Manufacturing for Environment and Sustainability

Dr. Akepati S. Reddy Associate Professor, Thapar University Adjunct Scientist, TCIRD Patiala (PUNJAB) 147 004

Industrial Systems (Manufacturing Units!)

One of the three vital conversion systems designed, created and managed by human beings Heavily depend on technological and human resources Powered by conventional primary energy sources (fossil fuels) and electrical energy
Solar radiation is usually undesirable and considered as nuisance

Linear systems transforming input materials into finished goods (and services) and wastes
Wastes represent lost production and inefficient use of resources/input materials

Natural resources

Technological and human resources Other natural resources Harvested renewable natural resources

Solar radiation

Harvested renewable natural resources

Natural ecosystem s

Agricultu ral systems

Secondary resources - Agricultural produce
Wastes and residues

Solar radiation and conventional energy

Wastes

Technological and human resources Other natural resources

Industria l systems
Industrial products
Conventional energy Wastes

Other natural resources

Technological and human resources

Human settlemen ts

Technological andWastes human resources

The vital conversion systems of mankind

Interactions of industrial systems with the environment

Interacts with environment through
taking in raw materials, energy, water and chemicals (including toxic/hazardous inputs and ecologically important inputs) inputs are becoming scarce natural resource base is depleting discharging wastes (solid, liquid and gaseous wastes, GHGs, hazardous wastes, radiation and heat, noise and vibrations, etc.)

Industrial products consume valuable resources and generate wastes during use Used industrial products, after service life, are disposed off as wastes

Industrial systems and environment

Both resource consumption and wastes disposal are polluting the environment
Polluting the physical environment (land, water and air) Changing climate, stratospheric ozone layer depletion, and biodiversity loss Depleted and polluted natural resource base Shrinking and unhealthy natural ecosystems and agricultural systems Adversely affecting the finite self-cleansing and resource regenerating capacities of the environment

Polluted environment deteriorates the natural resource base of the environment

Sustainability
Meeting needs of the present without compromising on the legitimate needs of the future generations (Our Common Future Earth Summit, 1992, Rio)
Equality across the world and among the generations!

Polluted environment and depleted natural resource base are making the world unsustainable Meeting the needs (specially biological needs) of majority human populations is threatened Physical environment is becoming less habitable Human settlements are more challenged by more frequent and high intensity natural disasters/calamities Symbiotic coexistence of human settlements with

Sustainable development
Imbibing sustainability concept in all human activities needed
Extraction, storage, transportation, production/manufacturing (by industrial and agricultural systems), use and disposal

Impose limits to renewable resources use Use resources (specially non-renewables) conservatively (proper allocation) and efficiently Find substitutes and compliments to the scarce natural resources Maximize use of flow resources (convert into fund resources!) Use recycled materials in place of virgin resources

Sustainable development
Increase dependence on human and technological resources Maximize human resource use, optimize individual workers productivity, and make human work meaningful/interesting Complement (rather than replace) human work with technology

technology should support extensive use of human resources

Use technology to find new resources and expand the resource base, and to enhance the resource utility value

United Nations indicators of sustainability Agriculture Desertification Deforestation Air quality Ozone layer Greenhouse gas Water Waste volume Nutrition Hazardous Non-renewable Gender Toxic chemicals Poverty equality Education Bio-diversity Health Sanitation Child mortality Housing Employment Population Crime wastes materials

 Key areas of concern in sustainable manufacturing

Manufacturing for sustainability

GHG emissions Material consumption (water, non-renewables, toxic chemicals and ecologically important materials) Wastes (including hazardous wastes)

Ozone layer, air quality, employment, gender equity and health are also important Sustainable manufacturing (in the narrow sense) thus should include the technologies that transform materials without
GHG emissions Using non-renewable or toxic materials Generating wastes

 Use less material (raw materials, water and chemicals) and energy Substitute input materials

Options for sustainable manufacturing

Non-toxic for toxic, renewable for non-renewable, and recycled inputs for virgin resources Substituting ecologically important inputs

Reduce unwanted outputs (avoid or reduce wastes, and encourage cleaner production and industrial symbiosis) Convert outputs to inputs (recycle and reuse wastes, and recover from wastes) Changed structures of ownership and production
Product service systems Deliver function rather than product to customer

What to manufacture?
Manufacture the products having the least life cycle environmental costs
ISO 14040 series of standards provide a systematic and standardized approach for Life Cycle Analysis/assessment

Design for Environment can be used to design products with least environmental costs Design for Dismantling can be employed in the design of products
Reversible manufacturing and modular design of products Dismantling the used products for recovering reusable and recyclable components and updating products through replacing modules become feasible

What to manufacture?
Sustainable manufacturing is possible when consumer demands eco-friendly and least environmental cost products Consumer should be environmentally conscious and environmental information on products should be made available to consumer to facilitate right decisions Eco-labeling, energy star rating etc., provide environmental information on products ISO 14020 series of standards provide a systematic and standardized approach for ecolabeling

 Manufacturing process employed influences

Input materials needed Material and energy intensities of products

How to manufacture/produce and using what inputs?

Product design influences the manufacturing process used For sustainability manufacturing process should
Use non-hazardous, non-toxic and environmentally acceptable inputs, and recycled materials Minimize/eliminate use of scarce non-renewable resources and ecologically important and environmentally damaging resources

Quality of input materials is also important for sustainability (minimizes reworks and waste generation) Green chemistry can provide sustainable

 Sustainable manufacturing process should ensure source reduction of wastes

Right technology, infrastructure, machinery, equipment and instruments System approach and process approach Documented procedures and management practices Total involvement of all the concerned personnel

How to manufacture/produce and using what inputs?

Reduced waste generation can mean

Efficient use of input materials and resources Enhanced productivity Reduced embodied material and energy content of products

 Process improvement and sustainable manufacturing can be achieved by

Breakthrough approach

How to manufacture/produce and using what inputs?

Technology management and R&D bring about breakthroughs

Kaizen approach for continual improvement (modern management systems using PDCA cycle can achieve this)
EMS (BS 16001), EMS (14001), OHSMS (OSHAS 18001), QMS (ISO 9001), etc. can achieve Lean manufacturing can support sustainable manufacturing Can improve the process and the product quality, can minimize waste generation, can

Resource efficiency and waste avoidance/reduction

Sufficiently different from Lean Manufacturing - involves identification and steady elimination of the following 7 (+2) types of wastes
Transport (moving products that is not actually required to perform the processing) Inventory (all components, work in process and finished product not being processed) Motion (people or equipment moving or walking more than required to perform the processing) Waiting (waiting for the next production step) Overproduction (production ahead of demand) Over processing (resulting from poor tool or product design creating activity) Defects (the effort involved in inspecting for and fixing defects) Manufacturing goods or services that do not meet customer demand or specifications Waste of unused human talent

Goal of lean manufacturing is cost reduction not resource efficiency and waste avoidance/reduction

Resource efficiency and waste avoidance/reduction

Goal of resource efficiency and waste avoidance/reduction is environmental protection and sustainability USEPAs Waste Hierarchy is the corner stone for most waste minimization strategies Aim of the Waste Hierarchy is

Extract maximum practical benefits from products, while benefiting the environment through generating minimum of waste and orienting the manufacturing process towards sustainability

W a ste H ie ra rch y

Resource efficiency and waste avoidance/reduction

Pretreatment of waste may be needed
To increase the recycling and reuse potential of wastes To recover residual materials, byproducts and resources To make the waste compatible for mixing with other wastes for further treatment and disposal

An integrated approach is needed for the resource efficiency and waste avoidance/reduction
Reduce, reuse and recycle, recover, treat and disposal steps are used in the same order of priority Reduces manufacturing costs Makes cost-effective and consistent compliance

energy raw material Industrial process product

Recycling & reuse

Wastes for Recycling & reuse secondary wastes byproducts & resources recovered

energy raw material wastes from other processes Pre-treated wastes From other units energy raw material treated wastes for recycling & reuse

Waste pretreatment

treated wastes for recycling & reuse

Waste treatment

secondary wastes byproducts & resources recovered

treated wastes for disposal

Integrated approach for waste management

Resource efficiency and waste avoidance/reduction

Manufacturing units can implement Poll. Prev. Programs
Analyze manufacturing unit to inventory wastes, and to identify and prioritize opportunities for waste minimization Investigate individual opportunities, identify options, feasibility analysis and select options for implementation Implement selected options as pollution prevention projects

EMS (ISO 14001) are replacing Poll. Prev. Programs

Identify significant environmental aspects and manage Achieve continual environmental performance improvement and orient manufacturing units towards sustainability Frame environmental policy, set objectives/targets consistent to policy and implement policy through achieving objectives

Housekeeping and implementation of 5S also helps

 Sorting: Eliminate all unnecessary tools, parts, and instructions, prioritize things as per requirements and keep them in approachable places. Straightening: There should be a place for everything (clearly labeled or demarcated) and everything should be in its place. Items should be kept close to place of use, and arrange items to promotes efficient work flow. Systematic cleaning: Keep the workplace tidy and organized, clean the work area, and be sure everything is restored to its place after use. Standardizing: Work practices should be consistent and standardized. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's. Sustaining: Once the previous 4 S's have been established, they should become the new way to operate. Safety: It is sometimes added. However, it is reasonable to assume that a properly planned and executed 5S program will improve workplace safety. Security: It is also sometimes added. Consider