Karl R. Haapala

A Review of Engineering Research in Sustainable Manufacturing

Karl R. Haapala 1 School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, 204 Rogers Hall, Corvallis, OR 97331 e-mail: Karl.Haapala@oregonstate.edu Fu Zhao School of Mechanical Engineering, Division of Environmental and Ecological Engineering, Purdue University, 585 Purdue Mall, West Lafayette, IN 47907 e-mail: fzhao@purdue.edu Jaime Camelio Department of Industrial and Systems Engineering, Virginia Polytechnic Institute and State University, 235 Durham Hall, Blacksburg, VA 24061 e-mail: jcamelio@vt.edu John W. Sutherland Division of Environmental and Ecological Engineering, Purdue University, 322 Potter Engineering Center, West Lafayette, IN 47907 e-mail: jwsuther@purdue.edu Steven J. Skerlos Department of Mechanical Engineering, University of Michigan, 2250 GG Brown Building, Ann Arbor, MI 48105 e-mail: skerlos@umich.edu David A. Dornfeld Department of Mechanical Engineering, University of California, 6143 Etcheverry Hall, Berkeley, CA 94720 e-mail: dornfeld@berkeley.edu I. S. Jawahir Department of Mechanical Engineering, University of Kentucky, 414C UK Center for Manufacturing, Lexington, KY 40506 e-mail: jawahir@engr.uky.edu A Review of Engineering Research in Sustainable Manufacturing Sustainable manufacturing requires simultaneous consideration of economic, environmen- tal, and social implications associated with the production and delivery of goods. Funda- mentally, sustainable manufacturing relies on descriptive metrics, advanced decision- making, and public policy for implementation, evaluation, and feedback. In this paper, recent research into concepts, methods, and tools for sustainable manufacturing is explored. At the manufacturing process level, engineering research has addressed issues related to planning, development, analysis, and improvement of processes. At a manufac- turing systems level, engineering research has addressed challenges relating to facility operation, production planning and scheduling, and supply chain design. Though economi- cally vital, manufacturing processes and systems have retained the negative image of being inefficient, polluting, and dangerous. Industrial and academic researchers are re- imagining manufacturing as a source of innovation to meet society’s future needs by under- taking strategic activities focused on sustainable processes and systems. Despite recent developments in decision making and process- and systems-level research, many chal- lenges and opportunities remain. Several of these challenges relevant to manufacturing process and system research, development, implementation, and education are highlighted. [DOI: 10.1115/1.4024040] Andres F. Clarens Department of Civil and Environmental Engineering, University of Virginia, D220 Thornton Hall, Charlottesville, VA 22904 e-mail: aclarens@virginia.edu Jeremy L. Rickli Department of Industrial and Systems Engineering, Virginia Polytechnic Institute and State University, 217 Durham Hall, Blacksburg, VA 24061 e-mail: jlrickli@vt.edu Corresponding author. Contributed by the Manufacturing Engineering Division of ASME for publication in the J OURNAL OF M ANUFACTURING S CIENCE AND E NGINEERING . Manuscript received July 11, 2012; final manuscript received March 4, 2013; published online July 17, 2013. Editor: Y. Lawrence Yao. Manufacturing and Sustainability The concept of sustainability emerged from a series of meetings and reports in the 1970s and 1980s, and was largely motivated by environmental incidents and disasters as well as fears about Journal of Manufacturing Science and Engineering C 2013 by ASME Copyright V AUGUST 2013, Vol. 135 / 041013-1 Downloaded From: http://manufacturingscience.asmedigitalcollection.asme.org/ on 07/09/2014 Terms of Use: http://asme.org/terms

Infusing sustainability principles into manufacturing/mechanical engineering curricula

Sustainability issues are increasingly important among governments, consumers, and corporations around the world. Many companies are directing their resources to reduce the environmental impact of their products and services. To remain competitive in the global economy, these companies must recruit employees who understand the impact of their decisions on the environment and society, while at the same time influencing the companys bottom line. It is the mission of universities to prepare these future employees to meet this need. A group of faculty and students in the Dept. of Mechanical Engineering-Engineering Mechanics at Michigan Technological University is working to address this growing demand. This paper assesses the current undergraduate mechanical engineering curriculum at Michigan Tech with regard to sustainability and identifies barriers to incorporating sustainability throughout the curriculum. A benchmarking study, progress made at Michigan Tech, and a vision for the future of the mechanical engineering curriculum are presented.

Challenges for the Manufacturing Enterprise to Achieve Sustainable Development

Manufacturing enterprises are striving to achieve sustainability through changes in products, processes, and systems. Decision-support tools and methods are rooted not only in improving environmental aspects of manufacturing, but also in ensuring long-term productivity and social well-being. Refocused efforts on the development of sustainable technologies can further aid continuous improvement and stimulate revolutionary advancements industry-wide. Current and future challenges facing the manufacturing industry are addressed in terms of manufacturing enterprise, product life cycle design, and manufacturing processes and systems. Opportunities for future research are discussed within each of these areas.

Comparative life cycle assessment of 2.0 MW wind turbines

Wind turbines produce energy with virtually no emissions, however, there are environmental impacts associated with their manufacture, installation, and end of life. The work presented examines life cycle environmental impacts of two 2.0 MW wind turbines. Manufacturing, transport, installation, maintenance, and end of life have been considered for both models and are compared using the ReCiPe 2008 impact assessment method. In addition, energy payback analysis was conducted based on the cumulative energy demand and the energy produced by the wind turbines over 20 years. Life cycle assessment revealed that environmental impacts are concentrated in the manufacturing stage, which accounts for 78% of impacts. The energy payback period for the two turbine models are found to be 5.2 and 6.4 months, respectively. Based on the assumptions made, the results of this study can be used to conduct an environmental analysis of a representative wind park to be located in the US Pacific Northwest.

Integrating Life Cycle Assessment Into the Conceptual Phase of Design Using a Design Repository

This paper describes efforts taken to further transition life cycle assessment techniques from the latter, more detailed phases of design to the early-on conceptual phase of product development. By using modern design methodologies such as automated concept generation and an archive of product design knowledge, known as the Design Repository, virtual concepts are created and specified. Streamlined life cycle assessment techniques are then used to determine the environmental impacts of the virtual concepts. As a means to benchmark the virtual results, analogous real-life products that have functional and component similarities are identified. The identified products are then scrutinized to determine their material composition and manufacturing attributes in order to perform an additional round of life cycle assessment for the actual products. The results of this research show that sufficient information exists within the conceptual phase of design (utilizing the Design Repository) to reasonably predict the relative environmental impacts of actual products based on virtual concepts.

Integrating Sustainability Assessment into Manufacturing Decision Making

Prior efforts have focused on environmental assessment coupled with manufacturing cost analysis; however, few have attempted integrated sustainability assessment for manufacturing. An approach is developed for sustainable manufacturing decision making and demonstrated for a machining work cell. Assessment results are obtained and discussed for three production scenarios. A multi-criteria decision making method is applied to aggregate the results from individual economic, environmental, and social assessments. Limitations and future opportunities revealed by this study are discussed, including the challenges of incorporating actual production data, accessibility to social information, and amenability to the optimization of a spectrum of loosely coupled sustainability metrics.

Stability and Biological Responses of Zinc Oxide Metalworking Nanofluids (ZnO MWnF™) using Dynamic Light Scattering and Zebrafish Assays

Zinc oxide nanoparticles (ZnO NPs) have demonstrated the ability to improve lubrication and thermal conductivity and are promising metalworking lubricant and coolant additives due to their low cost compared to other NPs. Though nanomaterials are a focus of research due to their potential to enable advanced technologies, little is known about their effects on the environment and human health. This research investigates two main characteristics of ZnO metalworking nanofluids (MWnF). First, the stability of ZnO NPs (20 nm) is investigated using dynamic light scattering (DLS) for mixtures of a microemulsion (TRIM MicroSol 585XT) and several dispersants, all of which are commercially available. Second, toxicological assessments using a zebrafish assay method are conducted to survey the effect of ZnO NPs on MWnF safety. The research revealed that none of the dispersants enhanced the stability of ZnO NPs more than the prepared microemulsion alone. The work also revealed that ZnO MWnF had a significantly higher toxicity than the prepared microemulsion. This demonstrates the need for precautionary development of metalworking nanofluids.

Sustainable Manufacturing Analysis for Titanium Components

Product designers are seeking effective ways to meet customer requirements, government policies, and internal business drivers for sustainability. Sustainable products encompass attributes including recyclable and renewable materials use, low energy consumption, cost competitiveness, and consideration of safety and health concerns. Beyond product attributes, however, sustainable products are cognizant of a broader life cycle perspective, which necessitates consideration of manufacturing and supply chain issues during design. Current life cycle assessment tools are often deficient in assisting design for manufacturing efforts due to coarseness of available process data or even a lack of representative process models. In addition, such tools consider only the environmental impacts and do not account for broader sustainability measures. Research with a titanium component manufacturer is addressing these deficiencies. A unit process modeling-based method is described to assist in strategic decision making to balance cradle-to-gate economic, environmental, and social attributes. A set of metrics is defined and used as a basis for comparison of design alternatives. The method is demonstrated for analysis of titanium component alternatives resulting from design for manufacturing activities. It is shown that this method can assist engineers in developing more sustainable products.© 2011 ASME

A review of engineering research in sustainable manufacturing

Karl R. Haapala 1 School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, 204 Rogers Hall, Corvallis, OR 97331 e-mail: Karl.Haapala@oregonstate.edu Fu Zhao School of Mechanical Engineering, Division of Environmental and Ecological Engineering, Purdue University, 585 Purdue Mall, West Lafayette, IN 47907 e-mail: fzhao@purdue.edu Jaime Camelio Department of Industrial and Systems Engineering, Virginia Polytechnic Institute and State University, 235 Durham Hall, Blacksburg, VA 24061 e-mail: jcamelio@vt.edu John W. Sutherland Division of Environmental and Ecological Engineering, Purdue University, 322 Potter Engineering Center, West Lafayette, IN 47907 e-mail: jwsuther@purdue.edu Steven J. Skerlos Department of Mechanical Engineering, University of Michigan, 2250 GG Brown Building, Ann Arbor, MI 48105 e-mail: skerlos@umich.edu David A. Dornfeld Department of Mechanical Engineering, University of California, 6143 Etcheverry Hall, Berkeley, CA 94720 e-mail: dornfeld@berkeley.edu I. S. Jawahir Department of Mechanical Engineering, University of Kentucky, 414C UK Center for Manufacturing, Lexington, KY 40506 e-mail: jawahir@engr.uky.edu A Review of Engineering Research in Sustainable Manufacturing Sustainable manufacturing requires simultaneous consideration of economic, environmen- tal, and social implications associated with the production and delivery of goods. Funda- mentally, sustainable manufacturing relies on descriptive metrics, advanced decision- making, and public policy for implementation, evaluation, and feedback. In this paper, recent research into concepts, methods, and tools for sustainable manufacturing is explored. At the manufacturing process level, engineering research has addressed issues related to planning, development, analysis, and improvement of processes. At a manufac- turing systems level, engineering research has addressed challenges relating to facility operation, production planning and scheduling, and supply chain design. Though economi- cally vital, manufacturing processes and systems have retained the negative image of being inefficient, polluting, and dangerous. Industrial and academic researchers are re- imagining manufacturing as a source of innovation to meet society’s future needs by under- taking strategic activities focused on sustainable processes and systems. Despite recent developments in decision making and process- and systems-level research, many chal- lenges and opportunities remain. Several of these challenges relevant to manufacturing process and system research, development, implementation, and education are highlighted. [DOI: 10.1115/1.4024040] Andres F. Clarens Department of Civil and Environmental Engineering, University of Virginia, D220 Thornton Hall, Charlottesville, VA 22904 e-mail: aclarens@virginia.edu Jeremy L. Rickli Department of Industrial and Systems Engineering, Virginia Polytechnic Institute and State University, 217 Durham Hall, Blacksburg, VA 24061 e-mail: jlrickli@vt.edu Corresponding author. Contributed by the Manufacturing Engineering Division of ASME for publication in the J OURNAL OF M ANUFACTURING S CIENCE AND E NGINEERING . Manuscript received July 11, 2012; final manuscript received March 4, 2013; published online July 17, 2013. Editor: Y. Lawrence Yao. Manufacturing and Sustainability The concept of sustainability emerged from a series of meetings and reports in the 1970s and 1980s, and was largely motivated by environmental incidents and disasters as well as fears about Journal of Manufacturing Science and Engineering C 2013 by ASME Copyright V AUGUST 2013, Vol. 135 / 041013-1 Downloaded From: http://manufacturingscience.asmedigitalcollection.asme.org/ on 07/09/2014 Terms of Use: http://asme.org/terms

Reducing supply chain costs and carbon footprint during product design

Manufacturing companies continue to struggle with simultaneously assessing and reducing supply chain costs and carbon footprint early in the design process as consumers demand more sustainable products. An integrated product design-supply chain design approach is explored and applied to bicycle design. It is shown that the approach can successfully inform decision-makers on the consequences of their choices even when component alternatives are similar.