LCE2015
Efficiency to Effectiveness: Sustainability in Manufacturing
7-9 April 2015, Sydney Australia
School of Mechanical and Manufacturing Engineering, The University of New South Wales
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Conference Program

(Subject to change without notice)

 
Tuesday 7 Apr
Wednesday 8 Apr
Thursday 9 Apr
0900-1000  
Plenary Session
 
0900-0930
Welcome address
Dr. Stephan Krinke
Prof. Steven J. Skerlos
0930-1000
Prof. Michael Z.Hauschild
Dr. Bernard J. Kornfeld
Prof. Dr.-Ing. Christoph Herrmann
1000-1030  
Morning Tea
 
 
 
Energy and Resource Efficiency: a manufacturing system view (1)
Energy and Resource Efficiency: a manufacturing system view (2)
Energy and Resource Efficiency: a unit process view (1)
1300-
1230
LCA & LCC: Methodology
LCA & LCC: Case studies (3)
Sustainability in Product-Service systems
 
 
End of Life: Recycling
End of Life: Waste Management
End of Life Strategies
1230-1330
Lunch
 
 
Energy efficient Production Planning (1)
Energy and Resource Efficiency: a manufacturing system view (3)
Energy and Resource Efficiency: a process view (2)
1330-
1530
LCA & LCC: Case studies (1)
LCA & LCC: Case studies (4)
Technical solutions with life cycle thinking
 
 
End of Life: Remanufacturing (1)
End of Life: Disassembly
Energy and resource efficiency of cutting fluid strategies
1530-1600
Afternoon Tea
 
 
Energy efficient Production Planning (2)
Energy and Resouce efficiency: a manufacturing system view (4)
Energy and Resource Efficiency: a process view (3)
1600-
1730
LCA & LCC: Case studies (2)
Eco-design
Sustainability in Education and Research
 
 
End of Life: Remanufacturing (2)
Sustainability in Supply Chain
Sustainability assessment
Evening
Welcome Reception
Conference Dinner
 

Program Detail


DAY 1

Keynote 1

Room: Tyree Room

0930
Better – but Good Enough? Quantifying the Relative and Absolute Sustainability of our Technology and on the Challenges We are Facing
Prof. Michael Hauschild

Head of the Division for Quantitative Sustainability Assessment, Department of Management Engineering, Technical University of Denma

Sustainability is gaining prominence among the priorities of many large companies and as engineers we have taken the eco-efficiency challenge, optimizing the functionality and minimizing the negative environmental impacts of our products and technologies. Although impressive improvements in efficiency can be demonstrated in many local cases, increases in population, affluence and consumption create an opposite trend that we need to factor in when we are discussing sustainability of our technological developments in an absolute sense. The talk will discuss absolute boundaries for environmental sustainability, metrics for gauging our solutions against these boundaries and the need and possibilities of expanding our focus from efficiency to effectiveness.

+ More Info

S1 - Energy and Resource Efficiency: a manufacturing system view (1)
Room: Tyree Room
Chair: Prof. H. Bley
 
1030
Green factory supported by advanced carbon-based manufacturing
Dominik Rohrmus, Volkmar Döricht, Nils Weinert
(Germany)
The trend in the automotive industry is to reduce the size of engines while increasing power. The concept of leveraging considers not only the efficiency of manufacturing a product but all consumption of energy or other natural resources during the life cycle of the product. In this process, one of the bottlenecks to more efficient engines is the exhaust valve. The valve and valve seat together perform the function of ensuring the entry of air and combustible material, the output of combustion gases and the sealing function during the compression and combustion processes. The valve is the most demanding component in high efficiency engines. To ensure the rigor of operation while providing clean burning and low emissions, the application of special materials is necessary. The extremely high temperatures of the exhaust gases, the velocities of valves and the high operating pressure are only some of the parameters that cause wear on valves. The materials used in valve production must be characterized by good workability, low wear, good mechanical strength and good fatigue and corrosion resistance at high temperatures. In this context, the CCM / ITA and SENAI CIMATEC jointly developed a workbench to simulate the durability of valves and valve seats, analyze their wear resistance and evaluate their behavior with varying parameters. This paper shows the workbench development process and a new testing method that considers the high engine operation temperatures and focuses on reducing the new material development life cycle and the emissions during the product usage life time.
1050
Investigating the energy consumption of the PECM process for consideration in the selection of manufacturing process chains
Martin Swat, Andreas Rebschläger, Kirsten Trapp, Tim Stock , Günther Seliger, Dirk Bähre
(Germany)
The initial planning of manufacturing process chains provides the opportunity to sustainably influence the energy requirement for the manufacturing of industrial products by selecting the process chain with the lowest energy consumption. However, the task is still challenging due to the need for energy consumption data of manufacturing equipment. In this paper, the analysis of the energy consumption of a manufacturing process is illustrated by the example of the Pulse Electrochemical Machining (PECM) process. A comparison of two machine tool generations of the same manufacturer shows the improvement in energy consumption. Based on the information gained from the analysis, an approach for the provision of energy consumption data is presented.
1110
Method for Increasing Energy Efficiency in Flexible Manufacturing Systems in Machining Process - A Case Study
Hugo M. B. de Carvalho, Jefferson de Oliveira Gomes
(Brazil)
There is a growing demand for ultra-high speed precision machine tool spindles to create complex miniature devices and features, in consumer markets such as medical devices, electronics and communications. The key enabling drive technologies for spindle rotational speeds in the 100,000 rpm range includes electric motors, both AC and DC powered, and air turbines. In particular for high speed micromachining, turbine spindles have advantages in terms of precision and cost. A widely considered drawback of pneumatic technology though is low energy efficiency, but to date there has been little in depth analysis of commercial/state-of-art turbo-spindle energy performance. This paper provides a holistic comparative analysis of electric motor and turbine powered spindle electrical power requirements, by including the power demand of supporting systems and infrastructure. The analysis indicates that at present the energy usage associated with turbine spindles is significantly higher than electric spindles. However, a number of technically feasible energy efficiency measures are identified for turbine spindles, which would make their energy performance comparable with electro-spindles. The analysis and results will contribute towards an overall life cycle assessment of high speed turbo-spindle technology, and provide impetus to further explore energy optimization approaches and methods.
1130
Approach for implementing a control and optimization loop for an energy-efficient factory
Sylvia Wahren, Jörg Siegert, Thomas Bauernhansl
(Germany)
With the rising energy price and the ever-increasing consciousness of environmental friendliness, it is becoming practically helpful for manufacturers to have a clear view on how the energy is consumed at their shop floors, what the corresponding energy cost is, and how to reduce the energy consumption or the energy cost. However, there is currently limited literature investigating the energy cost minimization in manufacturing through production scheduling under volatile energy prices. This paper proposes a generic mixed-integer linear programming model to enable the job scheduling on a single machine for the purpose of minimizing the necessary energy cost without exceeding the due date. The results given by a case study on a surface grinding machine demonstrate this scheduling methodology effectively contributes to the reduction of greenhouse gas emissions during peak time periods by shifting the production load to off-peak periods, and leads to energy- efficient, demand-responsive, and cost-effective manufacturing processes.
1150
Assessing combined Water-Energy-Efficiency Measures in the Automotive Industry
Ina Schlei-Peters, Denis Kurle, Matthias Gerhard Wichmann, Sebastian Thiede, Christoph Herrmann, Thomas Stefan Spengler
(Germany)
A high recovery of lithium from recycled lithium ion batteries (LIBs) is essential to ensure the growth and sustainability of the electrical vehicle market. Without recycling, lithium demand is predicted to outstrip supply in 2023. Current industrial processes are focused on recovering cobalt and other valuable metals because, given lithium’s current low price, it is economically unfavorable to recover it. As part of our efforts to create a process where the recovery of lithium is economically viable we have analyzed the current industrial processes. We have determined that, when applied to recycling automotive LIBs, they are needlessly energy intensive and complicated. In these processes whole LIBs are incinerated, cryogenically cooled, or shredded under an inert atmosphere in order to make their cells safe to open. Instead of such extreme measures, LIBs can be disassembled by automated processes, which recovers valuable electronics for reuse, their cells can be discharged, which recovers residual energy, and then can be opened safely in air.
1210
An Investigation into Minimising Total Energy Consumption and Total Completion Time in a Flexible Job Shop for Recycling Carbon Fiber Reinforced Polymer
Ying Liu, Ashutosh Tiwari
(UK)
The increased use of carbon fiber reinforced polymer (CFRP) in industry coupled with European Union restrictions on landfill disposal has resulted in a need to develop relevant recycling technologies. Several methods, such as mechanical grinding, thermolysis and solvolysis, have been tried to recover the carbon fibers. Optimisation techniques for reducing energy consumed by above processes have also been developed. However, the energy efficiency of recycling CFRP at the workshop level has never been considered before. An approach to incorporate energy reduction into consideration while making the scheduling plans for a CFRP recycling workshop is presented in this paper. This research sets in a flexible job shop circumstance, model for the bi-objective problem that minimise total processing energy consumption and makespan is de- veloped. A modified Genetic Algorithm for solving the raw material lot splitting problem is developed. A case study of the lot sizing problem in the flexible job shop for recycling CFRP is presented to show how scheduling plans affect energy consumption, and to prove the feasibility of the model and the developed algorithm.

S2 - LCA & LCC: Methodology
Room: Gallery 1
Chair: Prof. M. Z. Hauschild
 
1030
Expanding the scope of LCA to include 'Societal Value': A framework and methodology for assessing positive product impacts
Kei L.F. Shin, James A. Colwill, Robert  I. Young
(UK)
As resources become scarcer, efficiency improvements alone will not bridge the widening gap between supply and demand, resulting in the need for additional non-financial mechanisms to ensure the fairer allocation of resources. This paper asserts that, in the future, companies will need to demonstrate their products' positive contribution to society as well as minimising their negative environmental/social impacts. A review and analysis of existing tools and assessment methodologies identifies current capabilities and highlights the need for 'Societal Value' assessment that considers both quantitative and qualitative factors .This paper concludes by proposing a systematic framework for addressing the 'Societal Value' of products as part of an integrate sustainability assessment and allows the evaluation and comparison beyond products' shared functionality.
1050
Leveraging life cycle assessment to evaluate environmental impacts of green cleaning products
Kathryn G. Van Lieshout, Cindy Bayley, Sarah O. Akinlabi, Lisa von Rabenau, David Dornfeld
(US)
The green cleaning industry continues to pursue products that reduce or eliminate impacts on human health and the environment; however, these impacts over the life cycle are not well understood. This study assessed environmental impacts of four green cleaning products from Method Products, PBC (all-purpose cleaner, hand wash, dish soap) and Ecover (dish soap). A life cycle assessment from cradle-to-grave was performed using ReCiPe and IPCC GWP methodologies. Results correlated greatest impact contributors to ingredient composition and identified the need to improve data quality. Based on the findings, a prioritized list of actions for green cleaning companies was developed.
1110
Towards More Holistic Environmental Impact Assessment: Hybridisation of Life Cycle Assessment and Quantitative Risk Assessment
Yumi Kobayashi, Greg M. Peters, Stuart J. Khan
(Australia)
Global and local environmental impacts of products or services can sometimes be in conflict with one another. Therefore, the importance of considering both impacts in environmental management must be recognised. Life cycle assessment (LCA) is useful in evaluating global impacts while quantitative risk assessment (QRA) is effective in local impact assessments. The benefits of combining LCA and QRA in this regard have been recognised. Advantages and disadvantages of different hybridisation approaches were critically examined in this paper. There seems to be no single best approach and a method needs to be carefully selected depending on the type of application.
1130
Cradle to Cradle: Effective Vision vs. Efficient Practice?
Marten Ewo Toxopeus, Bjorn de Koeijer, Albert Meij
(Netherlands)
Cradle to Cradle is a development paradigm with a focus on eco-effectiveness; improving the ‘positive footprint’ in contrast to the more conventional eco-efficient approaches; reducing the ‘negative footprint’. Industry is supported in their Cradle to Cradle efforts by an elaborate five level certification framework. The accredited institutes necessary for certification focus in practice mainly on material health, underexposing other aspects. This is illustrated by a case study on a development method for Cradle to Cradle compliant packaging, in which several conflicts between theory and practice explain why the eco- effective Cradle to Cradle vision result in a mere eco-efficient approach in practice.
1150
Analysis of potential relationships between functional analysis and life cycle assessment
Paulina Rodriguez Moreno, Serge Rohmer, Hwong-Wen Ma
University of Technology of Troyes (France)
The design of products with environmental considerations is a global strategy based on life cycle thinking. All stages of the design process should take into account environmental considerations in order to face the environmental challenge. Unfortunately, designers encounter difficulties in the case of brand new products due to the absence of environmental impacts feedback. The designers need assistance early in the design process to acquire environmental knowledge. In order to solve this problem, the paper argues that the functional analysis of products (early stage in the design process) and Life Cycle Assessment (late stage in the design process) can benefit each other in a collaborative process. A comparative analysis is first proposed between Functional Analysis (FA) and Life Cycle Assessment (LCA) to highlight propositions that could assist both FA practitioners and LCA experts. A strategy is then proposed to create a win-win situation to enhance environmental knowledge early in the design process.
1210
Data-intensive Life Cycle Assessment (DILCA) for Deteriorating Products
Raunak Bhinge, Amrita Srinivasan, Stefanie Robinson, David Dornfeld
(US)
In the current age of big data and sustainability, accuracy and effectiveness of life-cycle assessment (LCA) are becoming more important for strategic decision-making. This paper describes a data-intensive approach to life-cycle assessment, with the use phase of a lithium-ion mobile phone battery as a case study. LCA datasets involving a temporal dependence can be created for the use phase of products and to improve the accuracy of the analysis. In order to demonstrate the procedure, energy density data over the life-cycle of a lithium-ion battery and the evolution of its technology are analyzed to synthesize a more accurate methodology to perform the life cycle analysis of the product. In the case study, DILCA estimates an impact 47.8% to 42.9% higher than traditional LCA.

S3 - End of Life: Recycling
Room: Gallery 2
Chair: Prof. H. Kaebernick
 
1030
Design and Implementation of an End-of-Life Vehicle Recycling Center based on IoT (Internet of Things) in Korea
Hwa-Cho Yi, Jung Whan Park
(Korea)
It is important to monitor the dismantling process in recycling centers for end-of-life vehicles (ELVs) to facilitate estimation of the practical recycling rate. ELVs are valuable resources in urban mining, and a 95% ELV recovery rate will be required by law. In this research, a smart dismantling monitoring system and smart trolley system have been developed for an ELV recycling center. The smart trolley handles each ELV and is equipped with a weighing load cell, RFID tag for ELV identification, and Zigbee wireless communication device. When a trolley is loaded with a target ELV to be dismantled, the trolley is registered with the ELV. When arriving at a workstation, the trolley is identified by the station‟s RFID reader and delivers the current ELV weight via the Zigbee device. The required dismantling instructions are displayed on the station‟s PC monitor based on the corresponding vehicle part database. The developed system was implemented at a recycling center in central Korea. It facilitates remote real-time monitoring via Internet of each workstation‟s dismantling status and of vehicles currently being processed. The part dismantling results are stored in a computer server for future verification.
1050
System of decision-making assistance for the recycling of manufactured products
Khalifa Gaye, Amadou Coulibaly, Mickael Gardoni
(Senegal)
Recycling is a complex activity with long, sometimes unknown and not easily implemented processes. It requires diverse technologies from many fields of application. This sector is marked, on the one hand, by a lack of data, information and knowledge structuring, and a deficiency in management tools and in the sharing of this knowledge, on the other hand. These actors do not have the same understanding of the product, and are facing difficulties to take decisions for an optimal recycling. This paper suggests a system of information for decision-making assistance for an optimal recycling, applied to the sector of aeronautics for example. In so doing, we first establish a referential product model for recycling, to be used for the conception, utilization and recycling, and then the same model will be integrated in a team work structure. This structure allows a more fruitful collaboration between actors, with the eventual integrating of sundry viewpoints. This analysis offers a system of information for decision-making assistance for recycling, based on the product. The theory of the decision used in this study will help to optimize the recycling of the product, through an optimal choice of the actions to conduct.
1110
Recycling of CFRP for high value applications: Effect of sizing removal and environmental analysis of the SuperCritical Fluid Solvolysis
Michel Dauguet, Olivier Mantaux, Nicolas Perry, Yaoyao Fiona Zhao
(France)
The recycling of Carbon Fibers Reinforced Plastics (CFRP) wastes is becoming increasingly important in the aerospace industry. For most of the technologies, the recycled CF (rCF) are discontinuous, misaligned and unsized. Compared to thermal treatments, the orientation, the length and the brittleness of the rCF are better preserved with the SuperCritical Water Solvolysis (SCWS). The effect of the sizing removal on the recycled CFRP behavior is studied by conducting static characterizations. Realigned virgin CF were used to manufacture sample plates which were tested in shear. An environmental assessment was carried out on the CFRP end-of-life with a focus on SCWS.
1130
Scenarios For The Return Of Lithium-Ion Batteries Out Of Electric Cars For Recycling
Nirugaa Natkunarajah, Matthias Scharf, Peter Scharf
(Germany)
In current recycling plants for lithium-ion batteries, the disassembly process is executed manually. With the rising numbers of electric cars, the possible solutions for the disassembly process have to be investigated more deeply. The automation of disassembly steps can be a leading idea for the process design. However, the automation technology has to overcome various challenges to be successful such as unknown return rates, variety of battery systems or dangers during disassembly. This paper focuses on the return rates of various battery systems. Therefore, different forecasts on sales figures of electric cars with various economic, social, ecological and technological influencing factors are assessed. Moreover the lifetime of variant battery systems in electric cars, primary application, and a possible lifespan of the batteries in a secondary application are analyzed. The aim of the paper is to develop different scenarios for the return rates of lithium-ion batteries.
1150
Utilisation of reconfigurable recycling systems for improved value recovery from e-waste
Michael J. Barwood, Ji Lie, Tegan Pringle, Shahin Rahimifard
(UK)
The key features of reconfigurable manufacturing systems, including modularity, scalability and customisability, have provided production flexibility to enable manufacturers to deal with increasing demands for product variability and emerging smart materials. This increased complexity in design and material mix has also highlighted a need for more flexible and advanced technologies for recycling modern products at the end of their life. This paper examines the adoption of key features in reconfigurable systems to increase flexibility and automation in recycling activities. The application of such a ‘Reconfigurable Recycling System’ (RRS) has been illustrated using a specially designed robotic cell which disassembles and concentrates strategically important materials from components of electrical cars.
1210
Opportunities to Improve Recycling of Automotive Lithium Ion Batteries
Alexandru Sonoc, Jack Jeswiet, Vi Kie Soo
(Canada)
A high recovery of lithium from recycled lithium ion batteries (LIBs) is essential to ensure the growth and sustainability of the electrical vehicle market. Without recycling, lithium demand is predicted to outstrip supply in 2023. Current industrial processes are focused on recovering cobalt and other valuable metals because, given lithium’s current low price, it is economically unfavorable to recover it. As part of our efforts to create a process where the recovery of lithium is economically viable we have analyzed the current industrial processes. We have determined that, when applied to recycling automotive LIBs, they are needlessly energy intensive and complicated. In these processes whole LIBs are incinerated, cryogenically cooled, or shredded under an inert atmosphere in order to make their cells safe to open. Instead of such extreme measures, LIBs can be disassembled by automated processes, which recovers valuable electronics for reuse, their cells can be discharged, which recovers residual energy, and then can be opened safely in air.

S4- Energy efficient Production Planning (1)
Room: Tyree Room
Chair: Prof. I. Jawahir
 
1330
Energy-orientated machine scheduling for hybrid flow shops
Fabian Keller, Christina Schönborn, Gunther Reinhart
(Germany)
Due to the expansion of renewable energies in Germany, the electrical energy supply is shifting to a complex and volatile system. Therefore, supply and demand need to be synchronized in an efficient way. Companies can profit from capacity based supply conditions and price volatility of the market by implementing the concept of energy flexibility. The objective is, to transform the supply and price signals into the production organization. As one option, a production site can adapt its operation and therewith its power demand. This paper aims to develop a heuristic method for machine scheduling and to apply the result to a given problem, which considers energy flexibility.
1350
Analysis of Energy Oriented Switching Controlled Production Lines
Nicla Frigerio, Andrea Matta
(Italy)
The implementation of control strategies that reduce energy consumption during the machine idle periods is becoming a challenging goal to achieve energy efficiency in production systems. A general framework for switching the machine off / on has been recently proposed in literature for single machines. This paper studies the performance of a production line when a general policy is applied at machine level. The considered performance measures are the total energy consumed per part and the system throughput. Numerical results are based on discrete event simulation, and a comparison with the most common practices in manufacturing is also reported.
1410
E|Benchmark - a pioneering method for energy efficient process planning and assessment along
the life cycle process
Sven Kreitlein, Sabrina Schwender, Tobias Rackow, Joerg Franke
(Germany)
This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production from the perspective of production planning. Production planning is an organizational entity within an enterprise and deals with the creation and provision of all production relevant documents and equipment in order to achieve maximum efficiency through a minimum of resources and effort. The tasks of production planning are evaluated by means of their relevance for an energy efficiency comparison. For this, evaluation criteria are determined that consider influences on the production processes and basic goals of production. This is necessary due to the fact that tasks of production planning cannot be evaluated directly via energy consumption and energy efficiency. This results in 12 tasks through which a high leverage effect for a more energy efficient production can be achieved. Another possibility for an energy efficiency evaluation is presented via the approach of minimal value calculation. The underlying concept is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. By linking the minimum value calculation to the production planning, a predetermination of the theoretical energy consumption – and thus an energy efficient planning – is possible. The resulting energy saving potentials extend over the entire life cycle of a process and enable savings of an increasing energy amount.
1430
Evaluation of demand response actions in production logistics
Günther Schuh, Ulrich Brandenburg, Yuan Liu
(Germany)
Volatile electricity prices caused by an increase of renewable energy sources push producing companies towards taking in an active role in balancing the electricity grid. Possible actions at the customer side to actively adapt to volatile energy prices are called demand response actions. In production logistics such actions can be the modification of production schedules motivated by possible economic benefits. So far, the focus in scheduling problems has been the optimization in the dimensions of quality, time and costs. This paper presents the results of a simulation study on the economic benefits of demand response actions for a generic production system.
1450
Method for designing an energy-agile energy system for industrial manufacturing
Timm Kuhlmann, Thomas Bauernhansl
(Germany)
A volatile energy supply, where increasing energy costs take a high toll, as well as rapidly changing energy-related technologies are posing new challenges to sustainable manufacturing. The complex interactions between energy-related issues – such as renewable energy or energy efficiency – and a factory‟s economic goals prevent the consistent consideration of these topics at the stage of strategic factory planning. There is a lack of methodical support for planning an agile energy system. This paper presents the ongoing research work concerned with the development of a method to be applied during the early phase of factory planning for designing an agile energy system for industrial manufacturing. This method is based on a system dynamics approach considering the interactions between a factory and the volatile energy market.
1510
An energy-cost-aware scheduling methodology for sustainable manufacturing
Xu Gong, Toon De Pessemier, Wout Joseph, Luc Martens
(Belgium)
With the rising energy price and the ever-increasing consciousness of environmental friendliness, it is becoming practically helpful for manufacturers to have a clear view on how the energy is consumed at their shop floors, what the corresponding energy cost is, and how to reduce the energy consumption or the energy cost. However, there is currently limited literature investigating the energy cost minimization in manufacturing through production scheduling under volatile energy prices. This paper proposes a generic mixed-integer linear programming model to enable the job scheduling on a single machine for the purpose of minimizing the necessary energy cost without exceeding the due date. The results given by a case study on a surface grinding machine demonstrate this scheduling methodology effectively contributes to the reduction of greenhouse gas emissions during peak time periods by shifting the production load to off-peak periods, and leads to energy- efficient, demand-responsive, and cost-effective manufacturing processes.

S5 - LCA & LCC: Case studies (1)
Room: Gallery 1
Chair: Prof. P. Zwolinski
 
1330
Life Cycle Environmental Impact Evaluation of Newly Manufactured Diesel Engine and Remanufactured LNG Engine
Junli Shi, Tao Li, Zhichao Liu, Hongchao Zhang, Shitong Peng, Qiuhong Jiang, Jinsong Yin
(China)
The application of Liquefied Natural Gas (LNG) in vehicles is considered to be an important way to solve the energy and environmental problems. In China, many waste diesel engines are beginning to be remanufactured to LNG engines. In this study, a life cycle assessment is carried out to quantify the energy saving and environmental emission of a remanufactured LNG engine and newly manufactured diesel engine, both engines are compared by means of material usage, cumulative energy requirements and environmental emissions over the entire life. The results show that, compared with diesel engine newly manufacturing, LNG engine remanufacturing could reduce 42.62% of primary energy demand (PED); the environmental impacts reduction of acidification potential (AP) and nutrient enrichment potential (EP) could reach to 69.61% and 71.34%, which are most distinct; global warming potential (GWP) and photochemical ozone formation potential (POCP) can be reduced by 46.42% and 43.90% respectively.
1350
Framework to predict the environmental impact of additive manufacturing in the life cycle of a commercial vehicle
Mathias Burkhart, Jan C. Aurich
(Germany)
Adding layer after layer of material is the operating principle of Additive Manufacturing (AM) and has the potential to change fundamental conditions in all phases of the product life cycle. AM implications such as design freedom allow the optimization of product properties such as weight or efficiency to achieve a better life cycle performance. Considering AM implications for highly utilized products such as commercial vehicles may have big sustainable impacts if fuel consumption can be reduced. Thereby manufacturers are challenged to implement new manufacturing technologies that enable sustainable products and production. The objective of this article is to provide guidance for manufacturers to decrease the environmental impact of their product through manufacturing components with AM. Therefore a framework is presented to identify components with potential for improvement and to predict the required improvement to decrease the environmental impact with AM.
1410
Life cycle assessment of one-way and pooled pallet alternatives
Jonas Bengtsson, James Logie
(Australia)
Questions remain over the environmental performance of pooled pallets compared to one-way pallet alternatives. The environmental impacts of softwood, hardwood, plastic and cardboard pallets, for use in one-way and pooled pallet systems with manufacturing in either China or Australia, were compared with the use of life cycle assessment. The use of wood and regular maintenance leads to lesser environmental impact, as well as reduced servicing costs, in many typical applications through allowing a greater number of pallet uses between servicing and over the whole lifecycle. The environmental benefits of one-way pallets emerge for specific scenarios involving longer transport distances outside pooling catchments.
1430
Life Cycle Assessment of Electric Vehicles - A Framework to Consider Influencing Factors
Patricia Egede, Tina Dettmer, Christoph Herrmann, Sami Kara
(Germany)
The environmental impacts of electric vehicles (EVs) partially depend on the parameters of their site of operation. Variations of average driving patterns in different geographic locations and the use of heating and cooling due to local climate conditions have an impact on the energy consumption of EVs. In combination with the regional electricity mix these factors influence the environmental impact of EVs. Hence, these influencing factors must be included in an ecological assessment. The Life Cycle Assessment (LCA) method is used for the quantitative ecological assessment. An LCA can e.g. serve as a decisions support tool in vehicle engineering. This paper proposes a framework to consider influencing factors for the ecological assessment of EVs. A case study is used to demonstrate the capability of the framework.
1450
Interaction between New Car Design and Recycling Impact on Life Cycle Assessment
Vi Kie Soo, Paul Compston, Matthew Doolan
(Australia)
The use of lightweight materials and multi-material concepts in car manufacturing has been focused to produce more sustainable vehicles. This has resulted in significant reduction of carbon dioxide (CO 2 ) emissions during use phase to achieve the strict vehicle emission standards. Nevertheless, the varied range of joining techniques used to join multi-material vehicle designs presents challenges at the end-of-life, especially the feasibility of current recycling processes to recover materials in a closed-loop recycling. Life Cycle Assessment has been widely used to assess the environmental impacts throughout the vehicle life cycle stages. However, the correlation between the increasing development in new multi-material vehicle designs, and the commonly used shredding process for material recovery is not captured well in the current analysis. This paper presents a dynamic hypothesis that illustrates the time effect on life cycle analysis of a car to investigate the challenges associated to the material recovery efficiency. It shows that the short term effective reduction in environmental impact through multi-material structures have consequently created a long term effect of increasing waste produced. Thus, the current evolution in automotive industry adheres to the widely studied “Fixes that Fail” system archetype.
1510
Life Cycle Assessment and Comparison of CRT, LCD and LED Monitors
Vikrant Bhakar, Aashray Agur, A. K. Digalwar, Kuldip Singh Sangwan
(India)
The increasing consumption patterns in emerging economies like India and China with half the world population has increased the environmental concerns. E-waste in these countries is rapidly increasing and monitor is one of the major contributors to it. The paper aims at assessing the life cycle environmental impact of Cathode Ray Tube (CRT), Liquid Crystal Display (LCD) and Light Emitting Diode (LED) monitors. Life Cycle Assessment (LCA) of three widely used monitors has been performed based on the international standards of ISO 14040 series. The LCA was constructed using Umberto software version 5.6 and expressed with both CML (Centrum voor Milieuwetenschappen) 2001, mid-point assessment method and Impact 2002+, end point assessment method. This study is expected to guide policy makers in government to improve e-waste management strategies and also it will create awareness among the user. The monitor manufacturers may leverage the study to improve the environmental impact of these products. Sensitivity analysis for the use phase has been performed to confirm the robustness of results.

S6 - End of Life: Remanufacturing (1)
Room: Gallery 2
Chair: Prof. S. Takata
 
1330
A Study of Fatigue Remaining Useful Life Assessment for Construction Machinery Part in Remanufacturing
Yaozhong Wu, Weijia Li, Ping Yang
(China)
Remanufacturing is the process of returning a worn-out product to an „as new‟ condition. For large construction machinery parts with cracks, which are highly value-added, costly, and complexly processed, it is critical to assess the fatigue remaining useful life (RUL) for the following remanufacturing strategy. In this study, a simulation method based on the step-by-step finite element (FE) analysis is presented. The crack life and path are assessed by the linear elastic fracture mechanics theory. Furthermore, the substructure modeling technical is adopted to take account of the influence of structural details and loading shedding during crack growth. For a further step, the method is applied to concrete pump truck boom structure to investigate fatigue crack growth remaining lives and paths.
1350
Remanufacturing decision based on RUL assessment
Yawei Hu, Shujie Liu, Hongchao Zhang
(China)
With the insufficiency of resources and environment degradation, remanufacturing of the mechanical products earns widespread respect. Remanufacturing decision making, as one of the most research directions in remanufacturing field, becomes the research hotpot gradually as well. Systematic research on remanufacturing decision making by means related to RUL assessment will be a significant development in remanufacturing theory due to it is an essential consideration at what RUL level time the device should leave from service for remanufacturing. In this paper, an analytical decision method based on the RUL assessment is proposed for a remanufacturing program. A fatigue crack growth case is used to establish the SSM, estimate the probability density distribution curve of the residual life by particle filter algorithm, and make remanufacturing decision finally. Above all the case shows the validity of the aforementioned method.
1410
Exploring New Horizons for Remanufacturing: An up-to-date Overview of Industries, Products and Technologies
Rolf Steinhilper, Fernand Weiland
(Germany)
Remanufacturing has become an impressively booming technology within the past decade – serving both economical and ecological needs and conquering more industries and product sectors than ever before. The author, who runs the European Remanufacturing Technology Center (ERTC) at the University of Bayreuth, supports this trend by developing the appropriate new technologies by his team of three dozens of highly motivated and qualified engineers and scientists. This presentation offers an up-to-date overview of Remanufacturing´s role within today´s Life-cycle-Engineering efforts worldwide, pointing out progress achieved, milestones ahead and also severe obstacles to overcome. Relevant results of ERTC´s work here will be presented by examples from both the automotive and non-automotive industrial sectors.
1430
The Impact of Automotive Product Remanufacturing on Environmental Performance
Shanshan Yang, Hoong Yeap Ngiam, Soh Khim Ong, Andrew Yeh Ching Nee
(Singapore)
Remanufacturing, as an emerging industry with great potential, presents an excellent product end-of-life (EOL) alternative to extend the number of product life cycle from one to multiple. However, the procedure to quantify the environmental consequences of the complex life cycle of a remanufactured product is still not yet available. In this regard, a modified cumulative energy consumption method is proposed to effectively assess the relative environmental benefit of a remanufactured product and support the decisions on improving product design and EOL recovery system. The applicability and importance of the proposed methodology has been demonstrated by the two case studies, namely, automotive alternators and engine blocks.
1450
Towards facilitating circular product life-cycle information flow via remanufacturing
Jelena Kurilova-Palisaitiene, Louise Lindkvist and Erik Sundin
(Sweden)
In order to achieve a sustainable development, circular economy approaches and circular material flows are explored in industry. However, circular information flows remain essentially unestablished. The aim of this paper is to: 1) explore categories and types of product life-cycle information available for remanufacturing; 2) identify constraints for efficient product life-cycle information flow via remanufacturing; and 3) propose initiatives to facilitate product life-cycle information flow via remanufacturing. Data was collected through workshops and interviews at five remanufacturing companies. An accumulated Sankey diagram illustrates product life-cycle information flow, losses and bottleneck. Based on the analysis, possible initiatives to facilitate efficient product life-cycle information flow via remanufacturing are presented.
1510
WRCloud: a Novel WEEE Remanufacturing Cloud System
Xi Vincent Wang, Lihui Wang
(Sweden)
Cloud manufacturing is a new manufacturing paradigm that offers manufacturing capabilities in terms of Cloud services. As a specific type of manufacturing, Waste Electrical and Electronic Equipment (WEEE) remanufacturing experiences difficulties in system integration, data exchange and resource management, especially when the products reach the end of lifecycle. Thus it is possible to introduce the Cloud manufacturing paradigm into WEEE remanufacturing environment, to overcome the obstacles and bottlenecks. In this paper, a novel Cloud-based system is developed to support WEEE remanufacturing. The WEEE recycle/recovery capabilities are integrated and deployed as flexible services in the Cloud. Supporting mechanisms and technologies are also developed, which are presented and evaluated via case studies.

S7 - Energy efficient Production Planning (2)
Room: Tyree Room
Chair: Prof. L. Wang
 
1600
Increasing collaboration productivity for sustainable production systems
Günther Schuh, Christina Reuter, Annika Hauptvogel
(Germany)
Due to the potentials of Industrie 4.0 such as cyber-physical systems, manufacturing companies will connect their intelligent products and machines. The resulting smart factory enables integrated engineering across the entire value chain. Furthermore, intelligent assistance systems will support employees so that they can focus on value adding activities. Within the Cluster of Excellence “Integrative Production Technology for High-Wage Countries” of the RWTH Aachen University, which is funded by the German Research Foundation DFG, four mechanisms were developed regarding these current developments to increase collaboration productivity and therefore facilitate a sustainable production system. The mechanisms “radically short product development processes”, “virtual engineering of complete value chains”, “better performing than engineered” and “revolutionary short value chains” do not only improve manufacturing processes but also product development processes and thus meet current challenges as resource and energy efficiency.
1620
An approach for energy-oriented production control using energy flexibility
Cedric Schultz, Peter Sellmaier, Gunther Reinhart
(Germany)
Due to rising energy costs and growing awareness for green production, many companies expand their energy self-supply by wind or solar energy. To use this self-supply efficiently, producing companies aim to synchronize their energy demand with a limited energy supply. This has to be reflected in the companies’ production control strategies. This paper presents a concept for a short-term production control, which treats electric energy as a limited production capacity. The approach makes use of energy flexibility to align energy demand in production with energy supply while maintaining logistic goals.
1640
Simulation-based Approach for Eco-Optimized Production Control Systems
Christian Brecher, Simon Müller, Marc Kujas, Wolfram Lohse
(Germany)
Ecological factors are increasingly affecting the business practice of manufacturing companies. Recent guidelines and standards as well as a growing consumer-side demand for sustainable production influence the planning and control of production systems. We present an approach that includes ecological indicators in a multi-criteria production control under given constraints, e. g. cost and flow rate. A conventional approach that uses a single optimization function for ecological indicators is hardly possible due to the number of machines and upcoming data. Our approach includes more than one level of optimization so that the inclusion of multiple ecological indicators and constraints is possible.
1700
Making sustainability paradigms a part of PPC
Matthias Putz, Johannes Stoldt, Christin Fanghänel, Annett Bierer, Andreas Schlegel
(Germany)
The mounting pressure of the European legislative to improve the sustainability of production operations prompts companies to implement sustainability paradigms into their production planning and control (PPC). First results from an ongoing European project will show how the innovative Resource Networks Methodology can be used to alter the production organisation accordingly. In particular, novel PPC strategies improving the integration of renewable energy sources and other resource efficient technologies by using previously identified levels of flexibility will be presented. These are complemented by an approach for unifying the readiness levels for application (RLA) of similar methodologies. The latter will assist decision making during the development phase and in preparation for industrial implementations.

S8 -LCA & LCC: Case Studies (2)
Room: Gallery 1
Chair: Prof. H. Kaebernick
 
1600
Goal-oriented Life Cycle Investigations for composite manufacturing chains
Florian Lindner, Robert Schmitt
(Germany)
Holistic Life Cycle Investigations for products and the related manufacturing chains require large efforts. The pre- quantification of sensitivities for process inputs underscores their importance for the results and determines the required grade of accuracy for quantification. Those indicators support an expedient construction of process models for the LCA/LCC application. Furthermore, a pre-analysis of the differences between product systems for comparative investigations support an adequate and tailored setting of system boundaries. The approach for those goal-oriented Life Cycle Investigations is applied in a Use Case describing a manufacturing chain of automotive structural parts made of composites with a focus on environmental impacts. The results of the pre-analysis are used for recommendations and rules for an expedient development of LCA models and later investigations.
1620
Life Cycle Assessment of a mini hydro power plant in Indonesia: A Case Study in Karai River
Jessica Hanafi, Anthony Riman
(Indonesia)
Indonesia is a vast archipelago with more than 10,000 islands spread across the nation. One of the cyhallenge to provide better lives for the residents is energy distribution to remote areas. With many rivers in the islands, hydropower plants become the best renewable energy source for these remote areas. This paper aims to assess the life cycle of a mini hydro power plant in Simalungun, Indonesia. Life cycle inventory data were collected and impacts were assessed using SimaPro software. A sensitivity analysis comparing two methods, CML-IA and TRACI 2.1 were conducted. Result shows that carcinogenic, marine aquatic eco-toxicity and freshwater aquatic eco-toxiticity are the highest environmental impact, generated from the construction of the mini hydropower plant.
1640
Social Life Cycle Assessment of three Brazilian furniture companies
Carlos Alberto Shuch Bork, Durval João De Barba Junior, Jefferson de Oliveira Gomes
(Brazil)
The level of requirement by consumers regarding available information related to furniture produced in a sustainable manner is increasingly valued in the Brazilian market. The present paper aims to compare three companies which are self-referred to as sustainable with the purpose of characterizing the process of incorporation of the social requirements regarding the sustainability of their products. In this regard, the Social Life Cycle Assessment methodology was used based on the UNEP-SETAC impact indicators. It was therefore possible to suggest improvements in order that they may increase their performance on social sustainability and increase social benefits related to certain stakeholders.
1700
Development of the Methodology for Environmental Impact of Composite Boats Manufacturing Process
Yong-Kuk Jeong, Philippe Lee, SeungHoon Nam, Dong Kun Lee, Jong-Gye Shin
(Korea)
The environmental profiles certification means a method about assessment of environmental performance for building materials in building industries. This research discusses the methodology for the environmental impact evaluation and support system for composite boats manufacturing process using environmental profiles certification concepts. For this work, the generic yacht work breakdown structure (G- YWBS) which is developed for yacht engineering management system was used. The G-YWBS is detailed component breakdown structure, focused on the lifecycle of yacht including project management, manufacturing process, maintenance process, product information, and all the other relation things. Finally, environmental impact evaluation system was developed to calculate the environmental impact from the composite boat manufacturing process based on the G-YWBS.

S9 - End of Life: Remanufacturing (2)
Room: Gallery 2
Chair: Prof. R. Steinhilper
 
1600
Remanufacturing of electronic control units: An RFID based (service) interface
Joachim Kleylein-Feuerstein, Fabian Joas, Rolf Steinhilper
(Germany)
Remanufacturing of electronic control units (ECUs) is a challenging task. Current technology does not allow retrieving the status of installed electronics. In addition, it is not possible to access ECUs wirelessly without power supply. The wireless (service) interface radio-frequency communication (RFCo) has been developed to overcome these challenges. Here we show that by integrating RFCo into ECUs, operating data, general information, and the error log can be obtained without a mechanical connection. Furthermore, it is possible to update the firmware wirelessly. Consequently, the new interface RFCo permits faster and easier remanufacturing of ECUs, with results of superior quality.
1620
Remanufacturing-oriented geometric modelling for the damaged region of components
Yingzhong Zhang, Zhenyan Yang, Guangzhi He, Yun Qin, Hong-chao Zhang
(China)
The accurate additive manufacturing technology provides an effective and efficient means for remanufacturing or repairing high value and damaged engineering components. Important work to implement this technology is to construct the geometric model of the damaged or worn region, which lays the foundation for the computation of the tool path and the virtual digit repair. This paper discusses several forms of the damaged or worn region and proposes a hybrid B-rep model integrating subdivision mesh and exact boundary representation according to the data sources. A novel method to perform Boolean operations on the triangulated approximation surfaces and exact parameter surfaces is also presented. Finally, a modelling example and discussion are given to illustrate the effectiveness of the approach.
1640
Influence of powders and process parameters on bonding shear strength and micro hardness in laser cladding remanufacturing
Mingsan Xu, Jianfeng Li, Jibin Jiang, Bingbing Li
(US)
Laser cladding technology has been proved an effective method to remanufacture the damaged parts by cladding high performance materials. The type of alloy powders, laser output power, and scanning speed were selected as influencing factors to conduct orthogonal cladding experiment on the substrate of carbon steel C45. Bonding shear strength and micro hardness of the clad layer and the substrate was tested and analyzed. Metallography of the clad layer was evaluated by scanning electron microscope (SEM) image. The experimental results show that a good metallurgical bond is formed between the clad layer and the substrate without porous cracks and other defects.
1700
Simplified Life Cycle Assessment and Analysis of Remanufacturing Cleaning Technologies
Shitong Peng, Tao Li, Junli Shi, Hongchao Zhang
(China)
Remanufacturing cleaning can lay foundation for testing, painting and assembling waste products and components in remanufacturing procedure. Currently, high temperature decomposition and shot blasting cleaning are conventional industrial cleaning technologies for remanufacturing while supercritical CO 2 cleaning and liquid blasting cleaning are the relatively new ones. This study completed by the method of simplified life cycle assessment aims at comparing the environmental impacts of the cleaning process of these two types of cleaning technologies. Most of the data were collected from a remanufacturing company directly and some laboratorial data were used to speculate about the industrial data for the difficulties of collection. The results indicate that, compared with conventional cleaning technologies, the new cleaning technologies are relatively environmental friendly since they are more favorable in terms of several environmental impact indicators such as GPW, AP, EP, ODP, POCP, etc and most of emissions have been reduced dramatically.

DAY2

Keynote 2

Room: Tyree Room

0900
Life Cycle Engineering: The Roadmap to Emission Free Mobility
Dr. Stephan Krinke

Head of the department Environmental Affairs Product, Volkswagen AG

  

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Keynote 3

Room: Tyree Room

0930
Industry-university collaboration in sustainable manufacturing
Dr. Bernard John Kornfeld

Director of Service and Supply, Baxter Healthcare, Australia

A recurring theme in the economics of development is the tragedy of the commons – a situation in which independent actions guided by self-interest result in an outcome that is contrary to the overall and long-term interest of the many. Actors become “locked into a system that compels” them to strive for growth without limit within a finite system. Although some forward thinking companies recognize their role in transitioning to sustainable environmental practices, even the most well meaning may not have the capability to recognize and implement the most appropriate technology. Moreover, that technology might not yet exist in an industrial form and so such steps may well be speculative and risky for little or no return to the business. Polluting is asymmetrically favorable to industry and would rationally suggest inaction. A framework for industry-university partnership demonstrates how new and complex approaches to sustainable manufacturing can be implemented. Governments must support collaborative work with industrial norm entrepreneurs and academia to aid the introduction of technologies that are asymmetrically favorable to the interests of humanity at large and to future generations.

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S10 - Energy and Resource Efficiency: a manufacturing system view (2)
Room: Tyree Room
Chair: Prof. A. Matta
 
1030
Automatic Variant Configuration and Generation of Simulation Models for Comparison of Plant and Machinery Variants
Adrian Neyrinck, Armin Lechler, Alexander Verl
(Germany)
Manufacturers of machines and plants are faced with the challenge to quickly find, compare and evaluate solutions for their customers during the tendering phase. Besides acquisition costs, figures about life cycle costs and energy efficiency are claimed by sustainability-aware customers when making a choice between different possible solution variants. In this paper an approach for automatic variant compilation and simulation model generation, based on mechatronic modules, is introduced. The results, validated using an example application of a modular transfer system, show that using the proposed method can significantly speed up the process of finding the appropriate module configuration based on reliable simulation models even for non-simulation-experts.
1050
KPI-focused Simulation and Management System for Eco-Efficient Design of Energy Intensive Production Systems
Günther Riexinger, Philipp Holtewert, Axel Bruns, Sylvia Wahren, Khoi Tran, Thomas Bauernhansl
(Germany)
The optimal eco-efficient design of production processes guarantees sustainable and resource-efficient manufacturing systems. Within the scope of the European project “DAPhNE”, Fraunhofer IPA enables eco-efficient design with a new integrated system for the simulation and management of energy-intensive production systems as well as related key performance indicators (KPIs). The approach presented in this paper is based on a holistic production model and simulation system including dynamic KPIs with the focus on environmental, operational and economic aspects. A main objective of the developed system is to support the engineering and optimization phases to develop and maintain eco-efficient production systems.
1110
3d thermal climate monitoring in factory buildings
Gerrit Posselt, Paul Booij, Sebastian Thiede, Jeroen Fransman, Bart Driessen, Christoph Herrmann
(Germany)
Guaranteeing defined conditions, such as the temperature levels inside the factory’s building shell, is often important to produce high-quality products. Heating, ventilation and air conditioning (HVAC) equipment, as part of the technical building services, is energy intensive and accounts for a major share of the factory’s energy demand. For an effective utilisation, the HVAC system control has to compensate time dependent variations of building-internal loads and demands as well as changing weather conditions that can cause local temperature differences. In this paper, a computational fluid dynamic model, coupled with a wireless sensor network, is presented that allows the estimation of the temperature and air flows at every position in the factory building, in real-time. This can then be used to improve control strategies of HVAC systems towards a more energy efficient and demand oriented climate conditioning within factory building shells.
1130
Assessing the impact of embodied water in manufacturing systems
Smaeil Mousavi, Sami Kara, Bernard Kornfeld
(Australia)
In recent years the issue of improving energy and water efficiency in manufacturing systems has received increased attention. Rising energy prices, scarcity of quality water and imposed environmental regulations have been the main contributors to this issue. Water is consumed not only for raw material and products, but also for primary forms of energy, such as electricity. Therefore, it is important to measure energy and water consumption and to obtain insight into their usage patterns in manufacturing systems. In particular, such measurements can help to identify hotspots and inefficient processes. So far, a number of approaches have been developed to assess the environmental footprint of water and energy consumption, but few studies have been carried out to establish approaches to quantify their consumption, especially for water. This paper introduces a simulation-based approach that can be implemented to model energy and water flows in manufacturing systems. The approach contains a generic state-based model for a single machine and follows a bottom-up approach to construct the model of the whole system. This approach provides a reliable base for simulating operating conditions and evaluating different what-if scenarios in order to improve system performance. Then, one of the most appropriate methods for water footprint assessment in manufacturing industry is chosen, and a manufacturing site of a pharmaceutical company, as a case is studied to show how the proposed model can be applied.
1150
Simulation based assessment of lean and green strategies in manufacturing systems
Sebastian Greinacher, Emanuel Moser, Hanjo Hermann, Gisela Lanza
(Germany)
The increase of resource (energy and material) efficiency by eliminating unnecessary consumption represents the logical continuation from lean manufacturing to lean and green manufacturing. However, economic efficiency remains the primary decision criterion for the implementation of corresponding strategies. This paper presents a simulation based approach for monetary assessment of lean and green manufacturing systems considering non-monetary green limits. Inclusion of material and energy consumption as well as resulting greenhouse gas emissions enables planners to predict the overall economic performance of a factory. Furthermore, product variant specific footprints of material and energy demands as well as resulting emissions support in-depth analysis of value streams in manufacturing.
1210
Hierarchical modelling of complex material and energy flow in manufacturing systems
Samira Alvandi, Georg Bienert, Wen Li, Sami Kara
(Australia)
Over the past decades, the economic and environmental soundness of manufacturing systems are often questioned because of the large consumption of energy and primary materials. In order to investigate potential opportunities towards achieving the material and energy efficiency in these systems, it is essential to model these flows and associated complexity in detail. An isolated consideration of individual processes which in themselves are comprised of sub-processes is not a sufficient approach. To obtain a reasonable level of detail from the system, hierarchical structure of energy and material consumers in the system is required. In this paper a simulation based approach is presented to model energy and material flows. This approach considers hierarchical structure of energy and material consumers within the system. It can be served as a base to identify hotspots and to assess the effectiveness of retrofitting exercise through what-if scenarios. An industrial case study is used to demonstrate the applicability and the validity of the proposed approach.

S11 - LCA & LCC: Case Studies (3)
Room: Gallery 1
Chair: Prof. W. Sihn
 
1030
Carbon Footprint of Cassava Starch Production in North Eastern Thailand
Phairat Usubharatanaa, Harnpon Phungrassamia
(Thailand)
Carbon footprint was calculated for cassava starch product in Thailand. Objective of this study was to evaluate andcompare the global warming impacts of cassava starch production in 3 factories located in North-Eastern Thailand. The system boundary was defined from cradle to factory gate, starting from cassava cultivation and harvesting until cassava starch production by using life cycle assessment (LCA) methodology based on ISO 14040 series. The selected functional unit was 1,000 kg of dry native starch, excluding packaging. Input and output data were analyzed and results were shown in terms of global warming potential (GWP) impact categories. The average greenhouse gases (GHGs) emission value based on LCA methodology of 3 factories was 594 kgCO2e per one ton of dry native starch. The results indicated that the cultivation and harvesting procedure was the major source emitting GHGs, around 40-59% of the total, if the factory used the biogas from wastewater treatment plant. Based on this result, the estimated total GHGs emission of cassava starch production in Thailand in the year 2013 was a total of approximately 10,500 million tons of CO2e.
1050
Environmental impact analysis of a water supply system: study of an Indian university campus
Vikrant Bhakar, Nitesh Sihag, Rebekka Gieschen, Stefan Andrew, Christoph Herrmann, Kuldip Singh Sangwan
(India)
The paper aims at analyzing the water supply, its consumption, recycling and related energy consumption at a University campus in India. The university is located in semi-arid area and provides a unique example where the per capita water consumption is above the Indian average and the water is extracted from the overexploited groundwater aquifer. The groundwater is the only source of water supply providing 2.05 million liters of fresh water per day. In the last few years the university has embarked on water saving techniques using rain water harvesting and water recycling. The ground water extraction and its supply consume a lot of energy thereby increasing the environmental impact of the water supply. Mapping of the water source and consumption has provided valuable information to assess the major sources of water consumption and to take appropriate actions to optimize per capita water consumption and reduce water losses. The environmental impact of the water supply system on campus has been determined by conducting a life cycle assessment using Umberto NXT universal life cycle assessment software with ReCiPe endpoint and midpoint methods. It was found that tap water used in buildings has highest impact on environment while the recycled water used for irrigation has nearly zero impact.
1110
From LCC to LCA using a hybrid Input Output model - a maritime case study
Louise Laumann Kjær, Aris Pagoropoulos, Michael Hauschild, Morten Birkved, Jannick H Schmidt, Tim C. McAloone
(Denmark)
As companies try to embrace life cycle thinking, Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) have proven to be powerful tools. In this paper, an Environmental Input-Output model is used for analysis as it enables an LCA using the same economic input data as LCC. This approach helps align LCA and LCC while avoiding cut-offs in the LCA. The efficacy of the method is illustrated by a real case study of a tanker ship.
1130
Integrated Carbon Metrics and Assessment for the Built Environment
Soo Huey Teh, Thomas Wiedmann, Judith Schinabeck, Hazel Rowley, Stephen Moore
(Australia)
One third of global greenhouse gas emissions are emitted from the building sector contributing significantly to the problem of climate change. While more work has been done on decreasing direct emissions from the operation of buildings, embodied emissions of construction materials receive little consideration even though they constitute a significant additional proportion of emissions. The main objective of this study is to harmonise different data and methods such as Life Cycle Assessment (LCA), Input Output Analysis (IOA) and Material Flow Analysis (MFA) to accurately calculate the embodied carbon emissions of construction materials in Australia. This study will develop and streamline efficient hybrid methodologies in analysing embodied emissions of the built environment at multiple scales and develop a comprehensive database of embodied carbon LCI data for building and construction materials that will be derived from an economy-wide modelling framework. This work is part of the Cooperative Research Centre for Low Carbon Living under the Integrated Carbon Metrics project.
1150
Material Flow Cost Accounting extended to the Supply Chain - Challenges, Benefits and Links to Life Cycle Engineering
Martina Prox
(Germany)
Since May 2014 a new ISO Standard on Guidance for the extension of Material Flow Cost Accounting (MFCA) into the Supply Chain is in preparation. The contribution will elaborate on the challenges and benefits of this extension for the participating supply chain partners. As Material Flow Cost Accounting and Life Cycle Engineering are based on a similar demand on information about Material and Energy Flows along the Supply Chain, respectively along the life Cycle, synergies and differences between the two approaches will be discussed. As far as available guidance for successful collaboration in the supply chain will be given.
1210
KPI and LCA evaluation of integrated microwave technology for high temperature processes
Corina Dorn, Ralph Behrend, Dimitrios Giannopoulos, Loredana Napolano, Beatriz García Baños, Valentina James, Volker Uhlig, José M Catalá, Maria Founti, Dimosthenis Trimis
(Germany)
Nearly a quarter of the energy consumption of Europe is required for industrial processes. Huge efficiency potentials can be exploited. One such is under research within the EU funded project DAPhNE by developing an integrated solution for energy intensive firing processes with microwave technologies. A methodology towards the preliminary definition of Key Performance Indicators (KPIs) with focus on economical, environmental and operational aspects is presented within this paper. By means of lab-scale measurements, the preliminary selected KPIs are determined and benchmarked against conventional KPIs to develop an eco-efficient production system. Moreover life cycle assessment (LCA) results support the evaluation and quantify the environmental benefits of microwave heating. Lab-scale results indicate a high carbon emission reduction potential.
S12 - End of Life: Waste Management
Room: Gallery 2
Chair: Prof. S. J. Hu
 
1030
Resource Efficiency and Composite Waste in UK Supply Chain
Norshah Aizat Shuaib, Paul Tarisai Mativenga, James Kazie, Stella Job
(UK)
Rising demand for fibre reinforced polymer composite material and environmental issues necessitates resource efficient use of manufacturing and end of life composite waste. The impact of such sustainability or recycling initiatives can be limited and misguided if the global/national picture is not thoroughly considered. This problem is addressed in this paper with the aid of new Sankey diagrams generated from virgin material and waste volumes in the UK. Environmental footprints of virgin material and recycling were used to explore the resource benefits of composite re-manufacturing. The use of Sankey diagrams enables better decision making with respect to targeting sustainability effort.
1050
Towards a Circular Economy for End-of-Life Vehicles: A Comparative Study UK - Japan
Mélanie Despeisse, Yusuke Kishita, Masaru Nakano, Michael Barwood
(UK)
As the European Directive on end-of-life vehicle (ELV) treatment has heavily influenced policies in many countries, car manufacturers need to reconsider the early phases of the product design to enable better ELV treatment. This paper proposes policy, technical and business recommendations to improve the reuse, recycling and recovery (RRR) rate of ELVs. A comparative analysis between the United Kingdom and Japan is undertaken, in which the two countries’ contextual background is described along with their RRR performance from a lifecycle perspective. Barriers and countermeasures to improve the RRR rates are discussed based upon mutual learning between the two countries.
1110
Optimization of a non-hazardous Integrated Solid Waste Processing Line
Camille Jourdain, Peggy Zwolinski
(France)
The project described in this paper focuses on non-hazardous wastes coming from collection sites in France. The aim of this project is to increase the quantity and quality of reusable materials by optimizing the production chain for combustible and scrap metal, and to find the best way(s) for recovering “fines” which are currently disposed as final waste. This paper will highlight that the composition of the three sub- products (combustible for cement industry, scrap metal and fines) is interdependent, and that changes on one sub-product can impact the others. It will be shown that simple design or collection recommendations could improve significantly the value of the sub-products. The GISEMENT project is a partnership between two French companies: a recycler, a recycling equipment manufacturer, and a French laboratory, G-SCOP, specialized in Eco-design.
1130
Modeling the Value Recovery of Rare Earth Permanent Magnets at End-of-Life
Liang Cong, Hongyue Jin, Pete Fitsos, Timothy McIntyre, Yuehwern Yih, Fu Zhao, John W. Sutherland
(US)
Permanent magnets containing rare earth elements (REEs) such as Dysprosium and Neodymium offer an advantage over non-REE containing magnets (e.g., ferrite and AlNiCo) in terms of power relative to size. However, REE availability has varied significantly in recent years leading to volatility in the cost of rare earth permanent magnets (REPMs). The supply of REEs can be increased by recycling consumer products and industrial machinery that contain REPMs at product end-of-life (EOL). This paper discusses the REE recovery process for EOL products. The optimal dismantling of products is examined with an emphasis placed on obtaining used REPMs. The challenge of collecting, managing, transporting, and processing used products is addressed through the development of a cost model for REPM recovery. This model is used to investigate several EOL strategies for recovering REPMs. Sensitivity analysis is conducted to identify the key factors that influence value recovery economics. A hard disk drive serves as a case study for model demonstration.
1150
Use of post-consumer scrap in aluminium wrought alloy structural components for the transportation sector
Kristian Martinsen, Sverre Gulbrandsen-Dahl
(Norway)
Wrought alloy aluminium such as AA 6082 is traditionally based on virgin aluminium and some small amount of recycled internal scrap. The "sink" of recycled aluminium is mostly cast alloys. The papers describes how changes to the material tolerances, reverse logistics and novel sustainable business models are key elements for a sustainable use of post-consumer scrap in high-end structural components based on wrought alloy aluminium. The paper describes the results from the EU FP7 Project ―SuPLight‖ and demonstrates why a holistic view and a cross- disciplinary approach are needed. A generic framework for simulation-based optimization is described as well as novel aluminium technology preparing for post consumer scrap recycling of aluminium to high-end wrought alloys. An alternative manufacturing process route for wrought aluminium forging directly on casted billets, omitting the extrusion process step, has been developed.
1210
Assessment framework and material flow analysis of material recovery facilities within the U.S. to track consumer electronics by product category
Jennifer Mangold, Kathy Cristobal, Carole Mars, David Dornfeld
(US)
An assessment framework was developed to evaluate and characterize material recovery facilities within the U.S. that process e-waste. The framework consists of five key categories including, facility overview, operating model and process flows, product flows, collection methods, and facility resource use. The results were used to conduct a material flow analysis to develop a representative set of end-of-life pathways (e.g., reuse, refurbish, recycle) to better understand the flow of e-waste in the end-of-life management industry. The majority of products collected was from business sector collection routes. The largest number of products (by units) collected at 90% of facilities was mobile phones. It was also seen that most products went directly to recycling for material recovery and were not in the condition to be re-used or refurbished.

S13 - Energy and Resource Efficiency: a manufacturing system view (3)
Room: Tyree Room
Chair: Prof. K. Martinsen
 
1330
The need for better energy monitoring within industry
Kristine O’Rielly, Jack Jeswiet
(Canada)
Energy efficiency presents enormous opportunities for industry – reducing costs, stimulating economic growth, increasing productivity, and offering a significant reduction in environmental impact. Unfortunately, many companies – especially SMEs (small and medium enterprises) – still shy away from the opportunities that are available to them from energy conservation, due to a lack of in-house expertise, inadequate resources, or positive reinforcement through industrial feedback on the use of such techniques. Energy consumption is often ignored, with many companies not tracking their consumption data or having a thorough understanding of their primary energy needs or prominent areas of inefficiency. By speaking directly with companies about energy efficiency and collecting hard data, case studies have been developed, successfully demonstrating the benefits of implementing various energy efficiency strategies and the need for better energy consumption monitoring to ensure these projects are achieving desired energy reduction results. These case studies will be discussed in this paper.
1350
Energy Efficiency Evaluation for Machining Process in Flexible Manufacturing Systems in machining process - A Case Study
Hugo M. B. de Carvalho, Jefferson de Oliveira Gomes
(Brazil)
In the industry, the cost of electricity, although increasing, is not regarded as a production cost, and thus the energy efficiencies of equipment are usually not considered. To gain knowledge about energy efficiencies in the machining industry, this study proposes a new method of evaluating the machining process and the machines, devices, and equipment involved. To validate the suggested method, a case study in the automotive industry is presented, comparing the machining processes in two flexible manufacturing systems, one in which aluminium is machined and the other in which cast iron is machined.
1410
Availability-based payback method for energy efficiency measures
Robert Kasprowicz, Carolin Schulz
(Germany)
Energy-efficient technologies can lead to high energy and monetary savings in numerous industries. However, a lot of potential identified in industries remains untapped due to comparatively short requested payback periods. Usually, companies base the calculation of their payback period on initial investment costs in conjunction with annual monetary energy savings. Energy efficiency measures, however, often lead to synergy effects which are not taken into account. Against this background, we illustrate that taking machine availability into account can shorten the payback period of energy efficiency measures considerably. Furthermore, we demonstrate a methodology to standardize this availability-based payback calculation.
1430
Knowledge based and PLM facilities for sustainability perspective in manufacturing: a global approach
Farouk Belkadi, Alain Bernard, Florent Laroche
(France)
The optimization of resources and energy consumption of production system is one of the fields in which industries should make relevant improvements to successfully integrate sustainability aspects in the Factory of the Future (FoF). Due to the complexity of this issue, one of important challenge for the success of any assessment or resource optimization strategy concerns the control and the availability of all relevant data and knowledge along the product lifecycle. The aim of this work is to explore the capabilities of knowledge based frameworks combined to Product Lifecycle Management (PLM) approaches as a backbone for supporting resources optimization within a sustainability perspective.
1450
On the Applicability of Sustainability Assessment in Manufacturing
Anastasiia Moldavska, Torgeir Welo
(Norway)
The literature on sustainability assessment abounds with different tools, methods, models and frameworks, and the amount of literature on sustainability assessment applied to the field of manufacturing is rapidly growing. This study aims to review the state of the art associated with the latter, synthesising and analysing the applicability of the different approaches with their practical applicability in real-world manufacturing at the heart of the discussion. Based on review of research trends within sustainability assessment, we identified a list of tools addressing three pillars of sustainability which all can be applied on company level. These tools were evaluated from a manufacturing company’s point of view, including (1) reliability; (2) manufacturing company’s context; (3) time and resources required for assessment; (4) point out problem areas; and (5) point out solutions. Finally, the sustainability assessment framework based on a value chain concept is proposed as a possible solution for handling challenges related to sustainability assessment in manufacturing.
1510
Energy Efficiency Benchmarking Method for Mass and High-Mix Low-Volume Productions
Yee Shee Tan, Tobias Bestari Tjandra, Bin Song
(Singapore)
Manufacturing industry is the largest end-users of energy around the world. Continuous improvement of energy efficiency is seen as a key approach to reduce energy consumption, lower greenhouse gas emissions, and achieve sustainable manufacturing. Energy efficiency benchmarking is a technique to identify best practices to serve as possible benchmarks for measurement and management of energy efficiency improvement. However, it is a challenging task to identify the best practices and quantify the energy saving potentials in manufacturing environment, particularly when the operation is high-mix low-volume (HMLV). This paper presents an Energy Efficiency Benchmarking Methodology (E 2 BM), which can be applied for both mass and HMLV production environments. E 2 BM allows the quantification of energy efficiency gaps between manufacturing operations and the corresponding best practices, and hence reveals the potentials for achievable energy savings. Examples are given to illustrate the application of E 2 BM in different manufacturing operations.

S14 - LCA & LCC: Case studies (4)
Room: Gallery 1
Chair: Dr B. Song
 
1330
Quantifying the Life Cycle Water Consumption of a Machine Tool
Jahau Lewis Chen, Yen-Bou Chen, Hua-Chih Huang
(Taiwan)
Water is critically important to human life. However, the demands for fresh water in many regions are much more than those can load. The concept of water footprint came from virtual water which can help us roughly understand the water consuming of a product manufacturing process and after services. This paper presents a methodology for assessing water footprint of machine tools. Detail assessment steps and calculation process for life cycle of machine tools is described in this paper. The difficulty in inventory process and data selection during water footprint assessment will be presented. A case study is used to explain the capabilities of the proposed methodology.
1350
Assessing the environmental performance of machine tools - Case studies applying the 'LCA to go' Webtool
Florian Krautzer, Rainer Pamminger, Carl Diver, Wolfgang Wimmer
(Austria)
A simple, sector specific webtool was developed within the EU funded ‘LCA to go’ project, to enable SMEs to perform first environmental assessments of their industrial machines and machine tools. The tool was applied together with several SMEs, sixteen of which provided feedback on their user experience, applicability, value of the results and future plans with the tool. The software flow of the webtool is presented together with a summary of the outcome of the case studies. Based on the feedback and the application of the webtool further development options for the sector specific tool were developed.
1410
Application of Life Cycle Assessment (LCA) and Design of Experiments (DOE) to the monitoring and control of a grinding process
Diogo A. L. Silva, Remo A. P. Filleti, André L. Christoforo, Eraldo J. Silva, Aldo R. Ometto
(Brazil)
The number of studies on green manufacturing has increased over the past years and particular focus has been placed on machining processes and the application of Life Cycle Assessment (LCA). This paper reports the results of the use of a modeling approach that combines Life Cycle Assessment (LCA) and Design of Experiments (DOE) to investigate a cylindrical plunge grinding for 21-2N steel. The effect of two process parameters on the LCA results of the grinding machining was studied through an analysis of variance (ANOVA). The parameters investigated were type of CBN grinding wheel (JB126 K150 VSS and 8B126 K150 VT2) and different levels of specific material removal rate (50, 100, 150 and 200 mm³/mm.min).
1430
Environmental comparison of metal coating processes
Karel Kellens, Dimos Paraskevas, Wim Dewulf, Joost R. Duflou
(Belgium)
Taking into account the expected growth of the world’s population and increasing welfare level in developing countries, the global energy and material resource demand can be expected to increase significantly. Therefore, the environmental burden per unit produced should be strongly reduced in order to assure a sustainable impact level [1-2]. This paper describes the environmental assessment and comparison of two alternative metal coating techniques: i.e. electrostatic powder coating and fluidized bed sintering. The paper starts with a general description of both investigated metal coating processes. Subsequently the life cycle inventory data collection effort is described and an environmental impact assessment is performed for both processes. The environmental performance of both processes is compared taking into account the differences in expected life time of both coatings. Finally, an overview of potential improvement measures is provided.
1450
Metrics-based Sustainability Evaluation of Cryogenic Machining
Tao Lu, I.S. Jawahir
(US)
Cryogenic machining is considered as the most sustainable alternative to conventional flood-cooled, near-dry and dry machining approaches in machining processes. This paper presents the application of a sustainability evaluation methodology for manufacturing processes, focusing on cryogenic machining processes. The methodology used here involves a metrics-based Process Sustainability Index (ProcSI) evaluation. To address the proper process conditions for cryogenic machining, different machining parameters, namely the cutting speed and the coolant flow rate, are used in the experiments as the controllable variables. The ProcSI assessment helps to decide on the best cutting conditions from the sustainable manufacturing viewpoint. During the evaluation procedure, the process behavior under different process conditions is considered and discussed in the analysis to understand the process mechanism and its controllability for achieving improved sustainability.
1510
Tool State Assessment for Reduction of Life Cycle Environmental Impacts of Aluminium Machining Processes via Infrared Temperature Monitoring
Alessandro Simeone, Elliot Woolley, Shahin Rahimifard
(UK)
Modern industrial machining environments face new challenges in implementing process monitoring systems to improve energy efficiency whilst ensuring quality standards. A process monitoring methodology for tool state identification during milling of aluminium has been implemented through the utilisation of an infrared (IR) camera. A features extraction procedure, based on statistical parameters calculation, was applied to temperature data generated by the IR camera. The features were utilised to build a fuzzy c-means (FCM) based decision making support system utilising pattern recognition for tool state identification. The environmental benefits deriving from the application of the developed monitoring system, are discussed in terms of prevention of rework/rejected products and associated energy and material efficiency improvements.

S15 - End of Life: Disassembly
Room: Gallery 2
Chair: Prof. A. Raatz
 
1330
Two stage sequence generation for partial disassembly of products with sequence dependent task times
Robert J. Riggs, Xiaoning Jin c , S. Jack Hu
(US)
For disassembly sequence generation, partial disassembly and sequence dependent task times are typically not considered together in the same model. We developed a two-stage optimization program that first determines the optimal partial disassembly sequence according to reuse value only, followed by the second stage that finds the optimal partial disassembly sequence that also includes sequence dependence task times. We prove the optimality of the two-stage approach under the condition that all components with any positive reuse value must be included in the final sequence. If this condition does not need to be met, a task hedging policy is shown to be effective.
1350
Economic and Environmental Evaluation of Fasteners for Active Disassembly: A Case Study for Payment Terminals
Jef R. Peeters, Paul Vanegas, Wim Dewulf, Joost R. Duflou
(Belgium)
Prior research has demonstrated that design for disassembly enables higher recovery rates for precious and critical metals, as well as flame retardant plastics from End-of-Life (EoL) electronics. However, small EoL electronic products are nowadays commonly recycled in a size- reduction based treatment or can be directly treated in an integrated Precious Metal (PM) smelter-refinery. In this article, a methodology is described to calculate the Rate of Return (RoR) on investing in fasteners which can be simultaneously released by the application of an external trigger, following the principle of active disassembly. This methodology is used in the presented case study to calculate the ROR of implementing a pressure sensitive snap-fit in an electronic payment terminal which is sold in a product service system business model. In addition, the economic and environmental performances of an active disassembly based EoL treatment is compared with those of a manual disassembly and a size-reduction based treatment, as well as direct treatment in an integrated PM smelter-refinery. Results of the presented case study demonstrate that the ROR on investing in active fasteners for the case study product is 27%.
1410
Proposal of a Design Method for Dismantling Products with Split-Lines
Yumi Shiraishi, Naoya Miyaji, Shinichi Fukushge, Yasushi Umeda
(Japan)
An important process for the reuse and recycling of end of life products is their disassembly. In general, manual disassembly is a labor intensive and costly process. Especially, removing fasteners takes time and cost. For solving this problem, this paper proposes a design method for the partial dismantling of products with split-lines, which are added to the products at the design phase and enable to destruct the products along the line in order to extract target components. This method supports a designer in determining the location of split-lines by using the geometric model of the product. A case study shows that the dismantling of a LCD TV with split-lines reduces the number of manual operations needed for extracting target components.
1430
Robot Assisted Disassembly for the Recycling of Electric Vehicle Batteries
Kathrin Wegener, Wei Hua Chen, Franz Dietrich, Klaus Dröder, Sami Kara
(Germany)
The rising number of electric vehicles (EV) will eventually lead to a comparable number of EV batteries reaching their end-of-life (EOL). Efforts are therefore being made to develop technologies and processes for recycling, remanufacturing and reusing EV batteries. One important step of many such processes is the disassembly of EOL EV batteries, which poses a challenging task due to unpredictable lot sizes and volumes, as well as significant variations in battery design between different car models. In response to these challenges and the increasing demand, we present a concept for a battery disassembly workstation where a human is assisted by a robot. While the human performs the more complex tasks, the proposed robot performs simple, repetitive tasks such as removing screws and bolts. Such a robot requires 1) a suitable procedure for the unscrewing task, 2) a means of autonomously changing screwdriver bit in accordance with the variety of screws and bolts found in EV batteries, and 3) some means of acquiring information regarding the location of these fasteners. This paper summarises the results of our preliminary investigations.
1450
Impact of multi-material components on the assembly and disassembly of traction batteries
Alexander Tornow, Stefan Andrew, Franz Dietrich, Klaus Dröder
(Germany)
Battery electric vehicles as well as plug in hybrid electric vehicles suffer from high costs as well as low driving ranges. Both characteristics can be related to the battery system of the vehicle. In order to reduce weight within the battery system and thus enlarge the vehicle range, novel lightweight components based upon multi-material design are used within batteries. These might offer advantages within the production and use phase of the product life cycle but in the same way have negative effects on recycling and second life. This paper describes a design methodology that helps to evaluate the impacts of highly integrated multi-material components on the assembly and disassembly of traction batteries.
1510
Improvement of Optimal Disassembly Sequences of Complex Systems Family Using Petri Nets
Serigne Diagne, Amadou Coulibaly, Mbaye Sene
(France)
The identification of the optimal disassembly sequences of complex systems is very important for the evaluation at the early design stage of its maintainability and the analysis of its recyclability at the end of life. Several tools can be used to reach this goal (genetic algorithms, graphs, Petri nets, etc.). However, methodologies based on these tools do not take into account information such as the accessibilities and the positions of the links and the criticalities and the reliabilities of the components. They generally focussed on a single system too. Thus, we propose in this paper a methodology based on Petri Nets, using eXtended Conceptual Design Semantic Matrix (X-CDSM) and new disassembly indicators for improving optimal disassembly sequences of complex system's families at the early design stage.

S16 - Energy and Resource efficiency: a manufacturing system view (4)
Room: Tyree Room
Chair: Dr S. Krinke
 
1600
A sustainability indicator framework for Singapore small and medium-sized manufacturing enterprises
Hui Xian Tan, Zhiquan Yeo, Ruisheng Ng, Tobias Bestari Tjandra, Bin Song
(Singapore)
Assessment of industrial sustainability is an important step towards converting the theoretical goal of sustainable development into practice. One category of sustainability assessment tools is indicators. Indicators are useful tool to summarise and condense complex data into meaningful information and track performance progress over time. This article identifies 40 most commonly used sustainability indicators for Singapore small and medium-sized manufacturing enterprises (SMEs) from four internationally-recognised indicator frameworks through a systematic indicator selection method. These indicators could potentially facilitate local SMEs to manage their manufacturing systems. To ensure appropriate categorisation of the indicators into the sub-categories, content of each sub-category is analysed and a concise definition of nine sustainability terms are put forward. This study has proposed a comprehensive indicator framework in the context of Singapore.
1620
Decentralised energy futures: the changing emissions reduction landscape
Benjamin McLellan, Nick Florin, Damien Giurco, Yusuke Kishita, Kenshi Itaoka, Tetsuo Tezuka
(Japan)
The world is witnessing an energy revolution as renewables become more competitive and energy security becomes a high priority for an increasing number of countries. This development is changing the point along the supply chain ripe for reducing emissions. Whereas carbon capture and storage (CCS) coupled to coal or gas power production offers the potential to decarbonise the current centralised power systems, this relies on a significant increase in electrification to achieve deep emission reductions beyond the power sector, including industrial emissions and transportation. At the same time there is a trend towards decentralised industrial processes, e.g., driven by cost reductions in decentralised production systems and miniature processing plant. New strategies for reducing emissions from decentralised industrial and energy emission point sources will be increasingly important. This paper evaluates different emission reduction strategies that may be relevant to a decentralised energy and manufacturing future, including increased electrification, energy storage, renewable energy and renewable feedstock. Systemic opportunities or barriers and considerations of policy and decentralised decision-making are examined.
1640
Energy Use in Premanufacture (Mining)
Jack Jeswiet, James Archibald, Ursula Thorley, E. De Souza
(Canada)
The product material supply chain starts with stage 1 in manufacturing. In Life Cycle Analysis (LCA) or in an SLCA (streamlined LCA) this is premanufacture. Ideally the first stage starts with recycled material, however most material comes from mining, and will do so for the foreseeable future. The first stage has five elements: material, energy, solids, liquid and gas. Important considerations are water use (liquids), emissions (toxicity and carbon) and energy consumption. This paper considers energy use in mining extraction, in particular energy consumption by equipment such as LHD’s (Load-Haul-Dump machinery) and by HVAC systems.
1700
A big data analytics approach to develop industrial symbioses in large cities
Song Bin,Yeo Zhiquan, Low Sze Choong Jonathan, Derek Koh Jiewei, Denis Kurle, Felipe Cerdas, Christoph Herrmann
(Singapore)
A big problem for industry and large cities is the increasing waste streams from households as well as industries and their impacts to the environment. Treatment of the waste is expensive, and cities face challenges on waste disposal sites. A sustainable solution would be to realize industrial symbioses. The typical approach is to design and develop industrial parks each of which is aimed to be an industrial symbiosis. This approach is proven by successful cases, but is constrained by land scarce cities as well as the limited types and scales of the companies that can be included in an industrial park. The paper proposes a big data analytics approach to realize industrial symbioses among the industries in a city's close proximity. The waste streams and resource requirements of existing companies are identified and matched with resources needs directly or indirectly through conversion processes. The viability, critical elements and technical challenges of the approach are discussed.

S17 - Eco-design
Room: Gallery 1
Chair: Prof. Y. Umeda
 
1600
Accounting the impacts of waste product in package design
Tim Grant, Victor Barichello, Leanne Fitzpatrick
(Australia)
In Life Cycle Assessment (LCA), packaging has historically been considered environmentally damaging due to its material use and issues with disposal at the end of it life. Consumers’ relationship with packaging is short-lived with the focus of desire being the product contained in the package. Once received, the packaging is no longer required and in certain circumstances leads to waste management issues. Packaging designers however have long since known that the primary function of the packaging is to deliver the product to the consumer in such a way that the product is protected and its value possibly enhanced. However, to date packaging design tools which evaluate the environmental performance of packaging design have ignored the product delivery function, or at least considered it to be equivalent in all cases. The packaging quick evaluation tool (PIQET) is expanding its evaluation to incorporate product production impacts, product loss and the disposal of product loss into the life cycle of packaging. As a screening tool, it is not practical to include detailed LCAs of all products, however using environmentally extended input/output data to calculate the ratio of product to packaging impact allows providing sufficient guidance to the packaging designer as to the benefits of high quality packaging design. Even at modest waste levels, the impacts arising from product loss were found to exceed the impacts of packaging itself. The use of relative impacts from input/output data provides a way to characterize many products across different sectors; however it does not permit to show results specific to actual manufacturers.
1620
Evolving Product Information in aligning Product Development Decisions across Disciplines
Ellen Oude Luttikhuis, Jos de Lange, Eric Lutters, Roland ten Klooster
(Netherlands)
Today’s product development is fragmented across various disciplines all with their own fields of expertise. Maintaining overview in consequences and implications of decisions is difficult, since many stakeholders are involved. To optimise the product development, many methods are developed based on optimising the process of information exchange, which is required in analysing consequences and implications of potential decisions. This information exchange is often by means of communication between stakeholders. This paper describes an approach that is not based on the process, but on the product information itself, since the final product system is key in product development. The suitability of employing the Actor- Artefact network in aligning decisions across different disciplines by focusing on the evolving product information is investigated.
1640
Design and manufacturing of a sustainable pedelec
Tom Buchert, Jón Garðar Steingrímsson, Sabrina Neugebauer, The Duy Nguyen, Mila Galeitzke, Nicole Oertwig, Johannes Seidel, Randy McFarland, Kai Lindow, Haygazun Hayka, Rainer Stark
(Germany)
To facilitate the transition towards sustainable manufacturing, current practices and mechanisms for value creation need to be reconsidered along the whole product lifecycle. However, academic research on sustainability is still bound to narrow fields of applications. In this study, a multi-disciplinary research project is presented that focuses on the development of a sustainable pedal electric cycle (Pedelec) from a first idea to a ready-to-use prototype. The results of the project show how different scientific approaches for bottom-up improvement can be applied together in a concrete case. A holistic view on the product lifecycle proved as a meaningful framework for that purpose.
1700
Module based renewal planning of energy using products for reducing environmental load and life cycle cost
Hiroki Iijima, Saya Yoshida, Shozo Takata
(Japan)
For products whose environmental load during operation is significant, frequent product renewal could be a better option over the life cycle than longer use with intensive maintenance. However, such frequent renewal could result in an excess consumption of resources. To address such a problem, we propose the concept of module-based renewal in which only the modules that mainly contribute to the energy consumption are replaced. The concept is applied to the air-conditioning system of a commercial building to illustrate the effectiveness of such an approach. The results of a life cycle simulation show that module-based renewal is superior to whole renewal in terms of environmental load, resource consumption, and life cycle cost.

S18 - Sustainability in Supply
Room: Gallery 2
Chair: Dr B. Kornfeld
 
1600
Sustainability in the supply chain through synchronization of demand and supply in ETO-companies
Patrick Dallasega, Erwin Rauch, Dominik T. Matt
(Italy)
In the Engineer-to-Order (ETO) industry every product is unique and therefore, engineering design, production and installation is made to the specific customer order (batch-of-one production). Traditionally, Engineering, Fabrication and Installation work as separate departments connected in series. This means that customer orders are pushed from Engineering to the Installation on-site which causes long lead times, inefficient material transport and high and uncontrolled levels of Work-in-Progress (WIP). As a result, resource inefficiencies occur (costly labour delays) when the required quantity or quality of drawings or materials is not on hand in fabrication and on-site. This work presents a concept for aligning demand with supply using the Constant Work in Progress (CONWIP) control circuit and thus enabling a sustainable supply chain for ETO-companies. An industrial case study shows the current implementation in an ETO company acting as a first tier construction supplier.
1620
Coordination of a manufacturer and supply chain partners for product line design with consideration of remanufactured products
Ridvan Aydin, C.K. Kwong, Ping Ji
(Hongkong)
The coordination among supply chain partners for product line design (PLD) with consideration of remanufactured products has not been addressed in previous studies. This study aims at studying the coordination among a manufacturer, and supply chain partners using a game theoretical model for design of product lines that contain both new and remanufactured products. A multiobjective optimization model based on Stackelberg game theory is formulated to determine product line solutions, pricing decisions of supply chain partners and the product return rate for remanufacturing. A case study was conducted to illustrate the effectiveness of the proposed methodology.
1640
A system to increase the sustainability and traceability of supply chains
Michele Germani, Marco Mandolini, Marco Marconi, Eugenia Marilungo, Alessandra Papetti
(Italy)
The paper proposes a system to increase the environmental sustainability and to guarantee the traceability along the whole product supply chain. A methodology to efficiently model complex supply chains, share data between all the actors and measure the environmental sustainability, has been developed and implemented in a distributed software system. The experimental case study, realized in collaboration with a manufacturer of leather products, allowed demonstrating the effectiveness of the approach in the selection of suppliers and in the optimization of the whole supply chain, taking into account the environmental aspects together with the other constraints such as design, costs and quality.
1700
A green and economic future of inland waterway shipping
Wilfried Sihn, Heimo Pascher, Karl Ott, Sandra Stein, Andreas Schumacher, Giuseppe Mascolo
(Austria)
Presently, Central European waterways are utilized way below their capacities while traffic volume on rail and road is increasing constantly. Especially the road transport leads to high external costs caused by air pollution or congestion.Facing these problems, a new inland waterway ship called NEWS (FP7 Project, Development of a Next generation European inland Waterway Ship and logistics system) is being constructed. The resource efficiency is going to be increased by up to 30% due to the adjustable LNG-gas-electric propulsion system. Additionally the fuel consumption can be decreased by 10% due to a new hull design. The main targets of this new development are to reduce greenhouse gas emissions and other pollutants and to shift transport volumes from the road to inland waterways to enable sustainable freight transport.This new development will be integrated in a ready-to-use inland waterway transport concept to fulfil the goals for competitive and resource efficient transport of the European Commission.

 

DAY 3

Keynote 4

Room: Tyree Room

0900
Principles and Models to Promote Effectiveness in Sustainable Design
Prof. Steven J. Skerlos

Arthur F. Thurnau Professor of Mechanical Engineering and Civil and Environmental Engineering,Department of Mechanical Engineering, The University of Michigan (UM)

Sustainable design of breakthrough technology systems is fantastically challenging.  Think up a technology that protects the environment and perhaps a business model cannot be developed for it.  Think up a business model that resonates with the market and consumers use so much of the technology that Earth would have been better without it.  In the meantime the landscape is constantly shifting due to transient regulations.  This presentation focuses on two models for evaluating the effectiveness of would-be sustainable designs that simultaneously evaluate market success, environmental impact, and meeting societal needs under regulatory constraints.  One model is geared towards introducing new product categories via entrepreneurial ventures and the other model is geared towards mature and highly competitive products in oligopolistic markets.   Commonly cited sustainable design principles are evaluated for their effectiveness and utility in the context of advancing sustainability in practice.  

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Keynote 5

Room: Tyree Room

0930
The Positive Impact Factory: Transition from Eco-Efficiency to Eco-Effectiveness
Prof. Dr.-Ing. Christoph Herrmann

Professor for Sustainable Manufacturing & Life Cycle Engineering and co-director, Institute of Machine Tools and Production Technology (IWF), Technische Universität Braunschweig

Manufacturing of products and goods contributes to more than one-third of the global CO2 emissions caused by humankind mainly due to combustion of fossil fuels. Against the background of an exponentially growing world population and an increasing global affluence the CO2 emissions from manufacturing industry will very likely surpass the threshold regarding a 2°C peak warming. Current measures to reduce the emissions primarily focus on eco-efficiency, seeking mainly for minimized energy demand and to a smaller extend also for minimized resource consumption. However, this strategy of just “making things less bad” will not sufficiently be able to overcome the aforementioned challenges and it can not constitute an adequate long term solution for manufacturing. Instead eco-effectiveness needs to be aspired, containing manufacturing systems which lead to a positive recoupling between economy and ecology. Contemporary trends and solutions in industry prove that the metamorphosis towards eco-effectiveness has already started and is speeding up. This contribution gives an overview about related requirements for manufacturing and responds with a concept of a Positive Impact Factory. An evaluation methodology with suitable criteria is derived and applied to practical examples, allowing an evaluation of a factories’ stage towards a Positive Impact Factory.

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S19 - Energy and Resource
Room: Tyree Room
Chair: Prof. J. Sutherland
 
1030
An energy analysis of electric and pneumatic ultra-high speed machine tool spindles
Paul Harris, Barbara Linke, Stephen Spence
(US)
There is a growing demand for ultra-high speed precision machine tool spindles to create complex miniature devices and features, in consumer markets such as medical devices, electronics and communications. The key enabling drive technologies for spindle rotational speeds in the 100,000 rpm range includes electric motors, both AC and DC powered, and air turbines. In particular for high speed micromachining, turbine spindles have advantages in terms of precision and cost. A widely considered drawback of pneumatic technology though is low energy efficiency, but to date there has been little in depth analysis of commercial/state-of-art turbo-spindle energy performance. This paper provides a holistic comparative analysis of electric motor and turbine powered spindle electrical power requirements, by including the power demand of supporting systems and infrastructure. The analysis indicates that at present the energy usage associated with turbine spindles is significantly higher than electric spindles. However, a number of technically feasible energy efficiency measures are identified for turbine spindles, which would make their energy performance comparable with electro-spindles. The analysis and results will contribute towards an overall life cycle assessment of high speed turbo-spindle technology, and provide impetus to further explore energy optimization approaches and methods.
1050
Vibration Analysis and Energy Efficiency in Interrupted Face Milling Process
Hugo M. B. de Carvalho, Jefferson de Oliveira Gomes, Marco Antonio Schmidt, Vitor L.C. Brandão
(Brazil)
The planning of a face milling process determines how the milled part is produced: an incorrect or incomplete planning process will result in a loss of productivity. This paper proposes that loss of productivity be avoided by including vibration analysis and consideration of energy efficiency in the development of face milling processes for interrupted cutting. A new methodology was developed for inclusion of vibration analysis and consideration of energy efficiency in the design of face milling processes. A case study was examined in which the new methodology was applied to the milling process for an automotive engine block.
1110
Holistic Simulation Environment for Energy Consumption Prediction of Machine Tools
Eberhard Abele, Steffen Braun, Philipp Schraml
(Germany)
Resource efficiency and energy consumption more and more become high-profile quality attributes of modern machine tools. The energy consumption of machine tools, plants and facilities must be significantly reduced related to the value added in order to stay competitive, but not least in liability towards our environment. This article presents a model based simulation and prediction of the expected energy consumption of machine tools using a comprehensive simulation environment, which serves as a basis for energetic optimizations. The simulation system will be exemplarily presented by reference to turning and milling operations. This system is extended by adaptive control and optimization of the energy states of the machine tool through application of artificial neuronal network controller networks and additional expert knowledge data-base.
1130
Quantifying green manufacturability of a unit production process using simulation
Amandeep Singh, Deepu Philip, J. Ramkumar
(India)
Consumer awareness towards environment and sustainability is on the rise, which is forcing industry to face the challenge of balancing economic and monetary priorities against environmental and social accountabilities. New methods and techniques are being developed to cater these challenges in an efficient way. This work aims to develop a roadmap to convert a unit manufacturing process more ‘green’ by minimizing resource utilization. Live laboratory experiments were conducted to model various factors influencing the ‘greenness’ of the unit process which was surface grinding. We evaluated various control strategies (factor settings) using ABC algorithm, implemented in a numerical simulation mode. The experimental data suggested significant improvement on the Green Index of the process.
1150
Characterising energy efficiency of electrical discharge machining (EDM) processes
Wen Li, Sami Kara
(Australia)
Energy efficiency in manufacturing has become a critical topic among researchers and industries. As a result, there has been a worldwide effort to improve the transparency of the energy efficiency for all manufacturing activities. The studies of unit processes have provided fundamental knowledge for characterising energy efficiency of manufacturing processes, which has been initially applied to conventional processes (e.g. turning, milling, injection moulding, etc.). However, studies in nonconventional manufacturing processes remain absent. This paper presented an empirical approach to characterise the energy efficiency of electrical discharge machining (EDM) processes. The derived model revealed a reverse relationship between specific energy consumption and material removal rate (MRR). Owing to the stochastic nature of EDM processes, the existing analytical and semi-empirical MRR models cannot practically predict the MRR. Alternatively, the empirical approach was also applied to test different theoretical MRR models and to derive coefficients for prediction purpose. As a result, the combined empirical models can predict the energy consumption of EDM processes with an accuracy of more than 90 %. This methodology has been tested and validated for two ram EDM machines.
1210
Technical Performance and Energy Intensity of the Electrode-Separator Composite Manufacturing Process
Jan Schmitt, Gerrit Posselt, Franz Dietrich, Sebastian Thiede, Annika Raatz, Christoph Herrmann, Klaus Dröder
(Germany)
Energy storage is one of the key technological factors that determine the success of a sustainable future. Especially green mobility concepts for electric or hybrid electric vehicles highly depend upon storage technologies with high energy density and light-weight materials. At the same time, innovative production processes should be conceived that ensure energy and resource efficient manufacturing of these energy storage devices. This paper focuses on the technical as well as dynamic energetic performance analysis and evaluation of an innovative electrode-separator composite manufacturing process of lithium-ion batteries for automotive applications. The technical performance indicators such as battery capacity and the energy intensity of the manufacturing process are highly dependent upon process parameters, machine and product design. Hence, in-depth process knowledge must be acquired to understand interdependencies between all system components. Thus, the manufacturing process is analysed in terms of its dynamics, and correlations between process parameters, process energy demand and final product properties are assessed. The resulting knowledge is important for the subsequent design of large-scale products and processes involved design, as well as for characterisation of the manufacturing process for life cycle inventory databases or life cycle costing calculations.

S20 - Sustainability in Product-Service systems
Room: Gallery 1
Chair: Prof. T. S. Spengler
 
1030
Data-oriented technical complaint management for sustainable problem solution
Alexander Linder, Robert Schmitt
(Germany)
Research on technical complaint management has shown that it can be a driver of product quality improvements. Systematic handling and analysis of customer complaints, throughout the whole product lifecycle, has a significant positive impact on future products‟ quality. Nevertheless, the results of an empirical study within the machine tool industry provide evidence, that long-term effects for future product generations are rarely achieved. Based on this study, the paper examines reasons for this lack of sustainability in quality improvements. An approach to data-oriented technical complaint management is presented, which focuses on the transformation of complaint information to failure knowledge and its use for long-term quality improvements.
1050
A Study on Optimum Circulation Period of Products for Minimizing Lifecycle Energy Consumption
Yuji Mizuno, Naoya Kintoki, Yusuke Kishita, Shinichi Fukushige, Yasushi Umeda
(Japan)
Combination of long product lifetime and recycling is effective for reducing material use. However, in the case of products that uses energy in their use phase, early replacement of old products with new energy efficient products may contribute to reduction of lifecycle CO 2 emission. In the previous studies, we proposed a formula to calculate optimum circulation period (OCP) of the products based on the improvement of energy efficiency. The formula was applied to the products produced in 1991-2000. This paper calculates the OCP of the latest products and analyzes the effect of rapid circulation of products. As a result, OCP and RCP effects are different from the previous studies, because characteristics of latest products are different from products of 1991-2000. Especially, OCP of Hybrid Electric Vehicles excesses three times than the normal product life span. Special case of rapid circulation between different type products, such as Gasoline Vehicles and Hybrid Electric Vehicles was effective for CO 2 emission reduction.
1110
Target-oriented Modularization - Addressing Sustainability Design Goals in Product Modularization
Friedrich A. Halstenberg, Tom Buchert, Jérémy Bonvoisin, Kai Lindow,Rainer Stark
(Germany)
Through modularization, a large range of sustainability goals can be addressed in design, e.g. environmentally friendly end-of-life or improved MRO (maintenance, repair and overhaul) processes. The development of methods for product modularization raised increasing interest in recent years. However, published methods for product modularization still lack of flexibility and standardization. Numerous methods have been developed that are defined for one or a given list of design goals. As a result, it is still difficult for engineers to find and apply the right method for a defined set of design goals. In this paper, the field of modular product design methods has been analyzed with the aim to develop a Target- oriented Modularization Method that allows defining modular product structure according to user-defined design goals. The introduced method is demonstrated on the example of a Garrett GT2860R turbocharger.
1130
Growing Near Net Shape Components from Renewable Materials
Manuel Löwer, Anna-Lena Beger, Iliyas Raza, Jörg Feldhusen, Alexandra Wormit, Jürgen Prell, Björn Usadel, Thomas-Benjamin Seiler, Christoph Kämpfer, Henner Hollert, Martin Trautz
(Germany)
The integration of natural materials in today’s product development gains more and more importance. Society’s demand for ecologically produced and sustainably operable goods is a key driver for material scientists and engineers to substitute conventional substances such as metals or plastics. In addition, the entire lifecycle sets multiple requirements for the product developers entailing strategies for reuse and recycling. Most of these eco-design approaches are limited to the selection of the right material and the industrial processing, to shape and manufacture to the desired design. The authors of this contribution are scientists from the areas of cell-biology, eco-toxicology, structural-, engineering- and industrial-design, and teamed up to use directed natural growth of bio-materials (e.g. plants). The aim is to minimize conventional production steps and decrease the amount of resources for manufacturing. In the first step the team categorizes and analyzes potential plants in general and on a structural cell level. In addition, requirements for different sorts of products are defined, and matching parts of both databases are identified. The full paper will show first results and research of the potential function-plant relation and will give an overview of characteristic parameters for the holistic evaluation of near net shape grown products. These include exemplarily the amount of fertilizer needed, ecotoxicological implications, plant area needed, growth time, mechanical properties, design restrictions and possible surface quality.
1150
Immaterial elements as drivers of sustainability in products and services
Julio Cesar Rivera P., Bernabé Hernandis O., Sheila Cordeiro M., Omar Miranda O.
(Spain)
The purpose of this study is to analyze aspects, needs, values, emotions and desires of users/consumers as part of the Immaterial Dimension and its connection to Sustainability. As hypothesis suggests that a greater knowledge of the behaviour of users/consumers, can be identified needs, emotional aspects and/or values which are directly related to sustainability. It may be possible through a systemic approach which is both multidisciplinary and multiobjective wherein the Outer System of the Concurrent Design Model is analyzed; identifying components belonging to the immaterial context and at the same time are related to sustainability. Hence arises it is necessary to go beyond physical product and product experience, since the point of interest is analyze the immaterial context in addition to material context, to identify how from this intangibility may be identify some key points to achieve sustainability.
1210
Maintenance decisions of part agent based on failure probability of a part using Bayesian estimation
Keisuke Nanjo, Yuki Yamamori, Yumihito Yokoki, Yuta Sakamoto, Hiroyuki Hiraoka
(Japan)
To realize effective reuse of mechanical parts for the development of a sustainable society, it is essential to manage individual parts over their entire life cycle. For that purpose, we are developing a part agent system using network agents. This paper describes a method for a part agent to predict possible states of its corresponding part in the near future. Bayesian network is applied to estimate a failure probability of the part and a simple deterioration model is applied to evaluate properties of the part. Initial results are shown on a life cycle simulation of the developed part agent.

S21 - End of Life Strategies
Room: Gallery 2
Chair: Prof. K. S. Sangwan
 
1030
Defining Circulation Factories - A pathway towards Factories of the Future
Felipe Cerdas, Denis Kurle, Stefan Andrew, Sebastian Thiede, Christoph Herrmann, Yeo Zhiquan, Low Sze Choong Jonathan, Song Bin, Sami Kara
(Germany)
Manufacturing companies are increasingly perceived not only on the basis of their products but also of their factories and their embedding within the environment. For this reason, both existing and future factories face the challenges posed by a dynamic and changing market environment. Thus, a gradual change from a throughput to a circular economy leads to the emergence of two categories of factory systems. One category is producing goods, while the second one is recovering and treating waste, residues and the rest of the product at the end of its life. Against this background, this paper introduces the concept of Circulation Factories which combines manufacturing with remanufacturing and recycling into one integrated system. Circulation Factories will enable the realization of an industrial symbiosis transferring waste to value. Drivers and challenges are discussed.
1050
Prerequisites for a high-level framework to design sustainable plants in the e-waste supply chain
Ilaria Barletta, Björn Johansson, Johanna Reimers, Johan Stahre, Cecilia Berlin
(Sweden)
Currently few attempts to properly structure knowledge that specifically supports a fully sustainable e-waste treatment system design have been proposed in literature. As a result, this paper sets up the prerequisites for a high-level framework to design sustainable plants in the supply chain of e-waste. The framework addresses production and environmental engineers mainly. The methodology grows out of literature studies, research project’s outcomes and interviews with a group of sector experts. Stemming from this, a list of prerequisites was presented for the case study of an automated plant for e-waste sorting in order to design it while considering the triple-bottom-line of sustainability.
1110
Conceptualizing ReX for aggregating end-of-life strategies in product development
Siru Sihvonen, Tuomas Ritola
(Finland)
Efforts towards a circular economy are accelerating and gaining more attention. Since product’s lifecycle is mostly determined during early product development phases, it is crucial to support those phases with explicit strategic directions. This paper examines the possibility to aggregate various definitions of end-of-life (EoL) strategies in a visually compelling way. We propose a taxonomy for communication between multidisciplinary product development teams using ReX, an abbreviation for alternative EoL strategies starting with prefix ‘Re’, such as reduce, reuse, repurpose, repair, remanufacture, recycle, and recover. We construct our taxonomy based on a) EU Waste Directive, b) a systematic literature review, and c) relevant theoretical constructs. Then we discuss whether ReX allows assessing potential EoL alternatives, and steering the product development efforts. Finally, we suggest ReX for supporting decision-making when several stakeholders are involved, common language is sought for, and significant EoL related decisions are made at the early phases.
1130
Proposal of a Closed Loop Framework for the Improvement of Industrial Systems' Life Cycle Performance: Experiences from the Linked Design Project
Daniele Cerri, Marco Taisch, Sergio Terzi, Andrea Buda, Kary Framling, Soumaya El Kaddiri, Ana Milicic, Dimitris Kiritsis, Simone Parrotta, Eric Peukert
(Italy)
The context where European manufacturers of industrial systems operate has dramatically changed over recent years: the pressure of emerging countries they have to face, policy makers’ environmental laws and industrial companies’ interests are pushing towards sustainable manufacturing and a holistic view of industrial systems. Designers and system engineers are the main actors involved, because they have high influence on product life cycle costs and environmental impacts. However they need tools to pursue a holistic view. The aim of this paper is to propose a closed loop framework to improve life cycle performances of industrial systems, focusing on the automotive sector.
1150
Machine-based Dismantling of End of Life Vehicles: A Life Cycle Perspective
Ezzat El Halabi, Mike Third, Matthew Doolan
(Australia)
Recent trends in the proper management of End of Life Vehicles have led some auto recyclers to adopt machine-based dismantling to improve their yield. The machines are modified excavators that allow a greater degree of control and force for vehicle disassembly. We present and discuss the results of a 3-month real world trial conducted at an Australian auto dismantler assessing the environmental impact of using a multi-dismantling machine for material segregation. The results suggest that this process is a better alternative to the current norm used by metal recyclers, shredding followed by shredder output separation, in terms of environmental impact but not energy consumption.
1210
Network Design and Optimization for Multi-product, Multi-time, Multi-echelon Closed-loop Supply Chain under Uncertainty
Anil Jindal, Kuldip Singh Sangwan, Sachin Saxena
(India)
This paper proposes the network design and optimization of a multi-product, multi-time, multi-echelon capacitated closed-loop supply chain in an uncertain environment. The uncertainty related to ill-known parameters like product demand, return volume, fraction of parts recovered for different product recovery processes, purchasing cost, transportation cost, inventory cost, processing, and set-up cost at facility centers is handled with fuzzy numbers. A fuzzy mixed-integer linear programming model is proposed to decide optimally the location and allocation of products/parts at each facility, number of products to be remanufactured, number of parts to be purchased from external suppliers and inventory level of products/parts in order to maximize the profit to the organization. The proposed solution methodology is able to generate a balanced solution between the feasibility degree and the degree of satisfaction of the decision maker. The proposed model has been tested with an illustrative example.

S22 - Energy and Resource Efficiency: a process view (2)
Room: Tyree Room
Chair: Prof. Ö. S. Ganiyusufoglu
 
1330
Customer Integration To Gain Cost Efficiency Alongside Tool's Life Cycle
Günther Schuh, Martin Pitsch, Thomas Kühn
(Germany)
Todays efforts to optimize industrial production processes exceedingly focus on tools’ life cycle costs. Toolmaker and its customer are the two entities influencing tools’ life cycle costs. Due to lack of information exchange neither life cycle assessment nor cost efficient life cycles can be realized. An effective lever for penetrating information exchange and therefore gaining cost efficiency alongside tool’s life cycle is the integration of the toolmaker into the value creation process of its customer. The so called customer integration succeeds through innovative product-service systems alongside tools’ life cycle networking the value creation processes of toolmaker and tool user. As the findings of research project TEC in this paper practical solutions for realizing customer integration are introduced and measures for gaining life cycle cost efficiency alongside tool’s life cycle are explained.
1350
Addressing sustainability and flexibility in manufacturing via smart modular machine tool frames to support sustainable value creation
Bernd Peukert, Stephan Benecke, Janire Clavell, Sabrina Neugebauer, Nils F. Nissen, Eckart Uhlmann, Klaus-Dieter Lang, Matthias Finkbeiner
(Germany)
Sustainability and flexibility are crucial aspects in todays’ manufacturing processes. Within this study an innovative approach of modular ma- chine tool frames (MMTF) equipped with micro system technology is presented that aims at enhancing flexibility of mutable production pro- cesses. This new approach extends the existing reconfigurable manufacturing systems (RMS). MMTF goes beyond the platform approach via minimizing the machine tool frame parts used for the building block system of manufacturing cells. The concept has been realized by integra- tion of modularized microelectronics and actuators enabling for integrity and accuracy of the machine tool frame. In this contribution, sustainable hotspots for the production of the MMTF are identified via a tiered life cycle sustainability assessment. From these findings, new approaches are derived that provide for a reasonable usage of mechanical and electronic components in MMTF for sustain- able value creation.
1410
How services influence the energy efficiency of machine tools: A case study of a machine tool manufacturer
Gülsüm Mert , Sebastian Waltemode, Jan C. Aurich
(Germany)
The development of machine tools is driven by the requirements of the customers and by the action of the competitors. More and more customers demand energy efficient machine tools to lower their energy consumption and reduce their energy costs. Machine tool manufacturers respond to the requirements of the customers and offer machine tools with energy efficient components. Besides optimizing technical components of machine tools, services can also increase the energy efficiency. This paper demonstrates that services not only raise the customer benefit but also offer a possibility to improve Key Performance Indicators regarding energy efficiency. It will be presented how services can improve the energy efficiency of a machine tool based on a case study of a machine tool manufacturer. First, the life cycle of a machine tool will be analyzed. Secondly, the energy efficiency will be assessed and services which increase the energy efficiency will be identified. Finally, impacts of the services on the energy efficiency of a machine tool will be evaluated.
1430
Life cycle oriented milling tool management in small scale productions
Dominik Heeschen, Fritz Klocke, Kristian Arntz
(Germany)
The milling technology is characterized as the most important manufacturing technology in a variety of industries. Moreover, recent developments in hardware and software issues have increased technology‟s complexity which is, beyond others, caused by different milling variants and a high number of different milling tools. Milling tools are responsible for a significant cost position in manufacturing driven companies which is shown in the paper by an industry wide survey. Due to the costly and wasteful production it can be shown that this is a significant cost driver. This paper introduces an integrated life cycle oriented approach for the standardization and optimization (including the reuse of tools by standardized repair processes) of milling tools in order to enhance the life cycle of milling tools, reduce overall costs and therefore raise the company‟s sustainability.
1450
Data Collection for Energy Monitoring Purposes and Energy Control of Production Machines
Eberhard Abele, Niklas Panten, Benjamin Menz
(Germany)
Data collection is one major prerequisite for energy efficient production facilities, enabling further analyses by assessing KPIs, condition or status monitoring applications and direct feedback or evaluation of efficiency measures. This paper presents a standardized approach to collect energy relevant data of production machines and their components on the PLCs. Energy data can both be directly monitored on a connected HMI or made available for standard interfaces and saved on a generic data server for monitoring and further computation using Matlab DLLs. Besides monitoring aspects, an approach is presented for empowering machine PLCs with energy control functions, allowing them to switch energy modes (e.g. standby, production-ready, operational) to reduce energy costs and CO 2 emissions. An implementation of the energy monitoring and control approach on a milling machine is presented in detail, followed by an overview of its use for energetic optimization.
1510
Optimization of Machining Parameters to Minimize Surface Roughness using Integrated ANN-GA Approach
Kuldip Singh Sangwan, Sachin Saxena, Girish Kant
(India)
The surface roughness is a widely used index of product quality in terms of precision fit of mating surfaces, fatigue life improvement, corrosion resistance, aesthetics, etc. Surface roughness also denotes the amount of energy and other resources consumed during machining. This paper presents an approach for determining the optimum machining parameters leading to minimum surface roughness by integrating Artificial Neural Network(ANN) and Genetic Algorithm (GA). To check the capability of the ANN-GA approach for prediction and optimization of surface roughness, a real machining experiment has been referred in this study. A feed forward neural network is developed by collecting the data obtained during the turning of Ti-6Al-4V titanium alloy. The MATLAB toolbox has been used for training and testing of neural network model. The predicted results using ANN indicate good agreement between the predicted values and experimental values. Further, GA is integrated with neural network model to determine the optimal machining parameters leading to minimum surface roughness. The analysis of this study proves that the ANN-GA approach is capable of predicting the optimum machining parameters.

S23 - Technical solutions with life cycle thinking
Room: Gallery 1
Chair: Prof. J. Jeswiet
 
1330
Minimization of the energy consumption in motion planning for multi-robot tasks
Stefania Pellegrinelli, Stefano Borgia, Nicola Pedrocchi, Enrico Villagrossi, Giacomo Bianchi, Lorenzo Molinari Tosatti
(Italy)
Recently, the importance of sustainable manufacturing has been widely discussed. The optimization of energy consumption in product manufacture has been deeply analyzed, mainly focusing on the energy directly absorbed by the manufacturing process. On the contrary, this paper focuses on the analysis and optimization of the energy consumption related to auxiliary robotic assembly processes, contributing to the identification of sustainable manufacturing strategies for pick and place robots. It proposes a methodology for the automatic generation of robot trajectories and the sequencing of the robot task, while minimizing the energy consumption. A probabilistic roadmap is created to identify a collision-free and minimum energy consumption trajectory for each couple of feasible tasks. Trajectory power consumption is evaluated exploiting dynamic information coming from the real robot motion planner using a model that takes into account the energy behavior of motors and drives and their operative conditions. A set of generated trajectories is selected, defining the task sequence and minimizing the robot cycle time. The differences between the results deriving by employment of the energy consumption minimization criterion versus time minimization criterion are presented through a simplified case.
1350
Resource efficiency optimization of manufacturing processes using evolutionary computation
Frank Kübler, Johannes Böhner, Rolf Steinhilper
(Germany)
Most resource efficiency optimization measures being discussed in resent publications focus on component downsizing and adaptive control of components regarding the standard ISO 14955. Optimization of discrete manufacturing process parameter is a further approach to reduce resource consumption during operation. This paper presents a meta heuristic genetic algorithm approach which has been used to determine a pareto front of feasible machining parameter. The pareto front is used to select optimal solutions for the resource consumption integrated multi- dimensional optimization task. The results are presented for a turning process with respect to resource consumption, machining time and machining cost under product quality constrains and machine performance limits.
1410
Supercritical CO2 cleaning of carbonaceous deposits on diesel engine valve
Weiwei Liu, Xiaochuan Qing, Mingzheng Li, Lihong Liu, Hongchao Zhang
(China)
Carbonaceous deposits can reduce the durability and performance of diesel engines. Chemical cleaning methods are widely used to remove the deposits in remanufacturing industry but the wasted liquid is harmful to the environment. In this paper the supercritical CO 2 cleaning technology, an environmentally friendly approach, has been used to remove these contaminants. The surfaces of diesel engine valve before and after cleaned were examined by field emission scanning electron microscope (FE-SEM) and Fourier transform infrared spectroscope (FT-IR). The testing results showed that most organic compounds were dissolved and the stubborn contaminants were changed to be removed easily after cleaning by supercritical CO 2 fluid. The new cleaning method can reduce carbonaceous deposits significantly without changing the surface properties of the diesel engine valve.
1430
Reducing the development life cycle of automotive valves and seat valves using a new workbench for high temperature wear testing
Luis Alberto Breda Mascarenhas, Jefferson de Oliveira Gomes, Andrey Teixeira Portela, Cristiano Vasconcellos Ferreira
(Brazil)
he trend in the automotive industry is to reduce the size of engines while increasing power. The concept of leveraging considers not only the efficiency of manufacturing a product but all consumption of energy or other natural resources during the life cycle of the product. In this process, one of the bottlenecks to more efficient engines is the exhaust valve. The valve and valve seat together perform the function of ensuring the entry of air and combustible material, the output of combustion gases and the sealing function during the compression and combustion processes. The valve is the most demanding component in high efficiency engines. To ensure the rigor of operation while providing clean burning and low emissions, the application of special materials is necessary. The extremely high temperatures of the exhaust gases, the velocities of valves and the high operating pressure are only some of the parameters that cause wear on valves. The materials used in valve production must be characterized by good workability, low wear, good mechanical strength and good fatigue and corrosion resistance at high temperatures. In this context, the CCM / ITA and SENAI CIMATEC jointly developed a workbench to simulate the durability of valves and valve seats, analyze their wear resistance and evaluate their behavior with varying parameters. This paper shows the workbench development process and a new testing method that considers the high engine operation temperatures and focuses on reducing the new material development life cycle and the emissions during the product usage life time.
1450
Efficiency and Environmental analysis of a systems for renewable electricity generation and electrochemical storage of residential buildings
Michele Germani, Daniele Landi, Marta Rossi
(Italy)
This study presents an approach for the evaluation of the energy efficiency and environmental impacts of a new modular and integrated system of renewable electricity generation and intelligent electrochemical storage systems, that allows auto-production and self-consumption of electricity in residential buildings. Homes with installed these renewable energy production systems are compared from an environmental and economic point of view, to the traditional ones, that draw electricity energy directly from the grid. In this context different scenarios are considered together with different configurations of power production and storage capacity, in order to compare different use cases. To this end, the environmental impact along all the life cycle of these systems is examined with the help of the SimaPro software simulation tool and quantitatively assessed.
1510
A cost and resource consumption model for improving resource-efficiency of configurable roll-to-roll processing
Yeo Zhiquan, Ng Ruisheng, Song Bin
(Singapore)
Roll-to-roll (R2R) processing is the process of creating functional films and printed electronic devices, such as printed RFID and printed lighting, by integrating various large area manufacturing processes into a single manufacturing line. It is poised to be a low-cost and efficient manufacturing technology. However, uncertainty and risk exists for the production of specific products in competition with conventional manufacturing approaches. Therefore, a configurable cost and resource consumption model was developed in order to assess the resource effectiveness of the R2R processing line for a specific product design and to identify areas of improvement. The model considers the technical and parametric relationships in terms of cost, manpower, materials, energy consumption and resource requirements. Using the model, hotspots in the manufacturing line were identified and appropriate recommendations were suggested to minimize resource usage and waste, thereby further reducing the cost of manufacturing and enhancing its commercial viability.

S24 - Energy and resource efficiency of cutting fluid strategies
Room: Gallery 2
Chair: Prof. S. Skerlos
 
1330
Cutting fluid drag-out and exhaust air in grinding processes: Influence on the eco-efficiency
Nadine Madanchi, Marius Winter, Christoph Herrmann
(Germany)
In grinding cutting fluids are crucial to enable an efficient cutting process and to achieve a positive surface quality. Moreover, cutting fluids are also important regarding the eco-efficiency. A relevant share of cutting fluid is lost due to drag-out via chips, workpiece, evaporation and exhaust air. Especially the latter depends on the selected process setting and thus represents a manipulable factor. Therefore this paper presents a method to measure the exhaust air related drag-out. Based on experimental studies influencing parameters are investigated and their impact on eco-efficiency is discussed.
1350
Adaptive and adequate lubrication for highest component-lifetimes in feed drive axes with ball screws
Jürgen Fleischer, Andreas Spohrer, Urs Leberle, Steffen Dosch
(Germany)
This paper presents an approach to raise the resource-efficiency of machines with ball screw based feed axes over their whole life cycle. Core of the approach is the usage of adaptive lubrication, which supplies optimal amounts of lubricant to the ball screw. This leads to increased lifetimes, reduced friction torques and more sustainability due to less consumption of lubricant. Therefore the resource-efficiency of feed axes is significantly enhanced. With a test rig the adaptive lubrication was validated by performed lifetime tests. Within the tests conventional non-adaptive lubrication was compared to adaptive lubrication. Results are lubricant savings and significant increases in component-lifetimes of approximately 70 %.
1410
Effectiveness of minimizing cutting fluid use when turning difficult-to-cut alloys
Paolo C. Priarone, Matteo Robiglio, Luca Settineri, Vincenzo Tebaldo
(Italy)
The environmental impact of lubricants is a key issue towards sustainable manufacturing. Even if dry cutting can be identified as the ultimate goal to achieve, lubrication is still a hardly surmountable industrial standard when machining difficult-to-cut alloys. In order to reduce the pollutant emissions and the problems related to the workers’ health, alternative systems as Minimum Quantity Lubrication (MQL) or Cooling (MQC) have been emerging over the years. This research aims to investigate the machinability of a Ti-48Al-2Cr-2Nb (at. %) alloy, applying low cutting fluid (water and emulsion) volumes to the cutting area in the form of a precision-metered droplets mist. The results in terms of tool wear/life, surface quality, lubricant consumption, and environmental impact are discussed with reference to those of MQL, wet and dry cutting. The experimental evidences show that, as far as tool life is concerned, the use of an emulsion mist is an advantageous strategy in comparison to MQL and dry cutting. Moreover, the flow rate and the type of cutting fluid are variables significantly affecting the process performance.
1430
Methodology of process oriented dimensioning of cooling lubricant pressure and volume flow for increasing resource efficiency
Benjamin Döbbeler, Fritz Klocke, Dieter Lung
(Germany)
In machining processes, especially when cutting difficult to cut materials such as nickel based or titanium alloys, the cooling lubricant supply strategies are often based on empirical knowledge. Notably, supply pressure and volume flow are key parameters which can be adapted even though they are partially interdependent. Mostly, these parameters are set too high to assure process stability, resulting in unnecessary energy and cooling lubricant consumptions. Within this paper, a methodology for dimensioning the necessary cooling lubricant supply and pressure is presented. In order to increase energy efficiency, the cooling lubricant supply pressure and volume flow will be adapted corresponding to the cutting process.
1450
Investigation into alternative cooling methods for achieving environmentally friendly machining process
Yogie Rinaldy Ginting, B. Boswell, Wahidul Biswas, Nazrul Islam
(Australia)
The machining of metals has traditionally involved the use of large quantities of water and oils for dissipating the cutting tool temperature, improving the surface finish of parts and increasing tool life. Invariably, the cutting fluid has become contaminated with use, has required being environmentally disposed and has accounted for approximately 17% of the total production cost of parts. A Streamline Life Cycle Assessment (SLCA) of machining of parts has been carried out to investigate the environmental and energy saving benefits associated with the replacement of traditional cooling method, with Minimum Quantities of Liquid (MQL) combined with cold compressed air.
1510
Energy efficient process chain: The impact of cutting fluid strategies
Nadine Madanchi, Denis Kurle, Marius Winter , Sebastian Thiede, Christoph Herrmann
(Germany)
Machining processes can be realized using different cutting fluid strategies – flood, dry and minimum quantity lubrication (MQL). The choice of each strategy directly influences the need of peripheral units (e.g. filter units) and additional processes within the process chain (e.g. washing). Thus, selecting an energy and resource efficient cutting fluid strategy depends not only on cutting fluid as a resource, but also on its inherent impact on the entire process chain. Therefore, this paper presents a method for decision support, considering technical boundary conditions and effects on the process chain layout as well as its application in a case study.

S25 - Energy and Resource Efficiency: a process view (3)
Room: Tyree Room
Chair: Dr S. Thiede
 
1600
Reduced commissioning time of components in machine tools through electronic data transmission
Steffen Dosch, Andreas Spohrer, Jürgen Fleischer
(Germany)
This article presents an approach to increase data availability over the life cycle of machine tool components. This includes the consideration of type-specific and instance-specific data of a machine component throughout its entire life cycle. Currently, the provision of the component data for the physical component is only realized by paper-bound data sheets. This leads to growing costs of the component through its commissioning. The presented approach proposes to store data on a RFID transponder attached to the component. In the article, a procedure to generate the optimum amount of data for instance-specific data is presented. This data are measured on a test bench, processed to generate the values and finally linked with the component over the whole life cycle. This enables increasing efficiency of the component by reducing the commissioning time during its life cycle.
1620
Analysis of tool utilization from material removal rate perspective
A. E. Bonilla Hernández, Tomas Beno, Jari Repo, Anders Wretland
(Sweden)
An end of life strategy algorithm has been used to study a CNC program to evaluate how the cutting inserts are used in terms of their full utilization. Utilized tool life (UTL) and remaining tool life (RTL) were used to evaluate if the insert has been used to its limits of expected tool life, or contributing to an accumulated tool waste. It is demonstrated that possible means to improvement exists to increase the material removal rate (MRR), thereby using the insert until its remaining tool life is as close to zero as possible. It was frequently found that inserts were used well below their maximum performance with respect to cutting velocity.
1640
Innovative High-Performance Ceramics - Challenge for the Life Cycle Engineering of Turbomachinery
Eckart Uhlmann, Martin Bilz, Jeannette Baumgarten, Tiago Borsoi Klein
(Germany)
Producers of turbomachines for the aviation and energy sectors have to meet the future challenges regarding environment protection, resource conservation and profitability. As part of the 2014 market and trend analysis on the subject of Life Cycle Engineering for turbomachinery, the market potential of the concept of Life Cycle Engineering for turbomachines as well as future trends and R&D issues have been identified. It has shown that the mechanical, chemical and thermodynamic characteristics of high-performance ceramics motivate new developments of Life Cycle Engineering in turbomachinery. However, particular material properties like high hardness and strength represent a challenge for the machining process of complex components made from high-performance ceramics. Since process and machining technologies are key components of the LCE concept, this paper will focus on the importance of a holistic hard machining of ceramic matrix composites with regard to technical and economic criteria.
 

S26 - Sustainability in Education and Research
Room: Gallery 1
Chair: Prof. C. Herrmann
 
1600
Effective Integration of Life Cycle Engineering in Education
Ellen Oude Luttikhuis, Marten Toxopeus, Eric Lutters
(Netherlands)
In practice, applying life cycle engineering in product design and development requires an integrated approach, because of the many stakeholders and variables (e.g. cost, environmental impact, energy, safety, quality) involved in a complete product life cycle. In educating young engineers, the same integrated approach should be strived for, because a mono disciplinary approach is often less effective. Therefor, direct application of the theory in practical cases is necessary. This paper describes experiences with effective LCE education using the advantages of project-led education. This is illustrated by describing LCE relevant courses and evaluation of graduation assignments incorporating successful integration of LCE elements.
1620
SimGreen: a serious game to learn how to improve environmental integration into companies
Feng Zhang, Peggy Zwolinski
(France)
The aim of this paper is to present the implementation of a new serious game called “SimGreen” to optimize the systemic programming of environmental actions into a company. Today, there are numerous environmental methods and practices developed to allow companies improving the way they try to decrease their environmental impacts. But all the existing methods are not independent and it can be helpful to consider all of them to make decision when managing the way to answer environmental objectives for a company. According to a cartography of environmental actions, which is a research result of a project named “convergence” funded by the French national research agency, we encourage the participants during the game to map all the possible environmental trajectories to answer an environmental objective. Then, we ask them to identify the most suitable environmental solutions depending on a specified context taking into account the different resources or competencies in the company. This serious game has been experimented in 8 sessions. The main feedback demonstrated that this serious game provides a joyful game to support the learning about systemic environmental integration.
1640
Enablers and Barriers of Sustainable Manufacturing: Results from a Survey of Researchers and Industry Professionals
Neeraj Bhanot, P. Venkateswara Rao, S.G. Deshmukh
(India)
Sustainable Manufacturing (SM) has gained significant importance in today’s competitive environment as many organizations still depend on natural resources and at the same time generate wastes and environmental pollution. However, the adoption of SM is a huge challenge for organizations since most of them are not aware on how to utilize the enablers and mitigate the effect of barriers of SM. This paper tends to present the opinions of various researchers around the globe and industry professionals on the important enablers and barriers and analyze them using statistical techniques to highlight the differences in opinions for strategic implementation of SM.
 

S27 - Sustainability assessment
Room: Gallery 2
Chair: Prof. W. Dewulf
 
1600
The Conceptualization of Sustainability in Operations Management
David Opresnik, Marco Taisch
(Italy)
Regardless of the pervasiveness of sustainability, a deeper understanding of sustainable operations management is still needed. The aim of this article is to provide theoretical foundations of sustainability (environmental) in operations management based on which patterns of sustainability operations strategies could be researched. Thus, sustainability (environmental) is first positioned within the enterprise on the managerial and operational level. Secondly, a framework depicting the relationships, impacts, functions and limits of sustainability as an operations strategy and as operations is designed. Among others, the need for a dedicated taxonomy of sustainability operations strategies and operations has been identified, supporting the concept’s operationalization.
1620
Sustainability Assessment in conventional and industrialized systems built in Brazil
Durval João De Barba Junior, Jefferson de Oliveira Gomes, Juliana Ferreira Santos Bastos de Lacerda
(Brazil)
Given the high amount of resources consumed and waste generated by the construction industry it was identified the need to seek for constructive systems that take into account three aspects of sustainable development - economic, social and environmental - in a balanced way. This paper aims at comparing through sustainability assessment in different industrialized building systems to the conventional system which are used in the construction of social housing in Brazil. An assessment that provides a way to improve production processes for sustainability of buildings is looked for, stimulating lower environmental impact, meeting the needs and providing conditions for their employees and users in the best cost/benefit ratio.
1640
Sustainability in Manufacturing through Distributed Manufacturing Systems (DMS)
Erwin Rauch, Matthias Dallinger, Patrick Dallasega, Dominik T. Matt
(Italy)
A growing number of manufacturing companies are working on the implementation of sustainable manufacturing and business processes. The objective of sustainable manufacturing initiatives is the creation of products by means of energy-efficient and resource-saving manufacturing systems. Furthermore, customer satisfaction will be achieved in future not only through the creation of products, but also through socially and environmentally responsible as well as economically efficient concepts of manufacturing avoiding negative effects for society. Distributed manufacturing systems (DMS) are currently discussed in science as a possible approach for the realization of sustainable manufacturing. Decentralized networks of adaptable and flexible mini-factories are not only helpful to reduce emissions through reduction of transports, but also serve for the growth and development of regional economic cycles. This paper gives an overview of trends towards DMS as well as reasons and arguments why Distributed Manufacturing Systems are appropriate concepts for more sustainable manufacturing.
1700
Sustainable Manufacturing: IPPMD Reference Model Applied to the Design of Reconfigurable Manufacturing Systems
Jhonattan Miranda, Dante Chavarría, Miguel Ramírez-Cadena, Arturo Molina
(Mexico)
This article proposes the use of an Integral Product, Process and Manufacturing System Development Reference Model (IPPMD- RM) as a tool to generate sustainable products. The IPPMD-RM allows companies to create partial and particular models in order to get a successful integration in the product development process. This reference model helps the designer in the product development process by specifying detailed activities, the flow of product information, methods that can be applied in each phase, and some other organizational issues. This article shows a case report of a design and development of a reconfigurable micro machine tool, also there are highlighted the advantages about environmental impacts (saving material resources, power saving, and working space) that it has. Results indicate that using this methodology enhances the sustainable design of reconfigurable systems in the integrated product, process and manufacturing systems development context, following the prescriptive models of design.

 

 

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