Beyond the 3R's: 6R Concepts for Next Generation Manufacturing:

Symposium on Sustainability and Product DevelopmentIIT, Chicago, August 7-8, 2008Beyond the 3R’s: 6R Concepts forNext Generation Manufacturing:Recent Trends and Case StudiesProfessor I.S. JawahirJames F. Hardymon Chair in Manufacturing Systems, andProfessor of Mechanical Engineering, andDepartment of Mechanical EngineeringUniversity of KentuckyLexington, KY, USAResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Presentation Outline• Sustainability: General Background• Total Product Life-cycle Consideration, including End-of-Life Options• Sustainable Manufacturing: Definitions, Basic Elements and MostCommon Terms• Product Sustainability Assessment – A Summary• Case Studies:(a)(b)(c)Machining Processes: Sustainability EvaluationConsumer Electronic Products: Development of a Sustainability Scoring Methodfor Laser PrintersAutobody Design and Manufacture: Total Life-cycle Analysis and Applications• National and International Trends• Scientific and Technological ChallengesResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainability:General BackgroundResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainability: Definitions• “Sustainability” means different things to different people• There is no universally acceptable definition for the term“sustainability”, but the most commonly known definitioncomes from the 1987 U.N. Brundtland Commission headedby Dr. Gro Harlem Bruntland:Dr. Gro Harlem Brundtland“ Meeting the needs of present without compromisingthe ability of future generations to meet their ownneeds”• Some of the most commonly known sustainability termsare:(a) Environmental Sustainability(b) Economic Sustainability(c) Societal SustainabilityResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Similar ThoughtsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

SocietyPeopleSUSTAINEnvironmentPlanetEconomyProsperityOBJECTIVESSociety• Improved Health• Safety• Enhanced Qualityof life• EthicsEnvironment• Cleaner Air, Water and Soil(Lower Toxicity & Pollution)• Eco-balance & Efficiency• Greater Implementationof Regulations, Codes, etc.(Improved Logistics)Economy• New Employment• Product and ProcessInnovation (TechnologicalAdvancement)• Large-Scale new businessopportunities(3 new “R”s)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainability DriversResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Significance of SustainabilitySource: http://www.beechenhill.co.uk/sustainability.htmResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

How many Earths have we got ??Can a single earth support the ever-increasing demands for resources ?Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

We will need six Earths for all countries to reach theU.S. level of consumptionResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable GrowthBalances economic, environmental and societal needsSource: che.chonbuk.ac.kr/data/ BASF%20-%20SH%20Lee%20lecture.pptResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

SustainableAgricultureSustainableEnergyEconomySustainableTransportationInnovationCreativitySustainableConstruction &BuildingTechnologySustainableHousingEnvironmentSocietySustainableArchitecture &DesignSustainableAssets &ManagementEducation & TrainingSustainableManufacturingSustainableCompanies &Business

SystemsSustainableManufacturingProductsProcesses

Ever-increasing Traffic Flow and PollutionA traffic jam idles motorists in Bangkok; carbon emissions from gasolineburningcars are one of the causes of global worming(Source: TIME Global Warming, 2007)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Global WarmingSource: US News & World Report, July 2004Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

US Waste Generation Rates and LandfillHow Long Does It Take for Some CommonlyUsed Products to Biodegrade ?Source: http://www.zerowasteamerica.org/images/6-1.gifResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Automotive and Consumer ProductsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USASource: http://www.inmagine.com/pdv031/pdv031027-photoCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

World’s Annual Material WasteResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Projected World Population by 2050Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

GDP Growth Rate6Percent/YearGDP Capita Growth Rate543210AsiaDevelopingWorldLatinAmericaAfrica World DevelopedWorldResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Most Common E-waste Components• Printed circuit boards• Cathode ray tubes• Wires and cables• Mercury switches• Batteries• Light generators (e.g., lamps)• Capacitors and resistors• Sensors and connectorsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Electronic Waste• Computer equipment is a complicated assembly of more than 1,000components, many of which are hazardous and toxic.• A major culprit in the hazardous waste areas is the computer monitorand television cathode ray tube (CRT), which contains five to eightpounds of lead.• The non-biodegradable refuse from e-waste and other sources oftenends up in land-fills or incinerators where toxic substances such asresidues of lead, cadmium, lethal mercury, carcinogenic asbestos, tinplates, arsenic, PVC and plastic waste, lead and cadmium batteriesetc. contaminate the land, water and air, posing serious health hazardsand affecting the environment.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USASource:http://www.tribuneindia.com/2004/20040322/login/main1.htmCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Legislative Drivers• Waste Electrical & Electronic Equipment (WEEE)Directive• Restriction of Hazard Substances (RoHS) Directive• End of Life Vehicles (EoL)• Eco-design of End Use Equipment (EuP) DirectiveResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Electronic Waste Covered by the WEEE LegislationResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Ten Categories of Electronic WastesCovered by the WEEE Legislation1. Large Household Appliances - washing machines, fridge/freezers, microwaves, fans,radiators, large appliances for heating rooms/beds/seating furniture2. Small Household Appliances - vacuum cleaners, irons, electric knives, clocks, scales3. IT and Telecom.- computers, calculators, phones4. Consumer Equipment - radios, TVs, VCRs5. Lighting Equipment - luminaires (excluding household), straight/compact fluorescentlamps, otherlighting of equipment for spreading or controlling light (excluding filamentbulbs)6. Electrical/Electronic Tools (excluding large scale stationary industrial tools) - drills, sewingmachines, sprayer/spreaders, lawn mowers7. Toys & Leisure/Sports Equipment - train sets, video games, cycle computers8. Medical Devices (excluding implanted and infected devices) (Excluded from RoHS) -dialysis, nuclear medicine, freezers9. Monitoring & Control Instruments (Excluded from RoHS) - smoke detectors, thermostats,measuring/weighing appliances10. Automatic Dispensers – coffee/drinks machines, ATMs.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Total Life-cycle ConsiderationsandEnd-of-life OptionsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Changing Faces of Life-cycle ProgressionRef: http://www.scienceinthebox.com/en_UK/sustainability/lifecycleassessment_en.htmlResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Cradle to Cradle Approach(Life-cycle Thinking – http://www.ami.ac.uk/courses/topics/0109_lct/)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Life-Cycle Stages of a Manufactured ProductSTAGE IV:POST-USESTAGE III:USESTAGE I:PRE-MANUFACTURINGSTAGE II:MANUFACTURINGSource: ALCAN: Life Cycle Management in the aluminum industryResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Take It Back!Extended Producer Responsibility (EPR) Laws- Require companies to take back products after their useful life- The goal is to induce manufacturers to# eliminate unnecessary parts# forgo unneeded packaging# design products that can easily be disassembled, recycled,remanufactured, or reusedSource: http://www.globalchange.umich.edu/gctext/Leo%20Wiegman/Moving%20Toward%20aonomy%20Jan05.pptResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Take It Back! (Contd.)• Several countries in Europe, Asia, and Latin America have implemented EPRlegislation for a wide range of products, including:- packaging- electric and electronic equipment-vehicles- tires- batteries- office machineryResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USASource: http://www.globalchange.umich.edu/gctext/Leo%20Wiegman/Moving%20Toward%20aonomy%20Jan05.pptCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing:Definitions, Basic Elements andMost Common TermsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing: Terms and Definitions• Environmentally-responsible manufacturing• Environmentally benign manufacturing• Cleaner processes (Green manufacturing)• Economically advantageous manufacturing (Leanmanufacturing)• Energy-efficient manufacturing• Manufacturing using renewable source of energyResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing: Basic ElementsExpectations:• Reducing energy consumption• Reducing waste• Reducing material utilization• Enhancing product durability• Increasing operational safety• Reducing toxic dispersion• Reducing health hazards/Improving health conditions• Consistently improving manufacturing quality• Improving recycling, reuse and remanufacturing• Maximizing sustainable sources of renewable energyResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing: Design Objectives• Designing for Repair, Reuse and Recycling• Designing for Waste Minimization• Designing for Product Disassembly• Designing for Energy Efficiency• Designing for Product Demanufacturing• Designing for Remanufacturing• Designing for Serviceability• Designing for Reduced Materials Use• Design and Manufacture for Reduced Costs• Sustainable Design and Manufacture (Designing forSustainability)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing: The Paradigm “E”• Ecology• Environment• Energy• Economy• Employment• Empowerment• Education• ExcellenceResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainable Manufacturing: DefinitionDesign and manufacture of high quality/performance productswith improved/enhanced functionality using energy-efficient,toxic-free, hazardless, safe and secure technologies andmanufacturing methods utilizing optimal resources andenergy by producing minimum wastes and emissions, andproviding maximum recovery, recyclability, reusability,remanufacturability, with redesign features, and all aimed atenhanced societal benefits and economic impact.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Evolution of Sustainable ManufacturingStakeholder ValueInnovation ElementsRemanufactureRedesignRecoverRecycleReuseReduceSustainable Manufacturing(Innovative, 6R-based)Green Manufacturing(Environmentally-benign, 3R-based)Lean Manufacturing(Waste Reduction-based)Traditional Manufacturing(Substitution-based)1980 1990 2000 2010 2020 2030 2040 2050TimeResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

3RCONCEPT6RCONCEPTRAWMATERIALSENERGYWASTESEMISSIONSResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Material flow and its Interaction with 6RsApplication ofLeanManufacturingConceptsREDUCETotal Life-cycle StagesPRE MANUFACTURINGMANUFACTURINGSubsequent(2 nd and beyond)Life-cycle StagesUSEREUSEApplication ofTotalSustainabilityConceptsRECYCLE3R Concept6R ConceptPOST USERECOVERREDESIGNREMANUFACTUREAcceptableRecovered MaterialQuality ?YResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USANLandfillCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Product Value Gained from 6RsPost-useSavings ($)gained byconsumerVALUE ($)ManufacturingUseReuseRemanufactureRedesignUsePre-manufacturingDisposalDisposalSavings ($)gained bymanufacturerRecycleRecoverLandfillTraditional product life-cycle1 st life-cycle of product (extended life-cycle)2 nd and subsequent life-cycles of productPRODUCT LIFE-CYCLE STAGESResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Product Sustainability Assessment:A SummaryResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Selected Eco-labels and Products StandardsProduct Specific StandardsForest Stewardship CouncilCertified WoodClean VehiclesCertified Green-e ProgramUS Green Building CouncilLEED Rating SystemCleaner and Greener CertificationResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USAOverall StandardsNatural Step System ConditionsNordic Swan Eco-labelGreen Seal Product StandardsLife Cycle Assessment (LCA)European Union Eco-labelEnergy Star Eco-labelSustainable Textile StandardCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Factors Affecting Product SustainabilityResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Integral Elements of Design for Sustainability (DFS)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Product Sustainability AssessmentResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Methodology for CalculatingProduct Sustainability Index (PSI)A new 3 step methodology is introduced.Step 1:• The product developers need to identify potential influencing factors based onnational/international regulations, federal and state laws, to be important factorsfrom their own perspective.• Focus on all three components of sustainability.• Focus on all four life-cycle stages.Step 2:• A 3x4 matrix that represents all components of sustainability and all four life-cycle stages.• Allocate a score/rating between 0-10 for each influencing factor.• Weighting can be applied to the influencing factors based importance.• Non-quantifiable factors can be scored based on designers’ experience and judgment.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Analytical Foundation ofProduct Design for SustainabilityStep 3:Methodology for Calculating PSIPSI( en _ pm)= {[ ∑ IFni=1( en _pm)i]/( n *10)}*100%PSI (en_pm)= Product Sustainability Index for Environment componentof Pre-manufacturing stageIF (en_pm)= Influencing Factor rated on a scale of 0-10 for the Environment componentof Pre-manufacturing stagen = Number of influencing factors consideredResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Analytical Foundation ofProduct Design for Sustainability (contd.)PSI en= [PSI (en_pm)+ PSI (en_m)+ PSI (en_u)+ PSI (en_pu)]/4where,PSI (en_pm)= Product Sustainability Index for Environment component of PremanufacturingstagePSI (en_m)= Product Sustainability Index for Environment component ofManufacturing stagePSI (en_u)= Product Sustainability Index for Environment component of Use stagePSI (en_pu)= Product Sustainability Index for Environment component of Post-use stageThe overall product sustainability index (PSI TLC) for a product over its total life-cyclePSI TLC= PSI so+ PSI en+ PSI ecPSI so = PSI for Society ComponentPSI en = PSI for Environment ComponentPSI ec = PSI for Economy ComponentResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

A Framework for Comprehensive Total Life-cycleEvaluation Matrix for Product SustainabilityPre-manufacturing Manufacturing Use Post-useScoreout of 10Influencing Factors in the Product Life-cycle StagesScoreout of 10Scoreout of 10Scoreout of 10Material Extraction 7 Production Energy Used 7 Emissions 9 Recyclability 7Design for Environment 8 Hazardous Waste Produced 9 Functionality 8 Remanufacturability 8EnvironmentMaterial Processing 6 Renewable Energy Used 8 Hazardous Waste Generated 9 Redesign 7Landfill Contribution 7(%) PSI (en_pm) = 70 (%) PSI (en_m) = 80 (%) PSI (en_u) = 86.67 (%) PSI (en_pu) = 72.5(%) PSI en =77.29Sustainability ComponentsWorker Health 8 Work Ethics 7 Product Pricing 7 Take-back Options 7Work Safety 8 Ergonomics 7 Human Safety 9 Re-use 6Ergonomics 7 Work Safety 8 Upgradeablility 7 Recovery 7SocietyComplaints 8(%) PSI so = 73.54(%) PSI (so_pm) = 76.67 (%) PSI (so_m) = 73.33 (%) PSI (so_u) = 77.5 (%) PSI (so_pu) = 66.67Raw Material Cost 6 Production Cost 6 Maintenance Cost 7 Recycling Cost 7Labor Cost 3 Packaging Cost 7 Repair Cost 6 Disassembly Cost 8Energy Cost 8 Consumer Injury Cost 8 Disposal Cost 4Economy Transportation Cost 5 Consumer Warranty Cost 7 Remanufacturing Cost 7 (%) PSI ec = 61.25(%) PSI (ec_pm) = 45 (%) PSI (ec_m) = 65 (%) PSI (ec_pu) = 70 (%) PSI (ec_pu) = 65(%) PSI pm = 63.89 (%) PSI m = 72.78 (%) PSI u = 78.06 (%) PSI pu = 68.06 (%) PSI TLC = 70.69SymbolScoreExcellent85-90%Good70-84%Average50-69%Poor< 50%Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Generic Product Sustainability ScoreAir PollutionRecyclability10MaterialConsumption010100Reliability0Price of ProductWorkerSafetyFuel EconomyHazardousSubstanceSociety Environment EconomyA Generic product sustainability score showing the influence of variousfactors on society, environment and economy and their sustainability ratingsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Matrix for Assessing the 6RsProduct Life-cycle Stages for Multiple Life-cycles1st Life-cycleSubsequent Life-cyclesPre-Manufacturing Manufacturing Use Post-use Pre-Manufacturing Use Post-useManufacturingSustainability ComponentsEnvironmentSocietyEconomyR1R1R1R1 R1 R1 R2 R3R4 R5 R6R1R1R1 R2 R3R4 R5 R6R1R1R1 R2 R3R1 R2R5R1 R2R5R1 R2 R3R1 R2 R3R6R1 R2 R3R6R1 R2 R3R1 R2R1 R2 R3R1 R2R1 R2 R3R4 R5 R6R1 R2 R3R4 R5 R6R1 R2 R3R4 R5 R6R4 R5 R6R6R4 R5 R6R1 - Reduce R2 - Reuse R3 - Recycle R4 - Recover R5 - Redesign R6 - RemanufactureMatrix showing a generic scoring methodology for assessing the 6Rs in terms ofeconomy, environment and society for multiple life-cycles.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Reduce, Reuse, Recycle:The Key to Sustainable Product Manufacturing• Internal program for sustainable product design &manufacturing• Reduces energy use• Reduces manufacturing waste• Reduces water use• Reduces emissions• ISO 14001 certification• ISO 14040 compliant product life cycle assessments (LCAs)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Recyclable to Certified Sustainable ProductReduceReduceRemanufactureReuseCertifiedSustainableProductRecycleReuseRedesignRecoverRecycleResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Studies and Present TrendsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Turning Operations2-D Cyclic Chip Formation 3-D Cyclic Chip FormationResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Basic Sustainability Elements in MachiningEnvironmentalFriendlinessMachiningCostPersonnelHealthSustainableMachiningProcessesPowerConsumptionOperationalSafetyWasteManagementFuzzy natureAnalyticalResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Regulating (Enforcing) OrganizationsMethodologies to measure sustainability variables as wellas regulations used to set the range of the variables can beobtained from many sources:• National Institute for Occupational Safety and Health (NIOSH)• Occupational Health and Safety Administration (OSHA)• Environmental Protection Agency (EPA)• Safety & Health Assessment & Research for Prevention (SHARP), etc.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainability Index: First ApproachOperationalsafety+PersonnelhealthMachiningcostPowerconsumptionWastemanagement+Environmentalfriendliness⎛ MC MC ⎞ ⎛ PC PC ⎞ ⎛ CB CB ⎞min−min−−minS = CMC⋅⎜+ 1 CPC+ CCB⋅+ SMC MC⎟ + ⋅⎜+ 1PC PC⎟⎜CB CB⎟⎝ max−min ⎠ ⎝ max−min ⎠ ⎝ max−min ⎠Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USASHEf (V, f, d) F (s i )Copyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Methodology for SSHES SHEPrimary fuzzy rulesOperationalsafetyPersonnelhealthEnvironmentalfriendlinessSecondary fuzzy rulesOperatorsafetyProcesssafetyWorkplacecontaminationWastesRecyclingTertiary fuzzy rulesMachining sustainability variablesResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Proposed Overall Sustainability Index for MachiningS=CSHE⋅SSHE+Cop⋅Sopwhere S SHE= sustainability index for safety, health and environmentalissues assessed using fuzzy logic,S op represents the operational sustainability level of the processaccording to the cost of machining, power consumption andwaste management, andC SHE and are weighting factors.C opResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Optimization for Operational Sustainability IndexFor the multi-pass turning operation problems,S( V , f , d ,( i 1,2,... N))op i i i==1N ⎡ ⎛ MC= ⎥ ⎤min− MCi⎞ ⎛ PCmin− PCi⎞ ⎛ CBi− CBmin⎞⎢C⋅⎜+⎟ + ⋅⎜+⎟ + ⋅⎜⎟MC1 CPC1 CCB⎣ ⎝ MCmax− MCmin⎠ ⎝ PCmax− PCmin⎠ ⎝ CBmax− CB ⎠⎦∑N i 0 minwhere the N parameter is the number of passes in a turning operation,V i is the cutting speed, f i is the feed rate and d i is the depth of cut for eachpassConstraints are presented as :MCmin≤MCi ≤ MCmax, PCmin≤ PCi≤ PCmax, CBmin≤ CBi≤ CBmax,( i =1,2,... N)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

The Structure of the Optimization ProcessMetalCuttingTheoriesSelectOptimizationObjectivesDatabase ofExperimentalResultsProcessModelOptimizationAlgorithm(SA)Most SustainableCutting ConditionsNumericalMethodsSet Constraintsof MachiningSustainabilityMeasuresResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Optimization ConstraintsConstraints for two-pass turningM RTwo-pass turningTurning pass Roughing pass Finishing passV (m / min)150-250 250-400f ( mm / rev)0.15-0.254 0.056-0.15d(mm)1.20-1.905 0.254-1.20MC($)1.7-2.6 2.5-4.1PC(KW )2.5-3.4 1.3-2.2CB 0.6 0.7R a( μ m)(N)F c3( mm / min)(min)3.2 0.81200 50030 000 15 000T 6.00 2.00Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Optimization Results for Two-pass TurningTotal depth of cut 2.7 (P) 2.9 (Q)[ C C , C ]MCOptimumcuttingconditions, [0.8,0.15,0.05] [0.6,0.35,0.05] [0.8,0.15,0.05] [0.6,0.35,0.05]PCCBTurning pass Rough Finish Rough Finish Rough Finish Rough FinishV (m / min) 150 250 150 250 150 250 150 257( mm / rev)(mm)f 0.247 0.116 0.235 0.116 0.229 0.112 0.215 0.107d 1.613 1.087 1.613 1.087 1.771 1.129 1.817 1.083PredictedmachiningperformanceandsustainabilityR a( μ m) 2.491 0.800 2.227 0.800 2.153 0.775 1.866 0.739F c(N) 1091 361 1037 361 1091 365 1051 3373M R( mm / min) 59782 31440 56798 31432 60936 21756 58635 30002T (min) 6.307 4.260 6.489 4.261 6.129 4.199 6.228 4.166MC ($) 1.734 2.500 1.782 2.500 1.853 2.578 1.935 2.619PC (KW ) 3.207 1.770 3.048 1.769 3.210 1.788 3.089 1.704CB 0.67 0.76 0.68 0.76 0.64 0.75 0.64 0.77S 83.58 92.17 71.80 81.73 73.38 94.12 67.47 92.41opSop87.88 76.77 83.75 79.94Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Contour Plot (Roughing)Feasible region in rough turning, V = 150 m/min, d t= 2.7 mmC , C , C = 0.8,0.15,0.05MC PC CBResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USA[ ] [ ]Copyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Contour Plot (Finishing)Feasible region in finish turning, V = 150 m/min, d t= 2.7 mmC , C , C = 0.8,0.15,0.05MC PC CBResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USA[ ] [ ]Copyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Proposed Sustainability Rating SystemEnvironmental FriendlinessEnergyConsumption8PersonnelHealth66203 7WasteReductionOperational SafetyMachiningCost0 2 4 6 8 10worstbestResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Study 2Consumer Electronic Products:Development of a Sustainability ScoringMethod for Laser PrintersResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Various Types of Laser and Inkjet PrintersLaser PrintersResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USAInkjet PrintersRef: www.lexmark.comCopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Elements of SustainabilityEnvironmentalImpactSocietalImpactResourceUtilization/EconomyProductSustainabilityScoringModelRecyclability/RemanufacturabilityFunctionalityManufacturabilityResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Framework for the Product Sustainability ModelProductSustainability Index6 SustainabilityElements24 Sub-ElementsThe index is theweighted average ofthese sub elementsThese factors areequally weighted44 InfluencingFactorsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Environmental ImpactSUSTAINABILITYELEMENTSSUB-ELEMENTSINFLUENCING FACTORSEnvironmental Impact Life-cycle factor Recovery rate after first lifeRecovery costPotential for next lifeEnvironmental effectsToxic substancesEmissionResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Societal ImpactSUSTAINABILITYELEMENTSSUB-ELEMENTSINFLUENCING FACTORSSocietal Impact Ethical responsibility Take back optionsProduct pricingSocietal impactSafetyQuality of lifeResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

FunctionalitySUSTAINABILITYELEMENTSSUB-ELEMENTSINFLUENCING FACTORSFunctionality Reliability Type of materialMaintenance scheduleService life/DurabilityUpgradeabilityMaintenance scheduleEase of installationOption for upgradeModularityErgonomicsMaintainability/ServiceabilityModules availableSafetyMaintenance scheduleResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Resource Utilization & EconomySUSTAINABILITYELEMENTSResource Utilization andEconomySUB-ELEMENTSEnergy efficiencyMaterial utilizationUse of renewable source of energyMarket valueOperational costINFLUENCING FACTORSProduction energyEnergy for useRecycle energyType of materialQuantity of materialCost of materialOption for other energy sourcesCurrent market valueCost to operateResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

ManufacturabilitySUSTAINABILITYELEMENTSSUB-ELEMENTSINFLUENCING FACTORSManufacturability Packaging Take back optionsPackaging materialQuantity usedAssemblyTransportationStorageNumber of parts/componentsCost of transportationCost for storageDuration of storageResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Methodology• Each influencing factor can be quantified differently, and they are all on ascale of 0-1, where 0 is the lowest and 1 being the highest rating.• Three categories represent the relative importance of all sub-elementsagainst each other: high, medium and low.• This grouping technique creates a weighting factor as well as thesimplification for any customization or changes for the future.• Specific weighting can also be calculated according to the number ofinfluencing factors in each category.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Study ModelInput / DataCalculations forInfluencing factorsWeightingfromIndustrialPartnersHigh ImportanceSub ElementsMedium ImportanceSub ElementsNSufficientData?YIndexResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Weighting for High and Medium CategoriesHigh Importance Weighting (%)Energy efficiency 29Material utilization 20Life-cycle factor 13Environmental effects 19Recyclability 19Medium Importance Weighting (%)Reliability 27Service life/ Durability 22Ethical responsibility 16Packaging 21Upgradeability 14Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Sustainability Scoring MethodologyHigh Importance Category Index = (Energy Efficiency Index * 29%) +(Material Utilization Index * 20%) +(Life-cycle Factor Index * 13%) +(Environmental Effects * 19%) +(Recyclability * 19%)Medium Importance Category Index = (Reliability Index * 27%) +(Service Life Index * 22%) +(Ethical Responsibility Index * 16%) +(Packaging Index * 21%) +(Upgradeability Index * 14%)Total Product Score = (High Importance Category Index * 70%) +(Medium Importance Category Index * 30%)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Life-cycle Factor• The level of expectation for multi-life-cycles is definedusing Life-cycle factor. The best level of expectation isconsidered as 1.• Influencing factors are plotted against sub-elements.• All y values denote an ‘index’.• The trend is predicted by using arbitrary values andcurve fitting.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Life-cycle Factor111.2Life-cycle factor (y 1 )0.80.60.40.20-0.20 2 4 6Life-cycle factor (y 2 )0.80.60.40.20-0.20 0.3 0.6 1Life-cycle factor (y 3 )10.80.60.40.200 1 2 3 4Time for recovery (x 1 )Cost of recovery (x 2 )Number of life-cycles (x 3 )yi= Life-cycle factor index for xix1= Time for recoveryx2= Cost of recoveryx3= Number of life-cyclesy1 = A1 e-B1x1y2 = A2 e-B2x2y3 = C3x3Ai, Bi, Ci depends on the empirical data.Life-cycle factor= (1/3) [ A1 e-B1x1 + A2 e-B2x2 + C3x3 ]Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Calculated Sustainability Score for Product 1Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Calculated Sustainability Score for Product 2Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Consumer Oriented ModelA survey was conducted to find out consumer expectationsSurvey Results10.000Average Rating8.0006.0004.0002.0000.000Environment Societal FunctionalitySustainability FactorsResourceUtilization/RecyclabilitySeries1 6.985 8.769 8.542 7.746 6.231Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Results of the Consumer SurveySustainability Element OEM (%)Consumer(%)Environmental Impact 30.5 18.3Societal Impact 8.0 22.9Functionality 31.5 22.3Resource Utilization & Economy 10.0 20.2Manufacturability 10.5 N/ARecyclability/Remanufacturability 9.5 16.3Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

OEM and Consumer Expectation Comparisons• Expectations need to be closer• Education of consumers on propersustainability valuesComparison between Manufacturer's and Consumer'sImportance Towards Sustainability ElementsEnvironmental Impact40.0• OEM commitment andRecyclability20.0Societal Impactresponsibility for sustainabilityapplicationsManufacturability0.0FunctionalityResource Utilization &EconomyOEMConsumerResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Study ResultsElements of Product 1Recyclability/RemanufacturabilityManufacturabili5%ty9%ResourceUtilization &Economy18%Functionality31%EnvironmentalImpact26%SocietalImpact11%Elements of Product 2Recyclability/Remanufacturability6%Manufacturability12%ResourceUtilization &Economy17%Functionality31%EnvironmentalImpact26%SocietalImpact8%Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Study Results (Cont’d)Comparison of Products 1 & 2Recyclability/RemanufacturabilityEnvironmental Impact0.400.300.200.100.00Societal ImpactManufacturabilityResource Utilization &EconomyFunctionalityProduct 1Product 2Comparison of the two product evaluationsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Case Study 3Autobody Design and Manufacture:Total Life-cycle Analysis and ApplicationsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Current and Potential Use ofAluminum Alloys in VehiclesResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Increasing Use of Aluminum in AutomobilesNorth American Total Aluminum ContentChangesPounds per vehicle3503002502001501005001832242512743191991 1996 1999 2002 2006YearTotal aluminum contentResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Aluminum Characteristics• A light metal, 35 percent as dense as conventional steel. Whenaluminum replaces steel, only 1 kg. is required to perform the samefunction as 2 kg. of steel.• A major structural material in the aerospace industry for many yearsdue to its properties (i.e., lightweight, highly resistance to corrosion,strong alloys, excellent conductor of electricity and heat, and a highlyworkable material).• Using aluminum to cut a vehicle's weight by 10% can boost its fueleconomy up to 8%, or as much as 2.5 extra miles per gallon.• Fuel savings, due to weight reduction, can more than offset, over thelife of the vehicle, the initial higher material cost of using aluminum.• A vehicle that uses less fuel (by lowering its weight with aluminum),produces fewer greenhouse gas emissions.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Aluminum Characteristics (Cont’d)• Over the average lifetime of a vehicle, every pound of aluminum that replacestwo pounds of steel can save 20 pounds of CO2 from being emitted.• Aluminum enjoys "sustained recyclability" - which means it can be recycledagain and again with no loss in material performance or quality.• Approximately 70 to 80% of aluminum used in today's vehicles is sourcedfrom recycled metal.• While aluminum today accounts for less than 5 to 10% of a car's content byweight, it accounts for almost 35 to 50% of the total material scrap value at theend of the vehicle's useful life.• An estimated 85 to 90% of post-consumer automotive aluminum scrap, at leastone billion pounds per year, is recycled today.• Recycling aluminum consumes only 5% of the energy required to produce newaluminum.Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Aluminum Limitations• Aluminum sheet per pound costs about 3 to 5 times more, comparedto the cost per pound for steel sheet.• Aluminum is only one-third as stiff compared to steel (this can besolved by making aluminum thicker than steel panels to ensure thatthey perform equally well but this imposes higher material cost andoffsets the weight advantage to a certain extent).• Primary aluminum production – highly energy intensiveResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Impact and Inventory Matrix of Life-Cycle StagesBody-in-White Life-Cycle StagesSustainabilityMeasuresPRE-MANUFACTURINGMANUFACTURING USE POST-USE TOTALAluminum Steel Aluminum Steel Aluminum Steel Aluminum Steel Aluminum SteelResource usage(energy use)0 3 2 5 5 5 2 12/20 13/20WasteoutputSolid/Liq.ResiduesAirEmissions2 2 4 4 4 4 3 14/20 12/201 3 2 3 5 2 4 3 12/20 11/20Environmental impact(e.g., toxicity, airpollution, etc.)2 3 3 3 5 3 5 3 15/20 12/20Societal impact (e.g. ,health, safety, andquality of life)3 3 2 2 4 3 4 3 13/20 11/20Economic impact (e.g.,costs, waste streamvalues)3 4 2 3 5 3 5 3 15/20 13/20Total 11/30 18/30 15/30 17/30 28/30 20/30 27/30 17/30 81/120 72/120Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Total Cost Comparison for Total Product Life-cycleTotal Aluminum Cost vs. Total Steel CostAluminum(75%R), Steel (25%R)(Year 1, Year 4, Year 10)Year 10Total cost ($)190001700015000130001100090007000500030001000-1000$16,017.43 $16,996.32Year 4$7,962.2 $8,135.67Year 1$3,492.80 $3,219.32Aluminum Steel Aluminum Steel Aluminum SteelMaterial ComparisonPre-manufacturing Manufacturing Use Post-use Total cost (Pre-manufacturing, Manufacturing, Use, Post-use)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Environmental Impact: Pre-manufacturing StagePRE-MANUFACTURING: CO 2 emissions asfunction of percent of material recycledCO2 emissions (kg.)250020001500100050000 25 75 100 Al(75%),% RecycledS(25%)SteelAluminumResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Total CO2 Emissions throughout Total Life-cycle30000Total CO 2 emissionsAluminum (75%R), Steel (25%R)(Year 1, Year 4, Year 14)Year 1427,008.01 23,686.8125000CO 2 emissions (kg)2000015000100005000Year 14,361.91 2,962.59Year 410,453.79 8,537.470Steel Aluminum Steel Aluminum Steel AluminumMaterial ComparisonPre-manufacturing Manufacturing Use Post-use Total CO2 emissionsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Environmental Impact: Use StageUSE: CO 2 emissions over the lifetime of vehicleCO2 emissions(kg.)3000025000200001500010000500001 2 3 4 5 6 7 8 9 10 11 12 13 14Number of yearsSteelAluminumResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

The Total Anticipated Relative BenefitTotal Ownership CostTotal CO 2 emissionsCost ($)Air Emissions (kg)SteelAluminumSteelAluminumMaterialMaterialPre-manufacturing Manufacturing Use Post-usePre-manufacturing Manufacturing Use Post-useResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Present National Trends:ASME’s Newest Research CommitteeonSustainable Products and ProcessesResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Proposed ASME-sponsored Activities• Developing an ASME handbook on “Sustainable Products and Processes”• Promoting nationwide the development and implementation of educational andtraining programs on sustainability science and engineering• Developing Codes and Standards for design and manufacture sustainableproducts and for developing manufacturing processes• Organizing and hosting of annual workshops and major international conferences,all focusing on sustainability of products and processes• Interacting with funding agencies, national laboratories and universities andinitiating partnerships for collaborative research projects• Developing interactions with the National Academy of Engineering (NAE) forcreating a National Task Force on Innovative Products and Processes forSustainability in order to retain the competitive advantage in global manufactureResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Present International Trends:International Academy forProduction Engineering(CIRP)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

CIRP Initiatives• Life-cycle Engineering Working Group – began in 1983• Life-cycle Engineering Annual Conference Series – started 15 years ago• Sponsorship of numerous international conferences including thefollowing major series:(a) International Conference on Design and Manufacture for SustainableDevelopment (United Kingdom)(b) International Life Cycle Engineering Conference Series(c) Carbon-free Manufacturing Working Group (Currently Proposing)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Present International Trends:International Journal ofSustainable Manufacturing(IJSM)Research Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

New Journal (Summer 2008)www.inderscience.com/ijsmResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY

Scientific and Technological Challenges• Developing scientific principles of sustainability forproduct design and manufacture• Education, training and dissemination of new knowledgeon sustainability science and engineering• Application of sustainability principles in product designand manufacture• Developing economic models for sustainable products andsustainable manufacturing• Developing and marketing sustainable products, processesand systemsResearch Institute for Sustainability EngineeringCollege of EngineeringLexington, KY 40506-0108, USACopyright © 2008 by Dr. I. S. Jawahir, University of KentuckyUNIVERSITY OFKENTUCKY