Professional Documents
Culture Documents
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
1
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
LMAS
(“Who
we
are”)
Research
in
the
LMAS
is
concerned
with
the
analysis
and
improvement
of
manufacturing
processes,
systems
and
enterprises
and
the
development
of
tools
to
analyze
their
su
stainability.
Research
is
focused
on:
-‐
metrics
and
analy.cal
tools
for
assessing
the
impact
of
processes,
systems
and
enterprises
-‐
modeling
sustainable,
environmentally-‐
conscious
manufacturing
processes
and
systems
-‐
green
supply
chains
-‐
manufacturing
technology
for
reduced
impact
-‐
manufacturing
technology
for
producing
advanced
energy
sources
or
storage
-‐
cleantech
-‐
sustainable
products
and
systems
Slide
2
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Product
Life
Cycle
–
Mfg
Focus
All
phases
are
important
and
impact
manufacturing!
Manufacturing
Slide
3
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Research
Topics
in
Sustainable
Mfg
Slide
4
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Scope
of
Analysis
Enterprise
Factory/Facility
Machine Tool
Machining Process
Tool-‐chip
interface
www.remmele.com/flash/contractManu/pca.html
www.caranddriver.com/features/7207/virtual-‐tour-‐
of-‐vws-‐transparent-‐factory.html
Slide
5
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
6
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
LMAS
Research
NIST
Mfg
Standard
Metrics
Samsung
DfM/MfD
EducaKon
Caterpillar
Partners
Mori
Seiki/DTL
Mfg
Energy
OpKmizaKon
Mori
Seiki/DTL
CGDM/ERG
Green
Machine
Tools
Green
Machine
Tools
BERC
CET/MOT
LUCE
Sustainability
CFI
ConsorKum
KAUST
Cleanability
Applica2ons
Tools
Slide
7
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
EducaKon
■ ~20
Graduate
Student
Researchers
(MS,
PhD,
Postdocs,
Visitors)
■ Courses:
■ Professional
MEng
on
Sustainable
Manufacturing
■ E290I
Sustainable
Manufacturing
(Dornfeld/Hutchins)
■ Engineering
and
Business
for
Sustainability
(EBS)
I Tools and Methods
II. Products, Processes and Services
III. Management, Strategy, Economics and Risk
IV. Policy and Systems
h_p://sustainable-‐engineering.berkeley.edu/
h_p://www.miraiinsKtute.org/
h_p://cgdm.berkeley.edu/
Slide
8
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Sustainable
Manufacturing
Partnership
(SMP)
SMP - A collaboration among leading companies and LMAS
to research, develop, evaluate and implement
sustainable manufacturing solutions
Slide
9
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
10
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Life
Cycle
Assessment
(LCA)
■ A
concept
or
methodology
to
evaluate
the
environmental
effects
of
a
product
or
acKvity
holisKcally,
by
analyzing
the
whole
life
cycle
of
a
parKcular
product,
process,
or
acKvity
(U.S.
EPA,
1993)
Slide
11
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Product
Life
Cycle
Conven2onal
Product
Design
Sand
Slide
Design
/
Prototype
Materials
Typical
Focus
Manufacturing
Use
End-‐of-‐Life
Slide
12
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Product
Life
Cycle
Holis2c
Product
Life
Cycle
Design
■ Cradle-‐to-‐Cradle
Start-‐of-‐Life
■ All
stages
embodies
design
Materials
■ All
stages
factor
in
supply
chain
■ ObjecKves:
Recycle
Supply
Mfg.
■ Total
cost
of
ownership
■ Carbon
emissions
Design
■ Resources:
energy,
water
■ Waste
Re-‐mfg.
Chain
Use
Re-‐use
End-‐of-‐Life
Slide
13
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Tools
■ GaBi
Sojware
■ SimaPro
■ Umberto
■ CES
Selector
■ Sustainable
Minds
■ EIO-‐LCA
■ Autodesk
■ Solidworks
Sustainability
Slide
14
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Tools
Ex.
–
CES
Selector
■ Advance
material
selector
sojware
for
opKmizing
material
performance,
cost
and
eco-‐design
■ Ashby
charts
■ Graphical
trade-‐off
comparisons
in
material
properKes
Slide
15
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Tools
–
SW
Sustainability
Source: solidworks.com
Slide
16
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Case
Study
-‐
Electronics
■ LCA
of
the
Mobile
CommunicaKon
System
UMTS
Report
Source:
Emmenegger,
M
F
et
al.
“Life
Cycle
Assessment
of
the
Mobile
CommunicaKon
System
UMTS:
Towards
Eco-‐efficient
Systems
(12
pp).”
InternaKonal
Journal
Of
Life
Cycle
Assessment
11.4
(2006)
:
265-‐276.
Slide
17
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Case
Study
-‐
Electronics
■ Eco
Indicator
‘99
results
per
life
cycle
stages
Slide
18
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Case
Study
-‐
Electronics
■ Considering
manufacturing:
Slide
19
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
20
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
IntroducKon
Enterprise
• Environmental
concerns
are
growing
– Customer
demand
– Increasing
regulaKon
– Increasing
costs
• Manufacturing
is
resource
intensive
– 31%
of
U.S.
energy
usage1
– 19%
of
total
world
GWP
emissions2
[1]
US
EIA,
“Annual
Energy
Review
2008,
Report
No.
DOE/EIA-‐0384(2008)”
Process/detail
[2]
T.
Herzog,
“World
greenhouse
gas
emissions
in
2005,”
WRI
Slide
21
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Energy
ConsumpKon
of
U.S.
Manufacturing
Sectors
Energy Consumed as Fuel
120% 1.49
x
108
GJ
9.27
x
107
GJ
1.14% 0.70% 0.54% 0.42% 0.09%
1.30% 0.56% 0.46% 0.38% 0.02%
2.54% 0.90%
Sum of the Percentage of Energy
100%
2.15%
3.06% 2.84%
7.06%
80% 7.58%
11.14%
60% 15.04%
20.41%
40%
21.69%
20%
0%
)
AL 2)
1)
AN ET 1)
ST AL 1)
2)
LS 3)
3)
AB 4)
PR ET 12)
)
IS 14)
AP RN 9)
)
H 324
PE 25
EQ 327
FA OO 36
TE MA 326
TE -E 335
23
AT AR 337
-E 315
16
TR -M (31
2
FO (33
-R (33
EL (31
FU (33
(3
(3
(3
(3
(3
(3
(3
(3
(
(
ER L (
D
AL
P
EM
PM R
XT CH
BE EC
XT TC
TC
E
O
O
ET
PL ET
O
IL
M
V-
C
-
PA
M
S-
C
-P
W
T
EC
M
N
P
P-
T-
N
-
O
B-
PE
EL
H
N
O
C
LE
Data:
U.S.
EIA
MECS
(2009)
“2006
Energy
ConsumpKon
as
Fuel”
Slide
22
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Facility
Energy
ConsumpKon
180 177
180 171 172
HVAC
160 Lighting
140 130
120
100 92 89
80 73
67 68 73
60
60 54
37
40 34
24 25
20
0
Fabricated Metal Machinery Computer and Electrical Equip., Transportation Furniture and
Products Electronic Appliances, and Equipment Related Products
Products Components
NAICS Industry
Data: U.S. EIA MECS (2009) “2006 Energy ConsumpKon as Fuel”
Slide
23
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Energy
Intensity
of
Computers
and
Electronics
Computer"&"peripheral"equipment" Value"of"Product"Shipments"
Value"Added"
Communica8ons"equipment"
Naviga8onal,"measuring,"medical,"&"control"instruments"
Audio"&"video"equipment"
Electrical"equipment"
Electric"ligh8ng"equipment"
Household"appliance"
Semiconductor"&"other"electronic"component"
Other"electrical"equipment"&"component"
Mfg"&"reproducing"magne8c"&"op8cal"media"
Data: U.S. EIA MECS (2009) “2006 Energy ConsumpKon as Fuel”
Slide
24
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Facility
Energy
ConsumpKon
600
Machines
HVAC
Energy Intensity [kWh/m2-yr]
500 482
Lighting
400
301
300
188
200 180 184 177 171 172
116
130
103
100 92 89
61 63 37
60
73 67
54
68 73
36 34 25
19 24
0
Mori Seiki Mori Seiki Mori Seiki FAB-METAL MACH (333) COMP-ELEC ELEC-ETC TRANS-EQP FURN (337)
Plant 1 Plant 2 Plant 4 (332) (334) (335) (336)
Data: U.S. EIA MECS (2009) “2006 Energy ConsumpKon as Fuel”
Slide
25
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
HVAC
Energy
Model
§ Influencing
Factors:
§ Outside
temperature
§ ProducKon
equipment
§ Manual
labor
&
body
heat
§ ProducKon
Volume
§ Slightly
posiKve
trend
110
60
40
EHVAC
=
a+b*V+c*t+d*t2
30
200
220 240
15
20
25
260 10
280 5
Avg. Temperature [C]
Volume [units]
Slide
26
©
LMAS
2013
Berkeley/
26
UNIVERSITY OF CALIFORNIA
LocaKon
Dependency
of
HVAC
Energy
12,000
Plant 1
9,837 Plant 4
10,000
HVAC Energy [MWh/yr]
7,969
8,000 7,427
6,114
5,828 5,625 5,559
6,000
4,000 3,604
2,000 1,411
1,024 1,152
796 806 777 879
545
0
Iga* Iga San Jose Detroit Munich Shanghai Chennai New Delhi
(Japan) (Japan) (USA) (USA) (Germany) (China) (India) (India)
*Actual HVAC energy consumpKon for two plants in Iga, Japan
Slide
27
©
LMAS
2013
Berkeley/
27
UNIVERSITY OF CALIFORNIA
Thank
you
for
your
a_enKon!
Contact
InformaKon:
Nancy
Diaz
(ndiaz@berkeley.edu)
Ph.D.
Candidate
Laboratory
for
Manufacturing
and
Sustainability
(LMAS)
University
of
California,
Berkeley
Slide
28
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
29
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Product
Life
Cycle
Raw
Material
Material
Manufacturing
Use
End-‐of-‐Life
ExtracKon
Processing
Informal
Reuse
Reuse
Resell
Formal
Secondary
Use
Refurbish
CollecKon
Processing
Recycling IncineraKon
Curbside
Landfill
CollecKon
Slide
30
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
E-‐Waste
E-‐waste
is
a
generic
term
encompassing
Consumer
Electronic
Product
various
forms
of
electric
Sales
in
the
U.S
and
electronic
equipment
that
have
ceased
to
be
of
any
value
to
their
owners
(Widmer
2005)
Slide
31
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Informal
Recycling
Resource Efficiency
LegislaKon
Slide
32
©
LMAS
2013
Berkeley
Image
Sources:
StEP-‐EMPA,
ERI,
ETBC
/
UNIVERSITY OF CALIFORNIA
“BeLer
processing
of
e-‐waste
would
not
only
reduce
the
amount
of
poten.ally
toxic
waste
sent
to
landfill
or
illegally
exported
overseas,
but
lead
to
greater
recovery
of
valuable
raw
materials”
–
European
Parliament
Slide
33
Berkeley
33
/
UNIVERSITY OF CALIFORNIA
CommunicaKng
Recycling
Efficiency
EOL Pathways Project
How
do
we
accurately
represent
reuse,
recycling
and
final
disposal
of
consumer
electronics
in
life
cycle
models?
PlasKcs
Metals
PCBs
Products
Slide
34
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Flow
Analysis
of
E-‐Waste
CollecKon
&
Processing
System Boundary
Slide
35
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Scope
of
Material
Flow
Analysis
Products
Collec2on
Facili2es
Pathway
Televisions
Consumer
Type
of
Facility
Recycle
LCD
Retail
Return
-‐ Recycle
Collec.on
-‐ Refurbish
Reuse
Plasma
Program
-‐ Reuse
Whole
System
CRT
Direct
Component
Computers
OEM
takeback
10
Facili2es
Refurbish
Laptops
Whole
System
Desktops
Business
Region
Component
Tablet
PCs
OEM
United
States
Slide
36
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
QuanKtaKve
&
QualitaKve
Assessment
Electricity
Indirect
Energy
Manual
Equipment
1
Disassembly/
Inventory
SorKng
Slide
37
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Federal
Trade
Commission
Recyclable
-‐
It
is
deceptive
to
misrepresent,
directly
or
by
implication,
that
a
product
or
package
is
recyclable.
A
product
or
package
should
not
be
marketed
as
recyclable
unless
it
can
be
collected,
separated
or
otherwise
recovered
from
the
solid
waste
stream
for
reuse,
or
in
the
manufacture
or
assembly
of
another
package
or
product,
through
an
established
recycling
program.
Unquali<ied
claims
of
recyclability
for
a
product
or
package
may
be
made
if
A
product
or
package
should
not
be
marketed
as
recyclable
unless
it
can
the
entire
product
or
package,
excluding
minor
incidental
components,
is
recyclable.
For
products
be
collected,
separated
or
otherwise
recovered
from
the
solid
waste
or
packages
that
are
made
of
both
recyclable
and
non-‐recyclable
components,
the
recyclable
stream
for
reuse,
or
in
the
manufacture
or
assembly
of
another
package
claim
should
be
adequately
quali<ied
to
avoid
consumer
deception
about
which
portions
or
components
or
op
f
troduct,
he
product
tohrough
r
package
aare
n
reecyclable.
stablished
Claims
roecycling
program.
f
recyclability
should
be
quali<ied
to
the
extent
necessary
to
avoid
consumer
deception
about
any
limited
availability
of
recycling
programs
and
collection
sites.
If
an
incidental
component
signi<icantly
limits
the
ability
to
recycle
a
product
or
package,
a
claim
of
recyclability
would
be
deceptive.
A
product
or
package
that
is
made
from
recyclable
material,
but,
because
of
its
shape,
size
or
some
other
attribute,
is
not
accepted
in
recycling
programs
for
such
material,
should
not
be
marketed
as
recyclable.
Slide
38
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Mass
Based
Recyclability
%PRMC = Potential Recyclable Material Content (as percent of total weight)
• Provides
single
approach
for
theoreKcal
recyclability
calculaKon
• Develop
standard,
consistent
method
for
calculaKng
recyclability
• Consistent
with
other
product
level
recycling
criteria
reporKng
–
(WEEE,
IEEE
1680.1,
IEC
Technical
Report)
Slide
39
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
CommunicaKng
Recyclability:
Recyclability
Calculator
Slide
40
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
Slide
41
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Sustainability
and
Manufacturing
Environment
Society
Economy
Manufacturing
Slide
42
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
DefiniKon
–
Social
Responsibility
■ Sustainability
requires
socially
responsible
products
■ ISO
26000:
Responsibility
of
an
organizaKon
for
the
impacts
of
its
decisions
and
acKviKes
on
society
and
the
environment,
through
transparent
and
ethical
behavior
that
■ contributes
to
sustainable
development,
including
health
and
the
welfare
of
society;
■ takes
into
account
the
expectaKons
of
stakeholders;
■ is
in
compliance
with
applicable
law
and
consistent
with
internaKonal
norms
of
behavior;
and
■ is
integrated
throughout
the
organizaKon
and
pracKced
in
its
relaKonships
InternaKonal
OrganizaKon
for
StandardizaKon,
“ISO
26000:
Guidance
on
Social
Responsibility,”
2010.
Slide
43
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Contextualized
Supply
Chain
Impacts
on
Social
En22es
Global
Community
ActualizaKon
Local
Local
Community
Esteem
Community
Local
AffiliaKon
Community
Slide
44
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Social
Impacts
of
Industrial
Processes
Slide
45
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
The
Sustainability
ConsorKum
Approach
Sustainability
Risk
Key
Performance
Indicator
Improvement
Opportunity
Slide
46
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Social
Impacts
-‐
Challenges
■ IdenKficaKon
-‐
Tier
1
■ No
consensus
on
the
risks
(or
indicators
to
measure
risk)
■ Opacity
of
supply
chain
■ Risks
need
to
be
prioriKzed
Slide
47
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Sustainability
Risks
–
What
are
they?
■ Human
and
Labour
Rights
■ Universal
DeclaraKon
of
Human
Rights
(UN)
■ InternaKonal
Labour
OrganizaKon
convenKons
Slide
48
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Sustainability
Risks
–
Where
are
they?
■ Where
…
■ In
the
world
■ In
the
supply
chain
■ In
the
organizaKon
■ Tools
■ Audit
results
■ Social
Hotspot
Database
■ Input/Output
LCA
■ LocaKon-‐specific
data
Sourcemap,
Typical
Laptop
Computer
accessed
7/18/12
from
h_p://srce.mp/nBnBZV
Slide
49
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
PrioriKzing
Social
Impacts
in
Design
Furthest
Up-‐stream
Supplier
Effects
of
Lifecycle
phase
mat’l
choice
in
Training
for
those
involved
in
raw
manufacturing
mat’l
extracKon
and
processing
Informal
recycling
Providing
connecKvity
to
people
for
enhanced
product
exchange
End
of
Life
and
health
care
Gravity
of
Impact
Most
egregious
-‐
affecKng
Opportunity
for
basic
rights
and
health
posiKve
impact
Slide
50
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Current
and
near-‐term
work
■ OperaKonalize
definiKons
of
social
impacts/risks
■ Collaborate
with
other
disciplines
■ (Green)
Materials
&
Chemistry
■ Public
health
■ Materials
science
(extracKon
and
processing
of
materials)
■ Business
■ EducaKonal
assessment
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©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Outline
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©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
Summary
■ Manufacturing
plays
an
important
role
in
the
sustainability
of
the
product
life
cycle
■ Truly
green,
sustainable
products
require
that
designers
and
manufacturers:
■ Consider
the
enKre
life
cycle
during
design
■ Assess
environmental
impacts
at
all
levels
of
manufacturing
enterprise
and
across
the
supply
chain
■ Implement
appropriate
end-‐of-‐life
strategies
■ Address
the
social
impacts
of
our
manufacturing
systems
and
the
products
that
they
create
Slide
53
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA
More
informaKon…
h_p://lmas.berkeley.edu
Blog:
h_p://green-‐manufacturing.blogspot.com/
Slide
54
©
LMAS
2013
Berkeley
/
UNIVERSITY OF CALIFORNIA