Session : 2

Sustainable Manufacturing

By :
Inaki Maulida Hakim
 Contents

1. Evolution of Production Paradigms

2. What is CP dan How CP is applied in practice:

CP practices
Benefits
Procedures

3. Green Manufacturing
Definition
Benefits and Different Aspects

4. Sustainable Manufacturing
Evolution
Definition
Example
 Course Objective

At the completion of this course the participants

will have understanding of :
- Evolution of environmental strategies, concept
of sustainable in manufacturing
- Basic concepts of sustainability approaches
- Methodology of CP implementation in industrial
enterprises
- How to develop and implement sustainability in
real world
Evolution of Production Paradigms

Source: F. Jovane, et al, “Present and Future of Flexible Automation: To

wards New Paradigms, CIRP Annals, 52, 2, 2003, 543.
Green…yes…
but…is
this really
sustainable?
Key transitions
What’s needed to make the last transition?

Automation
“F. W. Taylor”

Computer Aided
Manufacturing (CAM)
“M. E. Merchant”

Lean Manufacturing
“Toyota, et al”

Positive Impact Manufacturing

Key to each transition- the enabler

Break complex tasks into

elements;
organization and control

Move non-essential
elements outside
productive time

Minimize working capital

(cost of lack of quality)

Include whole life cycle cost

of environmental impact
 Closer Focus on Manufacturing

“Ecofacturing*”
or “Ecomanufacturing**” Green Machines

Green
Clean Power Manufacturing
Processes

Green Products

Source: * TM Taiheiyo Cement, Japan

**IGPA Newsletter, Dec. 2003
 Dimensions of design, manufacturing and environment

co$t
design
(functionality,
complexity,
life) (energy, consumables,
waste, hazards, end-of-life)

production/distribution
(quality, yield, throughput, flexibility/lean)
 Sustainability Frame of Reference

Consumption*
Rate of

Sustainable rate
•Any resource: energy,
material, water,air …

Today Future
How do we achieve this
“slope change”?
Cleaner Production Definition

“The continuous application of an integrated

preventive environmental strategy applied to
processes, products, and services to increase
overall efficiency and reduce risks to humans
and the environment.”

(United Nations Environment Programme)

 Cleaner Production Definition

Continuous Products Processes

Humans

Preventive STRATEGY for Risk Reduction

Integrated Services Environment

Cleaner Production principles

– precaution principle
– preventive principle
– integration principle
Cleaner Production procedures
The recognized need
to minimise waste

The first step Planning and

Organization

The second step Assessment

Phase

The third step Feasibility Analysis

Phase

The fourth step

Implementation

Successfully implemented CP projects

 Material and energy balances

Heat Power The Energy

Balance

Raw The Industrial Products &

Materials Waste
Process

The
Cooling Mass
Balance
Why are material and energy
balances so important?
The material and energy balances are not only used to identify the inputs
and outputs of mass and energy but their economic significance is related
to costs, such as:
• cost of raw material in waste
• cost of final product in waste
• cost of energy losses
• cost of handling waste
• cost of transporting waste
• cost of solid wastes disposal
• cost of pollution charges and penalties
CP assessment practices

Good Input Better Process

Housekeeping Substitution Control

Equipment
Modification
Process Technology
Change

On-site Production of
Recovery/ Product
Useful Modification
Reuse By-Product
What have we learned?

 The CP approach reduces pollutant generation at every

stage of the production process
 CP can be achieved through:
- good operating practices
- process modification
- technology changes
- raw material substitution
- redesign and/or reformulation of product

 The economic advantages of CP are:

- cost effectiveness
- increased process efficiency
- improved product quality and enterprise competitiveness
- cost of final treatment and disposal is minimised

 Effluent treatment, incineration, and waste recycling outside

the production process are not regarded as CP
!!!

CP is
a journey
not a destination
What is green manufacturing?
 Method for manufacturing that minimizes
waste and pollution achieved through
product and process design.

 Philosophy rather than an adopted process

or standard.
Green Manufacturing’s Goal
 The goal of sustainability.
• Every company when it comes to green
manufacturing should be conserving natural
resources for future generations.
Benefits Of Green Manufacturing
 Creates a great reputation to the public.

 Saves useless cost.

 Promotes Research and Design.

Process of Green Manufacturing
 Companies move from traditional end-of-
pipe control to new technologies.

 End-Of-Life Management
Different Aspects

 JIT Manufacturing

 Zero Emission Strategy

 ISO 9000 and ISO 14000

What is JIT Manufacturing?

 JIT Manufacturing
• Aspect of Supply Chain Management
• Emphasis on continuous cost reduction and
quality improvement
What is Zero Emission?
 Zero Emission
• “Elimination of all environmentally damaging
by products from the production process.”
• 16% of companies actively pursuing zero
emission.
• 85% of companies are pursuing reduced
emission strategies.
What is ISO 9000 and ISO 14000?
 International Quality Standards used by
companies on a voluntary basis.

 Motivates changes

 Companies is following quality standards

that are recognized.
Summary
 Green manufacturing is the elimination of waste through the production
process.

 Companies must step up and take responsibility for their actions.

 Green manufacturing promotes innovative design.

 Processes such as JIT and zero emission should be exercised by all

companies.

 Green manufacturing saves cost but more importantly it saves valuable

resources.
3R
Think supply chain…act process

Questions:

- Can you improve the process/product without

affecting up/down stream processes/products?
- If you cannot…what is the impact on adjacent elements?
- What are the “closed loop” parts of the design or process?

Input Process1 Processn … Output

What must be “sustained”
in manufacturing ?
 Performance, Quality and Safety

 Natural resources and Environment

 Lifecycle aspects
 Performance,
Quality and Safety
 Manufacturing must be sustainable in terms of:
• Performance (resource efficiency, energy efficiency, pollution reduction, …) of
– Products and Processes
• Quality of
– products (including services) and
– processes
• Safety of
– people (workers and other people affected in one or another way by
manufacturing processes or facilities and their products),
– facilities and infrastructure
 Maintenance of manufacturing facilities is important to sustain:
• (i) the performance of product and processes
• (ii) the quality of processes
• (iii) safety during product use and process operation
 Natural Resources
and Environment
Manufacturing should:

 Address world wide resources shortages and excess

environmental load to enable an environmentally
compatible life-cycle.

 Achieve minimum energy and material consumption in

manufacturing as well as over the entire life-cycle of
products and services.
 Life-Cycle aspects

 Sustainability of manufacturing is more and more

affected by life-cycle considerations:
- from design,
- procurement & production,
- transportation & setting up operation,
- use, maintenance and
- retirement & end of life of products.
Concept Sustainability
Sustainability Benefits
 Discounts  Entrepreneurial
Innovation
 Lower Energy
Consumption  Economic Stewardship

 Resource Conservation  Decreased Emissions and

Pollution
 Low Product Costs
 Improved Air and Water
 Improved/Competitive Quality
Prices
 Competitive Advantage
 9 Steps to Sustainability

1. Engage the support of 6. Set up a Collection and

Upper Level Management Storage System
2. Organize a 7. Purchase Recycled
Goods
Green Team
8. Train Staff and Promote
3. Conduct a Waste the Program
Assessment
9. Measure and Evaluate
4. Establish Waste Procedures and
Reduction goals Progress
5. Secure Recycling
Markets
Sustainable Manufacturing is defined in the last draft
of the IMS initiative as follows:

“Sustainable manufacturing is a platform for

development of innovative manufacturing
technologies which address world wide resources
shortages and excess environmental load to
enable an environmentally benign life cycle.”
Supporting Global Research for IMS2020 Vision
Excellence is Automotive Manufacturing
requires:
• Excellence in required competence areas.
• Verified products and processes (virtual
and physical).
• Discipline in product creation process.
• Rapid flawless launches/introductions.
• Ability to make several product models
including variants with alternative
powertrains (includes also bodies and
cabs for new powertrains) in the same
production system or in the same so-
called line.
• High availability (24 hours, 6 days per
week).
• High quality.
• High productivity.
• Reasonable manufacturing costs.
• Shorter order to delivery time.
• Mass customization.

Supporting Global Research for IMS2020 Vision

Supporting Global Research for IMS2020 Vision
Our targets are to significantly contribute to the reduction of
• emissions of fossil CO2 and other emissions from safe
vehicles and construction equipment by creating the pre-
requisites for manufacturing of innovative environmentally
friendly and safe products,
• all losses in Manufacturing Engineering and significantly
decrease the environmental impact of the manufacturing
processes. A strongly increased use of virtual tools for rapid
and accurate consequence studies and manufacturing
optimizations is held to be of great importance in this
context.

Supporting Global Research for IMS2020 Vision

 The present R&D program is,
furthermore, expected to
significantly contribute to
achievement of the following
Manufacturing Engineering and
Production related targets:
• 40% higher productivity in
Manufacturing Engineering (by, for
instance, extensive use of virtual
tools)
• 30% productivity increase in the
production processes.
• 30% lower environmental
impact in the manufacturing
processes.
Supporting Global Research for IMS2020 Vision
 Final conclusions

• Innovation in advanced manufacturing processes to be performed

through analysis of science, technology and market trends
• Continuous improvement to be ensured
• Monitoring of resources optimisation necessary