MMVA ZG534 Sustainable Manufacturing

By
BITS Pilani Abhijeet K. Digalwar
Pilani Campus
Department of Mech. Engg.

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 BITS Pilani
Pilani Campus

Lecture # 1(CH 1 and 2)

Introduction to Sustainable Manufacturing

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Course Objectives

• Enrich the skill and train the students to develop best

practices for sustainable manufacturing
• To enhance decision making skills to select and implement
effective manufacturing strategy for sustainable development
• The understanding of the students is fostered by means of
various hands-on assignments and project works/case studies.
• To understand the performance measurement systems and
track improvements toward sustainable manufacturing.
• The course is designed to give you an opportunity to learn
about sustainable manufacture, the growing national and
international efforts in reducing the environmental impact of
products, and how the environmental considerations affect
the design’s technical, economical and quality requirements.

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Course Objectives

• Understanding is fostered by various hands-on

assignments.
• You should be able to use the knowledge
gained in this course in practical design and
manufacture situations.

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Tentative Course Outline (See the
Handout)
• Environmental impact, reduction and approaches
• Life-Cycle Assessment
• Life-Cycle Costing
• Design for Recycling
• Design for Remanufacture
• ECDM, DFE approaches and guidelines
• Decision making for Sustainable Development
• Performance Measurement Frameworks

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Why Study This Course?

The focus of engineering design has primarily

been on achieving superior products from a
technical, economical and quality perspective.

However, there is an increasing awareness of

the effects of technological advances on the
environment.

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Questions to be addressed

1) what exactly is the impact of technical

systems on the environment? (and how can we
measure it?)

2) how can this impact be reduced?

3) what tools and techniques, decision making

tools are needed/available to support the
decision?

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Text Books

• G. Seliger, 2007, Sustainability in manufacturing, Springer-

Verlag, Berlin (ISBN 978-3-540-49870-4)
• G. Seliger, 2012, Sustainable Manufacturing: Shaping Global
Value Creation, Springer-Verlag, Berlin (ISBN 978-3-642-
27290-5 eBook)

• Reference Book(s) & other resources

Few are mentioned in the handout. Relevant research papers
will be provided.

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Modules

Module 1: Introduction to Sustainable Manufacturing

Module 2 : Life Cycle Engineering and Management
Module 3: Sustainable Product Design and
Development
Module 4: Sustainable Process Development
Module 5: Sustainable Systems for Manufacturing

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Learning Outcomes

• Understanding the fundamental concepts, strategies, principles and

philosophy for sustainable manufacturing.
• Understanding of the impact of value chain for sustainable manufacturing
• Ability to use IT-tools for decision making, with focus on multi criteria
decision making for sustainable manufacturing.

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 BITS Pilani
Pilani Campus

Lecture # 1
Introduction to Sustainable Manufacturing

BITS Pilani, Pilani Campus

Outline

– Fundamentals of sustainability
– Sustainable value creation
– Sustainable Manufacturing-definitions and
practices
– Progress from Lean to Green to Sustainable
Manufacturing
– Transformation of 3R to 6R concepts
– Innovation needs at product, process and system
levels

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Why is manufacturing becoming more
environmentally conscious?
Ask yourself the following questions:

Is your company trying to cope with increasing environmental

regulation?

Are your customers demanding better environmental

performance and data?

Do you want to lower your energy and materials costs?

Are you interested in producing and marketing greener

products?

Sustainable manufacturing has both benefits and costs, but it can help make your
company more competitive. Let’s discuss sustainability in manufacturing in more
detail.
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What is Sustainability?

A common definition of sustainable development is

that of the UN Brundtland Commission:
Environmental
(Planet) “Sustainable development is development that meets
the needs of the present without compromising the
ability of future generations to meet their own needs.”1

You will also hear about the Triple Bottom Line2

Social Economic
(People) (Profit) This concept suggests that, in addition to its
economic performance, a company must also
account for and focus on its environmental and
social performance to be truly sustainable.

Sustainability Another common way of saying this is “people, planet,

profit”2 Sustainability is the intersection of these three
concepts.
1 Brundtland Commission of the United Nations
2 John Elkington, Cannibals with Forks: the Triple Bottom Line of 21st Century business

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 The Environment and Manufacturing:
Important Concepts

• The intersection of the environment and manufacturing is discussed in many

different ways, often using terms that are not always clearly defined.

• These ideas can be confusing, and it may be difficult to tell how they apply to
your business.
• Here we will learn how to distinguish among several common concepts.

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Sustainable Manufacturing

• The Green Suppliers Network (DOC/EPA) defines clean

manufacturing as “a systematic approach to eliminating waste

Terms You’ll Hear

by optimizing use and selection of resources and technologies, • Green Manufacturing
there by lessening the impact on the environment.” • Cleaner Production
• Industrial Ecology
• Sustainable manufacturing focuses on both how the product is • Closed Loop
made as well as the product’s attributes. This includes the Production
inputs, the manufacturing processes, and the product’s design. • Sustainable
Production
• Eco-efficiency
• Sustainable manufacturing includes things such as making • Green Productivity
products using less energy and materials, producing less
• Clean Manufacturing
waste, and using fewer hazardous materials as well as
products that have greener attributes such as recyclability or
lower energy use.

• Sustainable manufacturing practices can range from very

simple process improvements to large investments in new
technologies and product redesign.

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Clean Technologies

• Clean or Environmental Technologies are technologies

associated with things like environmental protection,
assessment, compliance with environmental regulations,
pollution control and prevention, waste management,

Terms You’ll Hear

• Environmental
remediation of contaminated property, design and Technologies
operation of environmental infrastructure, and the (envirotech)
provision and delivery of environmental resources.
• Green Technologies
• Renewable energy technologies are also considered to be (greentech)
clean technologies.
• Examples of clean technologies include technologies for • Clean Technologies
(cleantech)
wastewater treatment, recycling, solid waste
management, solar panels and wind turbines.
• Many clean technologies can be used to green the
manufacturing process and are therefore important to
sustainable manufacturing.

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Green Products
• Making “green products” can be seen as part of sustainable
manufacturing, and we will discuss it in more detail later in the
module.

Terms You’ll Hear

• Life Cycle Design
• A green product can be any product that is designed to reduce its
• Life Cycle Assessment
environmental impact. A key concept is that environmental
(LCA)
concerns and impacts are taken into account from the beginning of
the product design process. This is important because most of a • Cradle-to-Cradle
product’s environmental impact is determined in the design phase. • Cradle-to-Grave
• Environmentally-
• The product may be made of recycled materials, designed so that it Sustainable Design
can be easily recycled, made without hazardous materials, or • Design for the
produced with less packaging. Environment (DFE)
• Sustainable Product
• There are no accepted standards for what constitutes a “green Design
product,” although there are rules from the Federal Trade • Design for Eco-
Commission about making environmental marketing claims. efficiency
• Eco-design
• There are also many eco-labeling programs that are used to identify
• Design for
and market green products, some of which are discussed in this Sustainability (DFS)
module.

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So What does Sustainable
Manufacturing Mean in Practice?
Using less
Using Using fewer Modifying packaging,
renewable materials and production lowering
materials that inputs and processes to product weight,
don’t deplete materials that use less energy, using more
the natural are non- water, and efficient
environment hazardous or materials and transportation
recycled to produce less and logistics
waste

Expanding the life

Working with
Designing your of the product,
stakeholders like
product to be making it easier to
reusable, customers and
repair or designing
retailers to reduce
remanufacturable, it to use fewer
the environmental
recyclable, or resources during
impact of sales and
biodegradeable use
distribution

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Sustainability is a Journey, not a
Destination

• Remember there is no such thing as a company

with no environmental impact. There is no
sustainability “destination”.

• Your goal should be continuous improvement –

making constant advances in your company’s
overall sustainability performance.

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Evolution of Sustainable Manufacturing
For many years, the main environmental focus with regards to manufacturing was pollution
abatement—preventing the pollution that has been created from getting into the environment.

The attention has shifted to cleaner production and pollution prevention. With cleaner production,
there are many opportunities for cost savings and other financial benefits for companies. 1

Then: Pollution Control and Now: Cleaner

Treatment Production

• End-of-pipe pollution abatement • Pollution prevention at the source (i.e.

(wastewater treatment, air scrubbers energy efficiency, waste reduction)
and filters)
• Benefits include environmental
• Benefits include better environmental performance, regulatory compliance,
performance and regulatory lower energy and material costs,
compliance increased marketability of products and
brand, employee recruitment and
• Not likely to produce direct financial retention, innovation, etc.
benefits

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 The Future: Industrial Ecology

• Industrial Ecology
“the study of the physical, chemical, and
biological interactions and
interrelationships both within and
between industrial and ecological
systems”
• It is based on systems thinking –
industry is an interdependent part of
the overall ecosystem.
• It studies the material and energy flows
through the system to find inefficiency
and waste.

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 Industrial Ecology: Towards a Closed
Loop System
One of the goals of industrial
ecology is to move industry from Resources Production Consumption Waste
a linear to a cyclical or closed
system where waste is used as
an input rather than disposed of. Linear System

An advanced version of this would Resources

be an Eco-Industrial Park where Energy
companies design their products
and processes to use fewer virgin
Production Production
materials and use each other’s
byproducts, co-products, or
wastes as inputs.
Consumption
Does your company produce
byproducts that could be used by
another company? Closed-Loop System

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How do you Implement Sustainable
Manufacturing?

It can be overwhelming to think about all the

work that would be required to make your
company more sustainable.
However, there is a spectrum of efforts you can
make towards sustainable manufacturing. Some
involve more effort and investment than others.
• Housekeeping
• Process Optimization
• Raw Material Substitution
• New Technology
• New Product Design
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Housekeeping
• Housekeeping is the simplest method of implementing sustainable manufacturing
practices.
• Housekeeping can be as simple as better inventory management, better
monitoring and scheduling of the production process, reducing loss from leaks,
spillage, and drag-out, and making sure equipment is maintained properly.
• It can also involve training your employees about sustainable manufacturing.

Example

• Arctic Cat Inc., a snowmobile manufacturer based out of

Minnesota, ran three 200hp and one 30hp multipurpose
air compressors that cost more than $105,000 to operate
annually. They identified and fixed over 400 leaks in the
Housekeeping compressed air lines and started to shut down the
Improvements in compressors at the end of the work days. Together, these
work practices efforts saved $21,400 per year and reduced energy use by
and 390,000 kWh annually.2
maintenance

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Process Optimization

• Process optimization involves changing your manufacturing process to minimize

waste, conserve raw materials, and capture and reuse waste materials.1
• There may be simple things you can do to change your production process to
become more sustainable.
• Maybe you can collect metal shavings for recycling, change the steps in a painting
process to use less paint, or rearrange your machines to minimize movement.

Example

• Texas Tile Manufacturing LLC, a vinyl flooring

manufacturer, conducted an assessment of its
production processes and identified numerous
Process areas to conserve energy and cut costs. Replacing
Optimization traditional pilot lights in material heaters with
Making spark igniters, they were able to save
adjustments to approximately $213,000 yearly on natural gas
processes to costs and through less required maintenance on
increase efficiency conveyor belts.2

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 Raw Material Substitution
• Although it is challenging, you may be able to find ways to substitute greener
materials for hazardous materials, chemicals with high environmental or health
impacts, materials that are non-renewable, or those that are scarce.
• You may also be able to find ways to eliminate materials that are used during your
production process but don’t remain in the final product.
• Example: use water-based solvents rather than chemical solvents.
• If the materials you are eliminating are considered hazardous, this can help you avoid
regulatory costs associated with storage and disposal of materials.
Example
• North American Decal had used solvent-based inks which
have high levels of volatile organic compounds (VOCs), a
significant air pollutant. The company began transferring to
less harmful UV curable inks which are of a higher quality,
have a longer shelf life, and cure faster. Switching to UV
Raw Material curable inks lowered maintenance costs, eliminated a
Substitution printing step, and even improved indoor air quality for the
Shifting to more company’s employees.
environmentally
sound inputs

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 New Technologies

• Utilizing new technologies involves incorporating more environmentally

responsible technologies and equipment into your production process.
• This can involve capital investments to purchase equipment that uses less
energy or materials or alternative energy production.
• For example, you might invest in more energy-efficient production equipment,
systems that reuse heat and energy, or more advanced water treatment
systems.
Example

• Harbec Plastics, a small injection

New molding company in Ontario, New York,
Technologies switched its traditional hydraulic
injection molding presses to electric
Enable lower
ones. This technology change has
resource resulted in up to 50% energy savings
consumption, over hydraulic presses, reduced noise,
waste generation, and shorter changeover and startup
emissions times.2

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 New Product Design
• Design your product to be greener from the ground up. This concept touches on all of the
previous sustainable manufacturing concepts. It can even include redesign involving
rethinking how your product is used, and may involve:
– Using recycled materials instead of new ones
– Using renewable materials
– Designing for easy disassembly, for recycling, or for remanufacturing
– Using less packaging and more recycled or recyclable packaging
• Green product design can have the same benefits as other aspects of sustainable
manufacturing, including improved resource efficiency.

Example

• Herman Miller used design-for-the-environment

principles when it redesigned its well known
Aeron chair. The chairs are now made up of up
to 53% recycled materials and are 94% New Product
recyclable. They are easily disassembled, Design
contain no PVC, and emit very low levels of
VOCs. Minimize impacts
throughout
product lifecycle

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The Relationship Between Lean and
Green

• If your company already uses lean manufacturing practices,

you may find it is easier to integrate environmental principles
into the lean process.
• Although lean does not traditionally focus on environmental
issues, Lean’s focus on eliminating waste can be adapted to
look for environmental waste.
• The Green Suppliers Network (GSN) calls this “Lean and Clean”
manufacturing. GSN found that companies could save up to
30% more by implementing lean and clean than if they
implemented lean manufacturing alone.

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Environmental Waste

• EPA’s Lean and Environment Toolkit describes

environmental waste as “any unnecessary use of
resources or a substance released into the air, water, or Traditional Wastes
land that could harm human health or the
environment.”1 Addressed by Lean:
DOWNTIME
• Environmental Waste includes:
•D efects
• Any energy, water, or other materials used that are more •O verproduction
than what is really needed to meet the customer’s needs •W aiting
• Hazardous materials and substances •N on-utilized Resources
•T ransportation
• Pollutants, residuals, and other material wastes released
into the environment (air emissions, wastewater •I nventory
discharges, hazardous wastes, solid wastes) •M otion
• As mentioned previously, adding “clean” to lean can •E xtra Processing
result in significantly greater returns for your company.
The following chart outlines how lean wastes have an
environmental impact.

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Adding Clean to Lean
Lean Waste Environmental Impact

• Energy and materials are consumed to make

Defective Products or
defective products, and defective products
Components
need to be disposed of.

Overproduction of • Materials and energy are consumed to make

Components or Final unnecessary products. Products may spoil or become
Products obsolete. Products may require hazardous materials

• Materials may spoil or become damage. Downtime

Waiting wastes energy for heating, cooling, and lighting.

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Adding Clean to Lean (Cont.)

Lean Waste Environmental Impact

• Energy is used for transport and produces emissions.

Unnecessary Transport or Transport can cause damage or spills. More space is
Motion needed for additional motion, requiring heating and
cooling.

• More packaging and space is needed for excess inventory.

Excess Inventory Storage could cause deterioration of products and waste.
Requires energy to heat, cool, and light inventory space.

• If processing is unnecessary, increases waste and energy

Extra Processing use. Consumes more parts and raw materials.

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Conclusion

In this contact hour you have learned:

– about some of the important concepts
related to sustainable manufacturing,
– how sustainable manufacturing has
evolved,
– how it can be implemented in a
manufacturing company, and
– how it can be integrated with existing
lean efforts.
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• Questions ?

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Thank You!

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