Design for Sustainable Manufacturing: Approach, Implementation, and Assessment
Abstract
:1. Introduction
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- Energy consumption reduction.
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- Waste elimination/reduction.
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- Product durability improvement.
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- Health hazards and toxic dispersion elimination.
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- Higher quality of manufacturing.
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- Recycling, reuse, and remanufacturing enhancement.
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- Development of renewable energy resources.
2. Sustainable Manufacturing Elements
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- Research: to develop, evaluate, and examine the specific sustainability requirements, such as energy and resource use, pollution, and climate change impacts. This phase of the model has a high potential as it helps to ensure sustainability at the pre-competitive level and focuses on the manufacturing environmental issues;
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- Commercialization: to refine the previous phases and co-operate with suppliers, vendors, and customers.
3. Sustainable Manufacturing: Needs and Concepts
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- Information: to make an effective assessment by providing the required quantitative and qualitative information;
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- Management and culture: to encourage and develop a sustainability-oriented culture in the organization through specialized sustainable departments inside the companies;
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- Procedures: to ensure applying the objectives and strategies for sustainable organization effectively.
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- Concepts: present comprehensive analysis of the economic, social, and environmental clusters, as well as other relevant considerations;
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- Methods and tools: development, improvement, and enhancement of smart tools and methods to support the concept of sustainability;
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- Data: to support the environmental impact and sustainability assessments, more detailed, comprehensive and robust data are needed across the overall product life cycle;
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- Manufacturing practices: to build sustainable indicators for measuring and monitoring purposes to increase the sustainability awareness among suppliers and customers;
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- Government policies: to achieve incorporation between companies and government through sustainable programs, and environmental factors–clean processes policy;
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- Research: academic and industrial research is needed to enhance the sustainability system by focusing on the manufacturing, design, and environmental aspects;
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- Integration: for all previous needs to achieve an integrated system, which represents the environmental, economic, and societal sustainable aspects.
4. Design for Sustainable Manufacturing
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- Design for repair, reuse, and recycle.
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- Design for waste and hazards minimization.
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- Design for product disassembly.
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- Design for continuous improvements.
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- Design for energy efficiency.
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- Design for remanufacturing.
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- Design for optimal materials use.
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- Design for cost effectiveness.
5. Practice and Implementation of Sustainable Manufacturing
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- Applying principles of utilized materials and inputs, which are non-hazardous and recyclable;
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- Developing and planning of production processes to reduce the consumption of energy, materials, and water;
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- Using renewable energy that does not affect the natural environment;
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- Developing product design to be reusable, re-manufacturable, or recyclable;
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- Expanding the design concepts of using fewer resources and applying easy-to-repair techniques;
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- Using efficient transportation and logistics systems.
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- Developing work practice and maintenance: This step is called the housekeeping step, and it is considered as a simple action to accomplish effective monitoring, inventory management, and scheduling in all production operations (e.g., reducing loss from leaks, keep equipment’s maintaining properly, sustainable training programs).
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- Process optimization: In this step, development in manufacturing processes is required to minimize waste, conserve raw materials, and reuse waste materials. Examples of actions during these steps are changing the steps in a specific process, determining the optimal settings for each operation, and or rearranging machines’ locations to minimize the total required movements. Also, the implementation of energy-efficient technologies offers significant effects, which support the sustainable manufacturing concepts. For example, using minimum quantity lubrication and dry cutting [43], cryogenic approach [44], waste management principles [45], modeling and optimization approaches [46,47], and artificial intelligence methods [48].
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- Raw material substitution: The main objective of this step is to replace hazardous materials and chemicals (high environmental impact) with sustainable materials (low health and environmental impact). The output of the current step contributes to reducing environmental and health concerns, as well as avoiding the regulatory costs associated with the storage and disposal of materials.
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- New technologies: This step depends on using more energy-efficient systems that enhance the environmental impact performance, as they have effective capabilities of saving heat and energy. However, for these technologies to have an effective impact to achieve sustainable systems, they need huge capital investment (i.e., initial costs problems).
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- New product design: This is considered the most difficult implementation step as it needs to transfer the whole system from the ground up to be greener (more sustainable). Some development keys to achieve this step are mentioned in Section 3; for example, smart methods, research, integration, and manufacturing practices.
6. Assessment of Sustainable Manufacturing Approach
7. Discussions and Future Trends
8. Summary
Author Contributions
Acknowledgments
Conflicts of Interest
References
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Reference | Sustainable Technology | Application |
---|---|---|
[49] | Using natural biodegradable oils with minimum quantity lubrication (MQL) | Achieve sustainable machining of Inconel 718 |
[50] | Applying different coolant pressures | Improve the machinability of Inconel 718 and Waspalloy |
[51] | Combined using of MQL and cryogenic techniques | Accomplish environmentally efficient machining for difficult-to-cut materials |
[52,53,54,55] | Application of MQL-nano-fluid technique | Enhancing the machinability of Inconel 718 and Ti-6Al-4V in terms of tool wear, power consumption, and surface quality |
[56,57] | Employing MQL with vegetable oil | Achieve sustainable machining of ADI |
[58] | Application of 6R approach and waste management techniques | Enhancing the construction waste recycling |
[59] | Additive manufacturing and nano-technology | Developing the characteristics of the final printed component |
[60] | Implementation of standard health and environmental regulations | Reducing the health and environmental concerns associated with machining operations |
Sub-Cluster | Individual Metric | Measurement Method |
---|---|---|
Direct cost | Labor cost | Total employee payment to machining positions/total number of product units made |
Operation energy cost | Total cost for energy consumed in machine operation/total number of product units made | |
Consumable-related cost | Total cost of consumables/total number of product units made | |
Cutting tool-related cost | Total cost for purchasing new tools + cost for regrinding used tools − cost of recycling used tools)/total number of product units made | |
Packaging-related cost | Total cost for purchasing new packages + used package treatment fee)/total number of product units made | |
Scrap cost | Total cost of scrapped product units/total number of product units made | |
Cost of by-product treatment | Total cost for by-product treatment which is not covered above)/total number of product units made | |
Training cost | Total training cost/number of employees | |
Indirect cost | Indirect labor cost | Total indirect labor cost/total number of product units made |
Maintenance cost | Total cost for equipment maintenance/total number of product units made | |
Audit and legal cost | Total cost of audits, legal services, and litigation/total number of product units made | |
Cost of safety investment | Total cost of equipment/total number of product units made | |
Capital cost | Cost of depreciation | Total depreciation of storage and fixed facilities/total number of product units made |
Cost of tools/fixtures investment | Total cost of jigs and fixtures/total number of product units made |
Sub-Cluster | Individual Metric | Measurement Method |
---|---|---|
Working environment conditions (health) | Chemical concentration | Chemical concentration in the working environment (break down to the chemical list |
Mist/dust level | Micro-particle concentration in the working environment | |
Noise exposure | Noise level in the working environment | |
Temperature | Temperature level in the working environment | |
Other hazardous exposure | Hazardous exposure level in the working environment | |
Physical load index | Physical load index | Measured physical load index |
Absentee rate | Health-related absenteeism rate | Health-related absenteeism rate |
Working environment conditions (safety) | Exposure to corrosive/toxic chemicals | Number of points with corrosive or toxic chemicals/total number of employees (break down to chemical list |
Exposure to high temperature surfaces | Total number of high-temperature points exposed to the operator/total number of employees | |
Exposure to high-speed components and splashes | Total number of points with high-speed components exposed to the operator/total number of employees | |
Exposure to high-voltage electricity | Total number of points with high-voltage electricity exposed to the operator/total number of employees | |
Other threatening exposure | Total other exposed points with hazardous effects (splash, sparks, high-energy laser, etc.)/total number of employees | |
Injuries | Injury rate | Total injuries/total number of product units made |
Sub-Cluster | Individual Metric | Measurement Method |
---|---|---|
Consumables | Ratio of consumables recovered | Mass of recovered consumables/total mass of used consumables |
Ratio of consumables reused | Mass of reused consumables/total mass of used consumables | |
Ratio of consumables recycled | Mass of recycled consumables/total mass of used consumables | |
Mass of disposed used consumables | Mass of used consumables going to landfill/total number of product units made | |
Packaging | Ratio of used packaging recovered | Mass of recovered packaging/total mass of used packaging material |
Ratio of used packaging reused | Mass of reused packaging/total mass of used packaging material | |
Ratio of used packaging recycled | Mass of recycled packaging/total mass of used packaging material | |
Mass of disposed used packaging | Mass of used packaging going to the landfill/total number of product units made | |
Used raw material (chips) | Ratio of used raw material recovered | Mass of used raw material recovered/total mass of used raw material |
Ratio of used raw material reused | Mass of used raw material reused/total mass of used raw material | |
Ratio of used raw material recycled | Mass of used raw material recycled/total mass of used raw material | |
Mass of disposed used raw material | Mass of used raw material going to landfill/total number of product units made | |
Scrap parts | Ratio of scrap parts recovered | Mass of scrap part recovered/total mass of scrap parts |
Ratio of scrap parts remanufactured | Mass of remanufactured scrap part/total mass of scrap parts | |
Ratio of scrap parts recycled | Mass of recycled scrap part/total mass of scrap parts | |
Mass of disposed scrap parts | Mass of scrap part going to the landfill/total number of products made |
Sub-Cluster | Individual Metric | Measurement Method |
---|---|---|
Production | In-line electricity consumption | Total electricity consumption of all units and equipment in the line/total number of product units made |
In-line fossil fuel consumption | Total fossil fuel consumption of all units and equipment in the line/total number of product units made | |
Transportation | Transportation electricity consumption | Total energy consumption of all transportation equipment in the beginning or end of the line/total number of product units made |
Transportation fossil fuel consumption | Total fossil fuel consumption of all transportation equipment in the beginning or end of the line/total number of product units made | |
Facilities | Electricity consumption on maintaining facility environment | Total energy consumption of all environmental maintenance units and equipment/total number of product units made |
Fossil fuel consumption on maintaining facility environment | Total energy consumption of all environmental maintenance units and equipment/total number of product units made | |
Production supply system | Electricity consumption of concentrated supply system | Total energy consumption of all supply system equipment/total number of product units made |
Fossil fuel consumption of concentrated supply system | Total fossil fuel consumption of all supply system equipment/total number of product units made | |
Maintenance | Electricity consumption on maintenance | Total electricity consumption for maintenance operations/total number of product units made |
Fossil fuel consumption on maintenance | Total fossil fuel consumption for maintenance operations/total number of product units made | |
Efficiency | Energy efficiency | Useful equivalent energy output from the process/total energy input |
Renewable energy | Percentage of renewable energy used | Total consumption of renewable energy/total energy consumption |
Sub-Cluster | Individual Metric | Measurement Method |
---|---|---|
Energy | GHG emission from energy consumption of the line | Total energy consumption/total number of product units made |
Percentage of renewable energy used | Total renewable energy used/total energy consumption | |
Water | Total water consumption of the line | Total water consumption/total number of product units made |
Restricted material | Mass of restricted materials in disposed consumables | Mass of restricted materials in disposed consumables/total number of product units made |
Mass of restricted material in disposed packaging | Mass of restricted material in used packaging/total number of product units made | |
Mass of restricted material in disposed raw materials | Mass of restricted materials in raw material going to landfill/total number of product units made | |
Mass of restricted material in scrap parts going to landfill | Mass of restricted material in scrap parts going to landfill/total number of product units made | |
Disposed waste | Mass of non-collected solid wastes | Total mass of non-collected solid wastes/total number of product units made |
Mass of non-collected liquid wastes | Total mass of non-collected liquid wastes/total number of product units made | |
Mass of non-collected gaseous wastes | Total mass of non-collected gaseous wastes/total number of product units made | |
Mass of solid wastes going to landfill | Total mass of solid wastes going to landfill/total number of product units made | |
Mass of liquid waste disposed | Total mass of liquid wastes going to landfill/total number of product units made | |
Noise pollution | Noise level outside the plant | Noise level measured outside the plant |
Heat | Heat generation | Heat generated by the manufacturing line/total number of product units made |
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Kishawy, H.A.; Hegab, H.; Saad, E. Design for Sustainable Manufacturing: Approach, Implementation, and Assessment. Sustainability 2018, 10, 3604. https://doi.org/10.3390/su10103604
Kishawy HA, Hegab H, Saad E. Design for Sustainable Manufacturing: Approach, Implementation, and Assessment. Sustainability. 2018; 10(10):3604. https://doi.org/10.3390/su10103604
Chicago/Turabian StyleKishawy, Hossam A., Hussien Hegab, and Elsadig Saad. 2018. "Design for Sustainable Manufacturing: Approach, Implementation, and Assessment" Sustainability 10, no. 10: 3604. https://doi.org/10.3390/su10103604