Sustainable Design and Manufacturing: Can we “Engineer our way” to a Sustainable Future? David Dornfeld Will C. Hall Fa

1. Sustainable Design and Manufacturing: • Can we “Engineer our way” to a Sustainable Future? • David Dornfeld • Will C. Hall Family Professor of Engineering • University of California • Mechanical Engineering Department • Berkeley CA 94720-1740 • Laboratory for Manufacturing And Sustainability (LMAS) DRAFT

2. Outline • Defining sustainability • Sustainability in an engineering context • Sustainability in a manufacturing context • Summary and tasks DRAFT

3. So…what does sustainable mean? One good definition of sustainability- "an economic state where the demands placed upon the environment by people and commerce can be met without reducing the capacity of the environment to provide for future generations.....your business must deliver clothing, objects, food or services to the customer in a way that reduces consumption, energy use, distribution costs, economic concentration,soil erosion, atmospheric pollution, and other forms of environmental damage. Leave the world better than you found it." From Paul Hawken, The Ecology of Commerce, Collins, 1993, p. 139. DRAFT

4. Then…what does sustainable require? If you are presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands of the future. This is a net zero impact. If you are NOT presently at a sustainable state…then meet the demands of today without compromising our ability to meet the demands of the future by reducing the environmental load/unit of commerce to offset any increase in unit production so as to achieve a sustainable state over time. That is, in the words of Hawken, your business must deliver clothing, objects, food or services to the customer in a way that reduces consumption, energy use, distribution costs, economic concentration, soil erosion, atmospheric pollution, and other forms of environmental damage at a rate greater than the normal growth in consumption would require. Business must have a “net positive impact.” DRAFT

5. Consumption with increased efficiency Consumption at “today’s rate” Rate of Consumption* Sustainable rate Today Future Sustainability Frame of Reference Required Consumption Rate to reach Sustainability • Any resource: energy, • material, water,air … How do we achieve this “slope change”? DRAFT

6. Mind the gap!Responses to the situation Time Scale Response Drivers Short regulations (green buildings gov’t/EU market Energy Star, CAFÉ, etc.) driven Medium alternate energy, hybrids, H2, resource limits and photovoltaic long range market Long tools to engineer sustainable change of approach, systems, life cycle env costs holistic view of effects included in product cost DRAFT

7. Think Global - Act Local Design and Manufacturing - think supply chain…act process Is the process - coupled? - decoupled? with respect to environmental impacts (materials, energy required, consumables, waste generated) DRAFT

8. Process1 Process2 Process3 ProcessN … 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? DRAFT

9. More details Let’s define the terms more specifically wrt manufacturing… DRAFT

10. Closed Loop Manufacturing: Renewing Functions while Circulating Material Source: T. Tani, “Product Development and Recycle System for Closed Substance Cycle Society,” Proc. Environmentally Conscious Design and Inverse Manufacturing, 1999, 294-299. Ref: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655 DRAFT

11. Closed Loop Manufacturing: Renewing Functions while Circulating Material • Each orbit in the figure corresponds to a life cycle option, such as • prolonged use by means maintenance, product reuse, part reuse, • recycling, and energy recovery. • To realize “closed-loop manufacturing” the product life cycle should • be managed by selecting proper life cycle options. • In selecting life cycle options, need to consider the environmental • performance or “eco-efficiency” of the option…defined as the ratio • of provided value to environmental load. • The closer the “loop” is to the user…the lower the load on the • environment. Source: S. Takata, et al, “Maintenance: Changing Role in Life Cycle Management,” Annals CIRP, 53, 2, 2004, 643-655 DRAFT

12. Detail design DFA DFE LCA Product definition Manufacturing Process selection/ development Recycling organizations All included in Sustainability End-of-life Product design, manufacturing and recovery After Ishii, K., "Incorporating End-of-Life Strategy in Product Definition," Invited paper, Eco Design '99: First International Symposium on Environmentally Conscious Design and Inverse Manufacturing, February 1999, Tokyo, Japan. DRAFT

13. Green Machines Green Manufacturing Processes Clean Power Green Products Closer Focus on Manufacturing “Ecofacturing*” or “Ecomanufacturing**” Source: * TM Taiheiyo Cement, Japan **IGPA Newsletter, Dec. 2003 DRAFT

14. Evolution of Production Paradigms Green…yes… but…is this really sustainable? Source: F. Jovane, et al, “Present and Future of Flexible Automation: To wards New Paradigms, CIRP Annals, 52, 2, 2003, 543. DRAFT

15. Key transitionsWhat’s needed to make the last transition? Automation “F. W. Taylor” Computer Aided Manufacturing (CAM) “M. E. Merchant” Lean Manufacturing “Toyoda, et al” Positive Impact Manufacturing DRAFT

16. 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 DRAFT

17. design (functionality, complexity, life) (energy, consumables, waste, hazards, end-of-life) environment production/distribution (quality, yield, throughput, flexibility/lean) Dimensions of design, manufacturing and environment co$t DRAFT

18. So….what do we learn from all this? • Think globally…act locally! • think corporate…..act departmentally! • think department…act system! • think system…act process! • think process….act machine! • think machine…act tool! (ok…ok…point made) • Waste, of any resource (time, money, energy, space, • consumables, etc.) costs…..eliminate waste (follow • Deming!) • Make the business case for sustainable manufacturing • by including life cycle cost of environmental impact • Include your suppliers/distributers in this through the design • process • Need analytical/engineering tools (design/process plan) to • enable decisions/tradeoffs DRAFT

19. How do we respond as engineers? • Make sure we evaluate the “real” impact of our technical solutions • in terms of how much of the “gap” we are removing (i.e. how • much is a particular technology “wedge” going to reduce the gap?*) OR design our technical solutions to have the largest impact on the gap. • Make the business case for sustainable manufacturing • by including life cycle cost of environmental impact (the “true cost” of the product including the ‘environmental capital’) • Include the supply chain in this through the design process • Develop analytical/engineering tools (design/process plan) to • enable decisions/tradeoffs based on life cycle costs…ie EnviroCAD • Make sure to include our social science/policy friends in the • discussion as there will be “side effects” • Capitalize on the technology innovations as entrepreneurs • Educate…educate…educate • Ref. S. Pacala and R. Socolow, "Stabilization Wedges: Solving the Climate Problem for the next 50 • Years with Current Technologies," Science, August 2004, Vol. 305, pp. 968-972. DRAFT