Table Of ContentGreen Manufacturing
David A. Dornfeld
Editor
Green Manufacturing
Fundamentals and Applications
Editor
DavidA.Dornfeld
LaboratoryforManufacturingandSustainability(LMAS)
UniversityofCalifornia,Berkeley
Berkeley,California,USA
ISBN978-1-4419-6015-3 ISBN978-1-4419-6016-0(eBook)
DOI10.1007/978-1-4419-6016-0
SpringerNewYorkHeidelbergDordrechtLondon
LibraryofCongressControlNumber:2012951130
#SpringerScience+BusinessMediaNewYork2013
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Preface
Theinterestandenthusiasmaroundthetopicofgreenmanufacturing,asafirststep
towardssustainablemanufacturing,hasencouragedalotofresearchandinvestiga-
tionintothiscomplexsubjectThisbooktriestogiveperspectivetothetermgreen
manufacturing—howitisdefined,whereis“fitsin”relativetosustainableproduc-
tion,whatarethebasicguidelinesandtoolsofthetradeforanalyzingandpracticing
green manufacturing,andsomeexamples ofapplications.Thecontent reflects the
research activities of the Laboratory for Manufacturing and Sustainability at the
UniversityofCalifornia,Berkeley, andis presentedinthevoiceofthe number of
studentresearchersinthelaboverthelastfewyears.Thisworkwasmotivatedby
the relatively little material on this topic in publication but the increasing interest
fromthepublicandourindustrialandinstitutionalpartners.Wearealsomotivated
by the importance of this aspectof manufacturing, ourcuriosity,and the need for
educational material in graduate course offerings in Mechanical Engineering at
Berkeleyandelsewhere.
Asthisisbeingwritten,researchinourlabandmanyotherlabsaroundtheworld
continues on subjects related to green manufacturing. There is undoubtedly much
more that could be included here but that will not be due to the continuously
evolvingnatureofthesubjectandtheconstantadvanceofresearchandunderstand-
ing. Like painting the Golden Gate Bridge across San Francisco Bay, when one
finishesatoneenditistimetostartagainfromthebeginning!
The perspective presented in this book is from the level of the manufacturing
process,machine,andsystem,aswellasthesupplychainandpackaging,sincefor
manycompaniesthebulkoftheimpact comesfromitemsorprocessesoutsideof
their immediate control. There is a lot of excellent strategic discussion about the
importance of green and sustainable manufacturing. But, at the execution level,
there is little engineering information—the material practicing engineers need to
fulfill the higher aspirations of their organizations as they move towards
sustainability. The authors hope that this view into green manufacturing from our
perspective will help the reader to understand a bit more some of the practical
aspectsofthetopicandencouragethemtolookmorecloselyattheprocessesand
systems around them in their work or research to observe the opportunities for
improvement,replacement,reuse,and,overall,reductionofimpact.Itshouldalso
allow them to quantify the effects of these improvements and impact reductions
v
vi Preface
and,hence,supporttheoverallgoalofgreeningmanufacturingaspartofthemove
towardssustainablemanufacturing.
This book is intended to be used as a basic reference text for industrial
practitionerstogetuptospeedongreenmanufacturingaswellasabasictextbook
foranadvancedcoursecomplimentedbyreadersfromsomeofthebookswerefer
to in this compilation. We will be using it in the graduate course in Mechanical
Engineering on Sustainable Manufacturing at UC Berkeley. Your feedback and
commentsonthebookwillbeappreciated.
A lot of the interest in the topic of green manufacturing at Berkeley has been
generated by readers of the green manufacturing blog—green-manufacturing.
blogspot.com.Ifyouhaveseenthisblogyouwillseeasimilartoneofdiscussion.
Weintendtokeepthediscussiongoingontheblogtoextendtheimpactofthisbook
andallowtheincorporationofnewmaterialasitappears.
Finally, most of the credit for the content of this book goes to the graduate
student researchers and visiting researchers to the Laboratory for Manufacturing
andSustainability.Thosewhohavespecificallycontributedtothisworkarelisted
atthebeginningofeachchapter.Otherswhocontributedbasedontheirpastwork
arecited.Currentresearchinformationandstudentandvisitingresearcherprojects
can be found on our lab Web site lmas.berkeley.edu. We also appreciate the very
capable assistance of Ms. Lexie Cousens who provided editorial assistance in the
productionofthisbook.
Berkeley,CA,USA DavidDornfeld
Contents
1 IntroductiontoGreenManufacturing..................................... 1
DavidDornfeld,ChrisYuan,NancyDiaz,TeresaZhang,and
AthulanVijayaraghavan
2 TheSocial,Business,andPolicyEnvironment
forGreenManufacturing.................................................. 25
HazelOnsrudandRachelSimon
3 MetricsforGreenManufacturing......................................... 49
CorinneReich-Weiser,RachelSimon,TimoFleschutz,
ChrisYuan,AthulanVijayaraghavan,andHazelOnsrud
4 GreenSupplyChain........................................................ 83
YifenChen,RachelSimon,CorinneReich-Weiser,andJustinWoo
5 PrinciplesofGreenManufacturing...................................... 107
MoneerHeluandDavidDornfeld
6 Closed-LoopProductionSystems......................................... 117
AthulanVijayaraghavan,ChrisYuan,NancyDiaz,
TimoFleschutz,andMoneerHelu
7 SemiconductorManufacturing........................................... 153
SarahBoydandDavidDornfeld
8 EnvironmentalImplicationsofNano-manufacturing................... 179
ChrisYuanandTeresaZhang
9 GreenManufacturingThroughCleanEnergySupply ................. 203
ChrisYuan
10 PackagingandtheSupplyChain:ALook
atTransportation......................................................... 223
RachelSimonandYifenChen
vii
viii Contents
11 EnablingTechnologiesforAssuringGreen
Manufacturing............................................................ 255
AthulanVijayaraghavanandMoneerHelu
12 ConcludingRemarksandObservationsAbout
theFuture................................................................. 269
DavidDornfeld
Index............................................................................ 287
1
Introduction to Green Manufacturing
David Dornfeld, Chris Yuan, Nancy Diaz, Teresa Zhang,
and Athulan Vijayaraghavan
If you are not part of the solution, you are part of
theproblem.
EldridgeCleaver
Abstract
Thischapterhasasitsobjectiveabasicintroductiontothetopictosetthestage
fortherestofthebook.Itintroducesfirsttheimportanceofthistopicnowand
thenthemotivation,basics,anddefinitionsassociatedwithgreenmanufacturing
andsustainability.Itdescribessomeofthedriversthatarecausinggovernments
and industry to take steps to green their processes, machines, systems, and
D.Dornfeld(*)
LaboratoryforManufacturingandSustainability(LMAS),DepartmentofMechanical
Engineering,UniversityofCaliforniaatBerkeley,5100AEtcheverryHall,Mailstop1740,
Berkeley,CA94720-1740,USA
e-mail:[email protected]
C.Yuan
UniversityofWisconsin,Milwaukee,WI,USA
e-mail:[email protected]
N.Diaz
LMAS,MechanicalEngineeringDepartment,UniversityofCalifornia,Berkeley,CA94720-1740,
USA
e-mail:[email protected]
T.Zhang
R.W.Beck/SAICEnergy,Environment&Infrastructure,1671DellAvenue,Suite100,Campbell,
CA95008,USA
e-mail:[email protected]
A.Vijayaraghavan
SystemInsights,2560NinthStreet,Suite123A,Berkeley,CA94710,USA
e-mail:[email protected]
D.A.Dornfeld(ed.),GreenManufacturing:FundamentalsandApplications, 1
DOI10.1007/978-1-4419-6016-0_1,#SpringerScience+BusinessMediaNewYork2013
2 D.Dornfeldetal.
enterprises.Adiscussionaboutthedistinctionbetweengreenandsustainableis
introduced with respect to incremental improvements, greening and achieving
overall sustainability. Strategies for achieving green manufacturing are
presented. Barriers and obstacles to greening manufacturing are presented
alongwithexamplesfromindustrialpractice.
1.1 Why Green Manufacturing?
1.1.1 Background
It is important to define, as best as one is able to, why it is important to focus on
green manufacturing. Green manufacturing is an important part of business. And
businessmustbeanalyzed“holistically”—thatis,donotfiddlewithjustlittleparts.
Doitrightforthewholesystem.Here’swhatPaulHawkenandtheLovinssaidin
NaturalCapital[1]:
Without a fundamental rethinking of the structure and the reward system of commerce,
narrowlyfocusedeco-efficiencycouldbeadisasterfortheenvironmentbyoverwhelming
resourcesavingswithevenlargergrowthinproductionofthewrongmaterials,inthewrong
place,atthewrongscale,anddeliveredusingthewrongbusinessmodels.
They go on to say that the best solutions are not simply some kind of tradeoff
between the objectives of economic, environmental, and social capital (the three
pillars of sustainability) but an integrated approach at all levels from “technical
devicestoproductionsystemstocompaniestoeconomicsectorstoentirecitiesand
societies.”
Sounds like manufacturing is a big part of that. There are strong business
pressures to embrace green manufacturing as will be discussed below. But, there
ismore.
All the data on energy consumption, global temperatures, CO levels in the
2
atmosphere,otherimpactsofindustrialization,andpopulationgrowthheadupand
to the right in the graphs—meaning things are moving toward more challenging,
and less sustainable, conditions. One may or may not fully agree with the
predictions, but from the perspective of cost of energy, availability of energy,
cost of treatment/disposal of waste products, materials, etc., things will get more
expensive. And, legislation marches on. The recent deliberations in the United
StatesCongresshaveagoaltoreduceCO by83%by2050andenvisionsomeform
2
of cap and trade program [2]. Governments in other parts of the world have even
more aggressive plans for reduction. If one relies on a global market for one’s
products, as increasing numbers of organizations do, one will be faced with the
demandsofgreenmanufacturingsoonerorlater.
Regardlessofanindividual’sfeelingstowardstheseverityofthesituation,there
are forces moving to make it more and more expensive and difficult to continue
“businessasusual”withrespecttoenvironmentalimpactsofmanufacturingaround
