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An Environmental and Economic Trade-Off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability

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An Environmental and Economic Trade-Off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability by Stefanie Lynn Robinson A dissertation submitted in partial satisfaction of the requirements for the degree of Doctor of Philosophy in Engineering – Mechanical Engineering in the Graduate Division of the University of California, Berkeley Committee in charge: Professor David Dornfeld, Chair Professor Alice Agogino Professor Sara Beckman Fall 2013 An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability Copyright 2013 by Stefanie Lynn Robinson Abstract An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to Inform Decision Making for Sustainability by Stefanie Lynn Robinson Doctor of Philosophy in Engineering – Mechanical Engineering University of California, Berkeley Professor David Dornfeld, Chair Increasing costs, consumer awareness, and environmental legislation have driven industry to reduce its resource consumption and the impact from that consumption. So, both traditional economic objectives (e.g., cost, time, and quality) and environmental objectives (e.g., CO2 emissions) have become strategically relevant for the manufacturing sector. For many manufacturing companies, production systems have a major influence on the environmental footprint of a product and therefore represent a major opportunity to minimize the company’s overall environmental impact. Currently within industry, there is not an accurate, effective, or widely accepted method to assess the resource consumption of process chains used to manufacture a product. As a result, this information is often not considered when making decisions about what processes to use. A considerable part of the energy and resource demand in manufacturing is determined during production planning. An important component of this planning is determining the process chains to be used. Process chains are a combined sequence of specifically arranged, single processes used to manufacture a product. As manufacturing processes are very resource intensive, it is now necessary to assess the resource consumption as well as the economics of these process chains. Because of this, additional information must be considered when selecting the process chains used to manufacture a product. Many life cycle assessment (LCA) tools focus on the materials and final disposition of a product, but do not include detailed information or data on the manufacturing required to fabricate the product. Sustainability impacts of discrete manufacturing processes and product value streams are needed to develop more complete LCAs. The development of a methodology and user tool to quantify sustainability impacts, leading to the identification of gaps and opportunities, is essential to facilitate decision making to support sustainability in manufacturing facilities. 1 To address these issues, this dissertation proposes an approach to evaluate and quantify the resource use in addition to the environmental and economic impacts associated with discrete manufacturing processes as part of a complex process chain. A methodology to evaluate multiple process chain configurations will be presented. First, a database of industrial assessment metrics was compiled. This database allows users to sort and select from a list of key metrics in order to choose the metrics that are relevant for the performance that they want to measure. Next, an industrial assessment methodology was developed. This methodology gives users an overview of the key areas to address when conducting an industrial assessment. This methodology, which was applied to three case studies, can be used in combination with the key metrics. In the second part of the dissertation, a resource consumption assessment and mapping methodology for complex manufacturing process chains was developed. This systematic methodology was developed to identify and quantify the resource consumption (energy, water, materials) for discrete manufacturing processes. The processes mapped include: welding (manual and robotic), cutting (plasma arc and laser), rework (air carbon arc cutting and hand grinding), and machining (milling). Next, a model consisting of database modules for each process was developed. This model quantifies the sustainability impacts (energy, water, and material consumption, waste generation, emissions, and resource consumption cost) of manufacturing process chains. The model was validated using a case study with Caterpillar Inc. for a process chain including welding, plasma arc cutting, laser cutting, and milling. Next, a process chain assessment tool was created. This tool enables manufacturers to assess the resource consumption and associated impacts of multiple fabrication process chain configurations. This enables a more comprehensive assessment compared to other software tools. Finally, a methodology modeled after the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) process was presented to show how to translate the results from the model and tool to an Environmental Value Stream Map and to translate those results into improvements in manufacturing systems. This methodology was validated on a machining operation in a Caterpillar facility. This research has developed and evaluated an effective approach for the analysis of energy, water, and other resource use in multiple processes in a manufacturing process chain. This allows manufacturers to better understand the resource consumption and environmental and economic impacts of fabrication process chains used to make a product. This dissertation helps to provide the technical understanding and tools to enable designers and manufacturing engineers to create manufacturing systems that are truly more sustainable. The implementation of this work can be directly applied to assessing and optimizing manufacturing process chains and the work presented in this dissertation directly contributes to the realization of a sustainable and prosperous manufacturing sector. 2 Contents Contents .................................................................................................................... i List of Figures ........................................................................................................ vii List of Tables ........................................................................................................ xiii 1 Introduction ........................................................................................................... 1 1.1 Resource Consumption Trends ............................................................................................. 1 1.2 Consumption of Resources in Manufacturing ....................................................................... 5 1.3 Sustainability and Manufacturing ......................................................................................... 9 1.3.1 What is Sustainability? ................................................................................................... 9 1.3.2 Sustainable Manufacturing ........................................................................................... 10 1.4 Business and Industry Drivers............................................................................................. 11 1.5 Organization ........................................................................................................................ 14 2 Manufacturing Systems and Analysis Tools ....................................................15 2.1 Manufacturing Processes and Systems ............................................................................... 15 2.2 Dimensions of Manufacturing ............................................................................................. 20 2.3 Production Systems ............................................................................................................. 27 2.4 Balancing Process Chain Effectiveness and Environmental Impact ................................... 32 2.5 Prior Work on Manufacturing Energy and Resource Efficiency Analysis ......................... 36 2.5.1 Process Chain Level ..................................................................................................... 36 2.5.2 Process Level ................................................................................................................ 37 2.6 Capability of Existing Assessment Tools............................................................................ 37 2.7 Review of Existing Assessment Tools ................................................................................ 41 i 2.7.1 Economic Input-Output Life Cycle Assessment (EIO-LCA) ....................................... 41 2.7.2 Energy Star Energy Tracking Tool (ETT) .................................................................... 43 2.7.3 Global Reporting Initiative (GRI) ................................................................................ 45 2.7.4 National Council for Advanced Manufacturing (NACFAM) Sustainability Framework Model ..................................................................................................................................... 46 2.7.5 The Organization for Economic Co-operation and Development (OECD) Sustainable Manufacturing Toolkit ........................................................................................................... 47 2.7.6 TechSolve Energy, Environment, Economy (E3) Approach ......................................
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