy use in manufacturing is in primary materials production 10 tons of material make 1 ton of products
    Materials Disposal Use Retail Assembly Componen ts

    Extraction

    Globalisation results in disposal far from production, so inhibits recycling

    Policy drivers:
    End-of-life legisation

    19

    Changed structures of production :


    Environment & structures of production:
    10% of World energy use is in freight Most energy use in manufacturing is in primary materials production 10 tons of material make 1 ton of products
    Materials Disposal Use Retail Assembly Componen ts

    Extraction

    Globalisation results in disposal far from production, so inhibits recycling

    Policy drivers:
    End-of-life legisation

    Commercial attraction of different structures:


    ~10% of US GDP is tied up in Supply Chain costs (Delaney, 2000) Near to market production allows tracking of demand (eg. Zara)
    Closed loop Closed loop Closed loop Closed loop Closed loop Closed loop

    Closed loop

    Ideal extension of Just-in-time is Make-toorder


    20

    Changed structures of production :


    Environment & structures of production:
    10% of World energy use is in freight Most energy use in manufacturing is in primary materials production 10 tons of material make 1 ton of products Globalisation results in disposal far from production, so inhibits recycling

    Technology:
    flexible small scale production technology, low tooling, low setup, trade-off flexibility against output rate small scale recycling technology - to convert used materials back into products with minimal damage to underlying material structure

    Policy drivers:
    End-of-life legisation

    Commercial attraction of different structures:


    ~10% of US GDP is tied up in Supply Chain costs (Delaney, 2000) Near to market production allows tracking of demand (eg. Zara)
    Closed loop Closed loop Closed loop Closed loop Closed loop Closed loop

    Closed loop

    Ideal extension of Just-in-time is Make-toorder


    21

    Incremental Sheet Forming - a new machine


    A substitute for pressing without specialist tooling Trades flexibility and setup times against production rate Allows new supply chain structures without stock

    22

    Flexible Ring Rolling


    If incremental sheet forming is possible, why not bulk forming? Early stage multi-university, two company collaboration

    23

    De-photocopying
    Existing paper recycling:
    Regional collection Pulping and de-inking Re-entry into original paper making process

    Novel process:
    Collection within the office Toner removal within the office Second or third use within the office, prior to conventional recycling

    24

    Recycling of Aluminium scrap by cold bonding


    Existing Al recycling:
    Collection, separation, sorting, cleaning Melting and casting in centralised capital intensive facilitites Ingots cost 5% of energy of virgin Al. Products from existing processing route

    Novel process:
    Collection (small scale), cleaning Deformation with high compression and high extension Lower strength product, but one stage from scrap to product, and 1% of energy of existing recycling process

    25

    Localisation in Jamaica
    For office chairs and carrier bags, what would be the environmental effect of:
    Increased internal assembly of products Increased local sourcing of raw materials Increased recycling

    Jamaica

    Rest of World

    Disposal

    Disposal

    Use

    Use

    Retail

    Retail

    For attractive scenarios:


    How would product costs change? What technology would make the change economically attractive? What legislative or policy instruments would be effective? Assembly Assembly

    Components

    Components

    Materials

    Materials

    Ground

    Ground

    26

    UK clothing & textiles


    Formal analysis of mass flow and existing environmental effects: Flows and stocks of all materials and related matter during a year in the UK must balance Estimates of effects outside UK Scenario analysis: Simple model of basic processes Explore and evaluate alternative supply chain structures Specify technology requirements Resource stock
    Production

    Environment

    Extraction

    Emissions

    Import

    Export

    Disposal

    Other regions

    Wastes

    27

    Sustainable Manufacturing
    Work in the Institute for Manufacturing developed since August 2003 (in person months Post-doctoral, PhD or Masters):

    Polymer

    Best practice and options Supply chain structure Flexible small scale production Recycling technology 3 66 12 9 6

    6 42 6 6

    6 3 3 24 3 3

    24

    Key priorities for developing new work: Sharing of best practice; workshops to develop options for change - cross-sectoral Polymers - small scale production and recycling
    28

    Generic 30 30

    Textiles

    Paper

    Water

    Wood

    Metal

    Food

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