Green ManufacturingGreen Manufacturing

Swati RastogiSwati Rastogi

OISM 470wOISM 470w

February 19, 2001February 19, 2001

Topics To Be CoveredTopics To Be Covered

• What is green manufacturing?What is green manufacturing?• Terms to knowTerms to know• GoalGoal• Nuts & bolts Nuts & bolts • How it worksHow it works• ObstaclesObstacles• Real world exampleReal world example• Critical thinking exerciseCritical thinking exercise• SummarySummary

What Is Green What Is Green Manufacturing?Manufacturing?

• Green manufacturing is a method Green manufacturing is a method for manufacturing that minimizes for manufacturing that minimizes waste and pollution. These goals waste and pollution. These goals are often achieved through product are often achieved through product and process design. and process design.

Terms to KnowTerms to Know

• Here are some terms to help you Here are some terms to help you better understand the idea of better understand the idea of green manufacturing:green manufacturing:

• Product design – includes the the Product design – includes the the definition of the product definition of the product architecture and the design, architecture and the design, production, and and testing of a production, and and testing of a system for production. system for production.

Terms to Know (2 of 2)Terms to Know (2 of 2)

• Three life cycle approaches to product Three life cycle approaches to product design:design:

• Design for reuse – refers to designing products so Design for reuse – refers to designing products so that they can be used in later generations of that they can be used in later generations of products.products.

• Design for disassembly – a method for developing Design for disassembly – a method for developing products so that they can be easily taken apart.products so that they can be easily taken apart.

• Design for remanufacture – a method for Design for remanufacture – a method for developing products so that the parts can be used developing products so that the parts can be used in other products.in other products.

Goal of Green Goal of Green ManufacturingManufacturing

• The purpose is to support future The purpose is to support future generations by attaining generations by attaining sustainability by the means of sustainability by the means of preserving natural resources.preserving natural resources.

Nuts & BoltsNuts & Bolts

• ““Environmentally benign Environmentally benign manufacturing will become one of manufacturing will become one of industry’s greatest strategic industry’s greatest strategic challenges, not only from an challenges, not only from an engineering perspective, but from engineering perspective, but from a business and marketing a business and marketing perspective as well.” (3)perspective as well.” (3)

Strategic ChallengesStrategic Challenges

• Range of coordinated actionsRange of coordinated actions• Trade and environment policies (mutually Trade and environment policies (mutually

supportive)supportive)• Eliminating environmental harmful Eliminating environmental harmful

subsidiessubsidies• Promoting the transfer of technologies Promoting the transfer of technologies

and financial resourcesand financial resources• Efficient operation of marketsEfficient operation of markets• Achieving greater international Achieving greater international

cooperation (4)cooperation (4)

ObstaclesObstacles

• Businesses have a responsibility of Businesses have a responsibility of influenceinfluence

• Prices of raw material and Prices of raw material and subsidized energy are essential subsidized energy are essential

• Lack of availability and information Lack of availability and information (4)(4)

Obstacles (2 of 2)Obstacles (2 of 2)

• High-profile leadershipHigh-profile leadership• Training programs need more Training programs need more

supportsupport• Accessibility to loans from the Accessibility to loans from the

governmentgovernment• National cleaner production centers National cleaner production centers

need to be established (4)need to be established (4)

How It WorksHow It Works

1)1) Rethink product and process Rethink product and process technologytechnology

2)2) Explore the market potentialExplore the market potential

3)3) Supply goods and servicesSupply goods and services

4)4) Extend producer responsibility (4)Extend producer responsibility (4)

How It Works (2 of 2)How It Works (2 of 2)

1)1) Reduce energy consumptionReduce energy consumption

2)2) Integrate promotionIntegrate promotion

3)3) Incorporate goalsIncorporate goals

4)4) Promote developmentPromote development

5)5) Integrate environmental costs (4)Integrate environmental costs (4)

Real World ExampleReal World Example

• The need for fossil fuels has lead to The need for fossil fuels has lead to discoveries of different methods of discoveries of different methods of manufacturing that replace manufacturing that replace renewable resources.renewable resources.

Real World ExampleReal World Example

• Petroleum.Petroleum.• Fossil fuel base for plastic.Fossil fuel base for plastic.• Can be replaced by plants.Can be replaced by plants.

» Corn can be fermented into Corn can be fermented into polyhydroxyalkanoates (PHA).polyhydroxyalkanoates (PHA).

» Final product is synthesized biologically and Final product is synthesized biologically and completely biodegradable.completely biodegradable.

• Fast food and packaging industry use polystyrene Fast food and packaging industry use polystyrene which has similar characteristics as PHA.which has similar characteristics as PHA.

Real World Example – How Real World Example – How It WorksIt Works

• Corn is grown and harvestedCorn is grown and harvested• Transported to manufacturing plantTransported to manufacturing plant• Glucose extracted and fermentedGlucose extracted and fermented• Cells are washed and spun in centrifuge Cells are washed and spun in centrifuge

twicetwice• Concentrated and dried into powderConcentrated and dried into powder

Critical Thinking ExerciseCritical Thinking Exercise

• ““Do you think that this process of Do you think that this process of turning corn or plants into other turning corn or plants into other fossil fuels will be beneficial to the fossil fuels will be beneficial to the environment in the future?” (3)environment in the future?” (3)

• Why or why not? Why or why not?

Researched ResponseResearched Response

• More energy is consumed during More energy is consumed during polymer production through plant polymer production through plant fermentation.fermentation.

• Energy is required to produce fertilizer, Energy is required to produce fertilizer, insecticide, and herbicides.insecticide, and herbicides.

• Energy is also required in growing, Energy is also required in growing, harvesting, and processing. (3)harvesting, and processing. (3)

Researched Response (2 Researched Response (2 of 3)of 3)

• Total energy for 1 lb. Of PHA s equal to Total energy for 1 lb. Of PHA s equal to the utilization of 2.38 lbs of fossil fuel the utilization of 2.38 lbs of fossil fuel resourcesresources

• Same amount of polystyrene using Same amount of polystyrene using chemical manufacturing needs only chemical manufacturing needs only 2.26 lbs of oil2.26 lbs of oil

• 19 times more electricity, 22% more 19 times more electricity, 22% more steam, and seven times more water steam, and seven times more water (3)(3)

Researched Response (3 Researched Response (3 of 3)of 3)

• 2.39 lbs would have to be burned to 2.39 lbs would have to be burned to make energy in fermentationmake energy in fermentation

• 1.26 lbs would be burned in chemical 1.26 lbs would be burned in chemical manufacturingmanufacturing

• Polluting effects are greater (3)Polluting effects are greater (3)

PredictionsPredictions

• ““Given adequate support, renewable energy Given adequate support, renewable energy technologies can meet much of the growing technologies can meet much of the growing demand at prices lower than those usually demand at prices lower than those usually forecast for conventional energy. By the forecast for conventional energy. By the middle of the 21middle of the 21stst century, renewable century, renewable resources of energy could account for 3/5 of resources of energy could account for 3/5 of the world’s electricity market and 2/5 of the the world’s electricity market and 2/5 of the market for fuels used directly. Moreover, market for fuels used directly. Moreover, making a transition to renewable-intensive making a transition to renewable-intensive energy economy would provide energy economy would provide environmental and other benefits not environmental and other benefits not measure id standard economic accounts”.(4)measure id standard economic accounts”.(4)

SummarySummary

• ““Cleaner production is a preventive Cleaner production is a preventive strategy that aims at promoting the use strategy that aims at promoting the use and the development of cleaner, and the development of cleaner, processes, products, and services”. (4)processes, products, and services”. (4)

• ““A key to more sustainable development A key to more sustainable development is long-term structural changes in the is long-term structural changes in the way our economies work”. (2)way our economies work”. (2)

BibliographyBibliography

1.1. ““Foster, S. Thomas. Foster, S. Thomas. Managing Quality: An Integrative Managing Quality: An Integrative ApproachApproach. Upper Saddle River: Prentice Hall, 2001.. Upper Saddle River: Prentice Hall, 2001.

2.2. ““Green Manufacturing Can Be Worse For Environment.” Green Manufacturing Can Be Worse For Environment.” Unisci.com.Unisci.com. http://unisci.com/stories/19993/0824995.htm (24 Aug http://unisci.com/stories/19993/0824995.htm (24 Aug 1999). 1999).

3.3. Green Manufacturing Is A Strategic Priority.” Green Manufacturing Is A Strategic Priority.” ManufacturingNews.com. ManufacturingNews.com. http://manufacturingnews.com/news/00/0915art1.html http://manufacturingnews.com/news/00/0915art1.html (15 Sept. 2000).(15 Sept. 2000).

4.4. ““Oslo Roundtable On Sustainable Production and Oslo Roundtable On Sustainable Production and Consumption.” Consumption.” Linkages.Linkages. http://www.iisd.ca/linkages/consume/oslo006.html.http://www.iisd.ca/linkages/consume/oslo006.html.