1.0 DEFINITION The Brundtland Commission's report (1987) defined sustainable development as "development which meets the needs of current generations without compromising the ability of future generations to meet their own needs". Although this didn’t speak to manufacturing, but the key words that require for sustainability is “do not harm”. Manufacturing has traditionally been associated with undesirable environmental side effects such as pollutions. It is necessary for the manufacturers to implement a manufacturing strategy that integrates environmental and social considerations in addition to the technological and economic. Dr. Jawahir, I.S. (2008) define sustainable manufacturing is “design and manufacture of high quality/performance products with improved/enhanced functionality using energy-efficient, toxic-free, hazardless, safe and secure technologies and manufacturing methods utilizing optimal resources and energy by producing minimum wastes and emissions, and providing maximum recovery, recyclability, reusability, remanufacturability, with redesign features, and all aimed at enhanced societal benefits and economic impact”. Sustainable manufacturing is an integrated field of study that combines technical feasibility with environmental responsibility and economic viability (Department of Mechanical and Mechatronic Engineering and Sustainable Manufacturing, 2015). Sustainable manufacturing is the pathway to re-establishing manufacturing as the main activity in the future clean economy, built on the principles of sustainability. Sustainable manufacturing includes two main products: manufacturing of “sustainable” products, and sustainable manufacturing of all products (NACFAM, 2009). The field cover the manufacturing of renewable energy, energy efficiency, green building, and other “green” & social equity-related products. Sustainable manufacturing of all products taking into account the full sustainability/total life-cycle issues related to the products manufactured. The main objective of sustainable manufacturing is to reduce the environmental impact related to manufacturing. For example, U.S. National Institute for Standards and Technology (n.d.) states that sustainable manufacturing is a systems approach for the creation and distribution (supply chain) of innovative products and services that: minimizes resources (inputs such as materials, energy, water, and land); eliminates toxic substances; and produces zero waste that in effect reduces greenhouse gases, e.g., carbon intensity, across the entire life cycle of products and services. In summary, sustainable manufacturing are economically sound since the process of manufactured products can conserve energy and natural resources, minimise the negative environment impacts, and safe for everyone (US Department of Commerce’s, 2015). 1 2.0 INNOVATION BASED MANUFACTURING ENGINEERING In the manufacturing sector, innovation usually refers to: product innovation, the introduction of innovative processes and equipment, often IT driven, and green technologies which reduce waste and use consumables more efficiently (NIBIS, 2015). The benefits of innovation can comprise: greater responsiveness to customer demands, faster turnaround times, reduced waste levels and downtime, improved product design and quality, greater potential for a wider product range, streamlined relationships with suppliers and customers (NIBIS, 2015). There are many areas with opportunities for manufacturers to innovate. It can divide into two major categories: strategy thinking and marketing strategy. For strategy thinking, it includes: competent sourcing, materials technology, factory process control, equipment maintenance, stock control and order processing, and logistics and warehousing (NIBIS, 2015). Component sourcing involves new components, new suppliers or an improved deal with current suppliers could improve the profits and product quality (NIBIS, 2015). Materials technology involve new materials that could improve the products or their packaging and presentation (NIBIS, 2015). Factory process control depends how to automate process control, including quality control, to give better efficiency and products (NIBIS, 2015). For equipment maintenance, an automatic scheduling of maintenance will ensure that equipment is kept running smoothly and comply with health and safety regulations (NIBIS, 2015). Stock control and order processing which is constantly look for better ways to streamline the order processing and stock control to ensure the right amount of stock (NIBIS, 2015). Logistics and warehousing involves how to deliver the products to the customers by taking advantage of new transport opportunities and keep warehousing costs to a minimum (NIBIS, 2015). For marketing strategy, it involves the IT systems, accounting procedures, customer and supplier relationship management, marketing, and design. IT systems must always keep up to date with developments in the IT systems used by manufacturer (NIBIS, 2015). Accounting procedures include accounting, invoicing and payments procedures should be streamlined with the stock control and order processing and must updated regularly (NIBIS, 2015). Customer and supplier relationship management is a valuable insights is gain into how to improve the products and their delivery from the customers and suppliers (NIBIS, 2015). Innovative marketing strategies are also an important way to set the products that manufacture apart from those produced by competitors (NIBIS, 2015). Design is another process for designers help to develop new products and services, or redesign the existing products to improve their functionality and client appeal (NIBIS, 2015). 2 2000. Besides. Hard technologies are hardware and software intensive whereas soft technologies are manufacturing and production know-how. Concurrent engineering is a method of designing and developing products. is a long term business strategy. MRP.1. CNC machines.1 Concurrent Engineering Concurrent engineering. The example of hard technologies are CAD. pg. bar codes. rather than producing goods and supplying customers from stock (NIBIS. implementing thorough JIT procedures can involve a major renovate of the business systems. SQC. 2015). WAN. decrease design and development time (PTC. hence it may be difficult and expensive to introduce. TQM. The example of soft technologies include concurrent engineering. The major difference between soft and hard technologies is soft technologies are not necessarily hardware or software dependent (Swamidass. in which the different stages run simultaneously. The main advantages of JIT is can improve production efficiency and therefore competitiveness. FMS. 2. 2000. and so on (Swamidass. a minor disruption in supplies to the business from just one supplier could force production to terminate at very short notice. Some of the innovation manufacturing technologies are explained for further understanding. 2015). and decreasing product defects. Concurrent engineering can lead to three kind of business benefits: competitive advantage. also known as lean production. rather than consecutively (PTC. 2015). reducing the capital that have tied up in stock. turns traditional manufacturing thinking beyond its limit. JIT manufacturing. 3 . pg. manufacturing cells. 4). enhance productivity. and so on (Swamidass. With no stocks to fall back on. 2000. JIT processes focus on producing exactly the amount require by manufacturer at exactly the time the customers require. leading to improved productivity and reduced costs (PTC. JIT manufacturing also opens businesses to a number of risks. The other benefits by JIT are: preventing over-production. LAN. 4-5). dispensing with the need for inventory operations. also known as simultaneous engineering. with long term benefits to business (PTC. 2015). . CIM. However. 2015).1 Hard and Soft Technologies Swamidass (2000) classify manufacturing technologies into hard and soft technologies. CAM. techniques and procedures.2 Just-in-time (JIT) production Just-in-time (JIT) production. pg. It decreases product development time and also the time to market. saving resources by streamlining the production systems. 5). TPM. 2. robots.1. minimising waiting times and transport costs. automated inspection.2. simulation and modelling. a type of innovation based manufacturing. especially those together with the supply chain. There are 8 primary elements of TQM.d. n.2. n. quick response manufacturing. 4 .d. SQC provides a means of detecting error at inspection. fact-based decision making. It uses strategy. points out the bottlenecks and trouble spots. Virtual manufacturing refers to new manufacturing entities created through very rapid integration of scattered resources in one or several firms (Swamidass. 2.1. pg.d. and communications (ASQ.). The rise of information technologies and Internet fuels the growth of virtual manufacturing (Swamidass. Total quality management can be summarized as a management system for a customer-focused organization that involves all employees in continual improvement (ASQ.d. continual improvement. 2. 2001). 2000.). provides a means of determining the capability of the manufacturing process. SQC is used to analyse the quality problems and solve them.5 Statistical Quality Control (SQC) Statistical Quality Control (SQC) is the term used to describe the set of statistical tools used by quality professionals (Improsys. are customer-focused. data. integrated system. 2010). n. and that eventually. 10). 10). pg. 2010). and virtual manufacturing. total employee involvement. n.).and Virtual Manufacturing Another type of flexible and responsive manufacturing is agile manufacturing. leads to more uniform quality of production. 2001).1. strategic and systematic approach. the traditional assembly line will be replaced by a system in which a nearly custom – made car will be produced by connecting individual modules (Kalpakjian. improves the relationship with the customer. reduces inspection costs. 2010). reduces the number of rejects and saves the cost of material.3 Agile-. and effective communications to integrate the quality discipline into the culture and activities of the organization (ASQ. it has been predicted that the automotive industry could configure and build a car within three days. 2000. Statistical quality control refers to the use of statistical methods in the monitoring and maintaining of the quality of products and services (Improsys. promotes the understanding and appreciation of quality control (Improsys. Agile manufacturing is a term that has been coined to indicate the use of the principles of lean production on a broad scale (Kalpakjian.). provides a basis for attainable specifications. For an example. process-centred.4 Total Quality Management (TQM) A core definition of total quality management (TQM) describes a management approach to long–term success through customer satisfaction (ASQ.1. Quick Response. CAE. E. the performance of structures subjected to static or fluctuating loads ad to varying temperatures can now be simulated. An MRPII output is a final labour and machine schedule. Data about the cost of production. is provided from the MRPII system to accounting and finance (Monk. These forecasts determine the raw materials demand (Monk. 2006). et al. E. MRP allows for the input of sales forecasts from sales and marketing. 2006). 2001. 2. et al. 2006). The goal of MRPII is to provide consistent data to all players in the manufacturing process as the product moves through the production line (Monk. While MRP allows for the coordination of raw materials purchasing. MRP and MRPII systems draw on a master production schedule. labour time and materials used. pg. 2001. et al.1. CAD allows the designer to conceptualise objects more easily without having to make costly illustrations. and tested more efficiently. the breakdown of specific plans for each product on a line (Monk.2.1. material requirements planning. et al. MRPII facilitates the development of a detailed production schedule that accounts for machine and labour capacity.6 Material Requirements Planning (MRP) and Manufacturing Resource Planning (MRP II) Material requirements planning (MRP) and manufacturing resource planning (MRPII) are both incremental information integration business process strategies that are implemented using hardware and modular software applications linked to a central database that stores and delivers business data and information (Monk. MRPII systems begin with MRP. E. et al. and human relations (Monk. et al. 2006). E. scheduling the production runs according to the arrival of materials (Monk. accurately and quickly than ever (Kalpakjian. CAM involves all phases of manufacturing by utilising and processing further the large amount of information on materials and processes collected and stored in the organisation’s database (Kalpakjian. et al.8 CNC Machines 5 . MRP is concerned primarily with manufacturing materials while MRPII is concerned with the coordination of the entire manufacturing production. pg. 2006).1. 11).7 CAD. 2006) . Using CAE. E. as well as final production numbers. computer-aided engineering (CAE) and computer-aided manufacturing (CAM) techniques. analysed. including machine time. pg. and CAM The constructing and studying analytical models is simplified through the use of computer-aided design (CAD). finance. 12). or prototypes (Kalpakjian. 12). E. 2. E. including materials. 2006). 2001. models. although costs are can then be manufactured hundreds or even thousands slowly coming down. the same with high precision and exact match. and can be repeated in exactly the same manner over and over again (Ryan.1 shows the advantages and disadvantages of CNC machines. machine tools function through numerical control. A computer program is customized for an object and the machines are programmed with CNC machining language (called G-code) that essentially controls all features like coordination. Table 2. Tools that can be controlled in this manner include mills. Under CNC Machining. Less trained/skilled people can operate CNCs unlike manual lathes / milling machines which require 6 enough to supervise several machines. CNC Machining is used in the production of many complex three-dimensional shapes (Ryan. On the surface. Firstly. In years gone by. however there is a unique software and control console are inside the computer to set the system apart for use in CNC machining. engineers needed years of training .1: The advantages and disadvantages of CNC machines. it may look like a normal PC controls the machines. 2009). this process can produce complex shapes that would be almost impossible to achieve with manual machining (Ryan. a CAD drawing is created (either 2D or 3D). CNC machining is used in manufacturing both metal and plastic parts. lathes. CNC machines are programmed with a design and CNC Disadvantages machines are more expensive than manually operated machines. CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools. 2009).The CNC in CNC Machining means Computer Numerical Control. It is because of these qualities that CNC Machining is used in jobs that need a high level of precision or very repetitive tasks (Ryan. Because of the precision possible with CNC Machining. 2009). the computer can control exact positioning and velocity. The CNC machine operator only of times. routers and grinders. 365 days a year and only turn off for irregular maintenance. and then a code is created that the CNC machine will understand. With CNC machining. The process is more precise than manual machining. 2009).This trial run is referred to as "cutting air" to avoid any mistake with speed and tool position that could result in a scraped part or a damaged machine. Table 2. Advantages CNC machines can be operated continuously 24 hours a day. 2009). Each manufactured product will be exactly needs basic training and skills. 2009). The program is loaded and finally the operator runs a test of the program to ensure there are no problems (Ryan. location and speeds (Ryan. There are many advantages to using CNC Machining.. feed rate. each one will vary slightly. it is a major tool use in JIT. There is no need to make a prototype or a model. 24). Besides. Many countries no longer teach designers / engineers. CIM play a major role in manufacturing in application of Computer Numerical Control (CNC) machines. 2015). and reduction in inventory (Kalpakjian. pg.9 Computer-Integrated Manufacturing (CIM) Computer-integrated manufacturing (CIM) is the use of computer techniques to integrate manufacturing activities. milling software used to drive the machines Training in the use of CNCs is available through the operated machines. and personnel. 2001. These include mathematical studied. better use of materials. Modern design software allows the designer to pupils / students how to use simulate the manufacture of his/her idea. CNC machines can be updated by improving the to operate centre lathes. 24). 2015). CIM improves production productivity by 40 to 70 percent. National Research Council.. A skilled engineer can make the same component manually operated lathes / milling machines etc. FMS. CNC machines can be programmed by advanced operate CNC machines compared design software such as Pro/DESKTOP®. Industries robots and so on.S. Adaptive control (AC). It also has a better control of production and management of total manufacturing operation and high quality products at low cost (Kalpakjian. Less workers are required to computer. 7 . as well as enhances engineering productivity and quality (Advameg.1. This means use of ‘virtual software’ that allows the operator to machines and other manually many of the old skills are been practice using the CNC machine on the screen of a lost. Pupils / students no longer develop the detailed skills required by engineers of the many times. enabling the manufacture of products that cannot be made by to manually operated machines. According to the U.. CIM can also decrease design costs by 15 to 30 percent. CIM is particularly effective because of its capability and responsiveness to rapid changes in market demand and product modification. However. even those used by skilled lead to unemployment. machinery. will manufacture each component as an exact match. This saves time and money. A CNC machine and engineering skills. 2001. if each component is carefully past. pg.skilled engineers. reduce overall lead time by 20 to 60 percent. 2. and automated systems. Investment in CNC machines can manual machines. and cut work-in-process inventory by 30 to 60 percent (Advameg. 3. processes and systems is a significant aspect of sustainable manufacturing. all these basic elements must work integrally to form the sustainable manufacturing. However. 34): 3. processes and systems is a significant aspect of sustainable manufacturing to promote integrated sustainable manufacturing. pg. reuse and remanufacturing Maximizing sustainable sources of renewable energy Integral Element of Sustainable Manufacturing Developing innovative products. To enable innovation in sustainable manufacturing. and it involves a holistic approach to manufacturing different from the traditional manufacturing practices where the quality and performance characteristics are measured and quantified independently. Fully integrated sustainable manufacturing will become an effective platform for developing sustainable products from sustainable processes and with related system integration. 2008. Developing the products.1 Basic Elements of Sustainable Manufacturing The expectations of sustainable manufacturing (Jawahir. process and systems levels with close interactions among each other. often without consideration of the effects of other integral elements.0 ELEMENTS OF SUSTAINABLE MANUFACTURING There are many basic elements for sustainable manufacturing.3. The emerging holistic and integrated approach requires all stakeholders to work together on common objectives with total commitment. 8 . innovation must be embraced at the product.2 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. Recent research on product sustainability evaluation shows a consistent trend towards the long-range development of a product sustainability rating system for all manufactured products (Jawahir. Ethics. This rating would be expected to represent the“level of sustainability” built in a product by taking into account all major contributing sustainability elements and their sub-elements (Jawahir. element and overall). The preliminary work in this area also considered ratings at all three levels (sub-element. Early work shows the following six product sustainability elements (Jawahir. The technological and societal impacts are also significant. 2013): Environmental Impact Societal Impact (Safety. 9 . etc. when this project is extended to the next level (Jawahir. 2013).) Functionality Resource Utilization and Economy Manufacturability Product’s Recyclability/Remanufacturability These interacting elements and sub-elements need to be fully studied for their effects on product sustainability. This benefit is compounded when a multiple life-cycle approach is adopted on the basis of continuous material flow (Jawahir. while the initial product cost could be slightly higher in some cases (Jawahir. process and system levels Product sustainability: Consideration of a total and comprehensive evaluation of product sustainability can lead to reduced consumer costs over the entire life-cycle of the product. This systematic study should provide a solid foundation for involving relevant “priority roles” and “trade-offs”. 2013). 2013). The overall economic benefits and the technological advances involving greater functionality and sustained quality enhancement are far too great to outscore with the current practice (Jawahir.1: Sustainable manufacturing at integrated product. 2013). Health.Figure 3. 2013). 2013). Other influencing elements and sub-elements will be identified as appropriate. Process sustainability: Manufacturing processes are many. and power consumption (Jawahir. 2013). finishing. emission of toxic materials or harmful chemicals. The observations and the existing modelling capabilities can be used to model the impact of the manufacturing process on contributing major sustainability parameters (Jawahir. The primary objective of identifying and defining the various contributing elements and sub elements of manufacturing process sustainability is to establish a unified. component design. The idea in developing this concept is to isolate the manufacturing process from the global picture of sustainability. 2013). etc. tool/work material selection. and their key characteristics. dispatching. 2013). If the processing includes the use of coolants. it goes through a few clearly defined production stages. among the various factors. 2013). lubricants. 2013). 2013). In a never-ending effort to minimize the manufacturing costs. the processing cost largely depends on the method used to produce the part/component and the work material selected (Jawahir. method of manufacture. standard scientific methodology to evaluate the degree of sustainability of a given manufacturing process (Jawahir. operator’s and machine safety. 2013). and each of them depend on the product being manufactured. packaging. safety and personnel health problems (Jawahir. Models developed for manufacturing variables can be integrated for achieving optimized performance 10 . 2013). In general. For example. 2013). 2013). if the production process of a simple component is considered. 2013). the industrial organizations are struggling to maintain the product quality. 2013): Energy consumption Manufacturing cost Environmental impact Operational safety Personnel health Waste reduction The motivation for recent sustainability studies of manufacturing processes comes from recent efforts in developing a manufacturing process sustainability index (Jawahir. remanufacturability. this poses environmental. these processes differ very widely (Jawahir. This evaluation can be performed irrespective of product life-cycle issues.. and to develop it up to the “level of acceptance” for common practice in industry (Jawahir. This makes the identification of the factors/elements involved in process sustainability and the demarcation of their boundaries complex (Jawahir. the following six factors can be regarded as significant to make a manufacturing process sustainable (Jawahir. of the manufactured product (Jawahir. transporting. metal removal/forming. Besides. storage. It is extremely hard to consider all of these stages in evaluating manufacturing process sustainability although they may directly or indirectly contribute to the manufacturing process sustainability. etc (Jawahir. recycling. Innovation in sustainable manufacturing education.(Jawahir. 2013). cryogenic and minimum quantity lubrication (MQL) machining have been shown for producing functionally superior machined products with significantly improved. 2013). doubling environmental. a recent trend observed is to develop sustainable products from sustainable processes. Source: Jawahir. process and system levels. Examples of establish innovative aspects in sustainable manufacturing are shown in Figure 3. 2013). Figure 3. 2013).2 for each component of innovation (Jawahir.2: Examples of innovative aspects in sustainable manufacturing at product. Finally. The innovation must enable developing an integrated sustainable value system for sustainable manufacturing with many value-contributing factors: value propositions such as socioeconomic value. socio-political value. (2013).1 Sustainable Products from Sustainable Processes As efforts continue to develop sustainable products and sustainable manufacturing processes. economic and societal values of product manufacture (Jawahir. and socioenvironmental value can be derived from this integrated system (Jawahir. 2013). product sustainability. technological value. potentially. Fully integrated sustainable manufacturing will become an effective platform for developing sustainable products from sustainable processes and with related system integration (Jawahir. 2013). 3. the optimized results can be used in defining the sustainability rating for the specific manufacturing process with appropriate weighing factors (Jawahir. in terms of 11 . Case studies involving the use of sustainable machining methods such as dry. thus enabling.2. performance. the ability to think and communicate systematically. becomes an important capability 12 . Thus.2 Sustainability Issues at the Systems Level The transformation of raw materials into more sustainable products through sustainable manufacturing processes requires careful coordination of various activities across and within the organizations that span the closed-loop supply chain (Jawahir. 2013). Innovation in sustainable manufacturing education. manufacturing system and supply chain design and operation must not only consider the behaviour of the socio-technical system. Figure 5 shows a schematic of activities involved in producing sustainable products from sustainable processes. 2013). Besides. but also integrate complexities of the interactions between the sociotechnical systems and the natural environmental environment to minimize the unintended consequences (Jawahir. sustainable manufacturing systems and supply chains must be designed and managed as integrated socio-techno-environmental systems from a total life-cycle perspective by considering the interfaces and interactions among the different sub-systems (Jawahir. 3. 2013). However. systems are adaptive and emergent entities characterised by various feedback and reinforcing loops without a proper understanding of which can lead to catastrophic behaviours of these systems given the complex contexts in which they operate (Jawahir. Figure 3. for sustainability improvement. 2013). given the intractable nature of systems for sustainability. Also.3: Proposed methodology for producing sustainable products from sustainable processes Source: Jawahir. 2013). (2013). quality and life (Jawahir.2. or systems thinking. 0 6R’s APPROACH 13 . economic and environmental implications of a variety of stakeholders.4. Recent advances in sustainable supply chain design that follows some aspects of the approach have addressed coordinating the design of sustainable products and systems by considering the social.that must be developed to increase the capability to design and manage such systems (Jawahir. the time-variant. Source: Jawahir.4: Protocol for Sustainable System Design. 2013). 4.4) through probabilistic Bayesian Belief Networks can provide methods to develop mitigations/interventions to improve sustainability of manufacturing systems and supply chains (Jawahir. adaptive behaviour of supply chains and implications on sustainability performance is also considered (Jawahir.The design protocol for designing such sustainable systems is shown in Figure 3. 2013). Innovation in sustainable manufacturing education. The modelling risks due to negative and unintended influences of economic. (2013). Developing tools such as sustainable value stream mapping (Sus-VSM) to assess the socio-techno environmental aspects at the manufacturing systems level have also been presented (Jawahir. 2013). Figure 3. 2013). environmental and social implications from and on other interdependent systems (Figure 3. reuse. Reduce primarily focuses on the first three stages of the product life – cycle and refers to the reduced use of resources or ‘source reduction’ in pre – manufacturing. 6R Manufacturing can be thought of as environmentally benign. Center for Sustainable Manufacturing (6RBIO. Jawahir. redesign. not just manufacturing. reuse. and occupational hazards without weaken the product quality or the manufacturing productivity at the process level. Figure 4.1: Closed – loop Material Flow – The 6R Approach Source: I. and has the potential to be used effectively by many organizations. toxic wastes. closed-loop manufacturing system that creates durable goods without negatively impacting the environment. by taking into account all the major life-cycle stages – pre-manufacturing. The 3’R’s is promoted through Green Manufacturing are (Kiritsis et al. 2011) are Reduce. manufacturing. There is a need to model and achieve optimized technological improvements and develop process planning to reduce energy and resource consumptions. Sustainable Manufacturing: The Driving Force for Innovative Products.S. Processesand Systems for Next Generation Manufacturing. 2008). reduced 14 . there is a need to consider all aspects of the entire supply chain. The 6R’s are the innovative elements whose additive implementation achieves sustainable manufacturing. There is a requirement to move beyond the traditional 3R concept which promotes green technologies (reduce. 2014). remanufacture) at the product level. recycle. use and post-use – over multiple life-cycles (Jawahir. recycle) to a more recent 6R concept to form the basis for sustainable manufacturing (reduce. and Recycle. Reuse. The 6R BIO product line is applicable to many industries.The 6R name was inspired by work done at the University of Kentucky. University of Kentucky. At the system level. recover. after usage in its first life – cycle. Remanufacturing involves the re-processing of already used products for restoration to its original state or a like – new form through the reuse of as much components and parts without loss of functionality (Kiritsis et al. where the performance in all life – cycle stages must be considered in making decision at any lifecycle stage. for subsequent life – cycles to reduce the usage of new raw materials to produce such products and components (Kiritsis et al. page 309).2: Application of 6R’s Across Product Life – cycle Stages Source: Kiritsis et al (2011). page 309). redesign. 2011. page 309).2. Engineering Asset Management.use of energy and materials during manufacturing and the reduction of waster during the use stage (Kiritsis et al. Redesign is the act of redesigning products for better resource utilisation during manufacture. and remanufacture. 5. The application of the 6R’s across the four stages for multiple life – cycles. where the frustum depicts the reduced resource footprint (for subsequent life – cycle) is illustrated in Figure 4. Recover involves the process of collecting products at the end of the use stage. Reuse is referring to the reuse of products or its components. sorting and cleaning for utilisation in subsequent life–cycles of the product (Kiritsis et al. use and to simplify future post–use processes through the application of techniques such as Design for Environment (DfE) to make the product more sustainable (Kiritsis et al. 2011. glass. disassembly into components. 2011. Figure 4. page 309).0 EVOLUTION OF SUSTAINABLE MANUFACTURING 15 . The 6R’s approach provide the framework to implement sustainable manufacturing. 2011. The additional 3 ‘R’s in 6R Approach are recover. 2011. page 309). and metal) that are considered waste into new materials or products Kiritsis et al. page 309). Recycle involves the process of converting material (such as paper. 2011. 2011. traditional manufacturing was substitution–based and relied upon relentless resource consumption to deliver value to customers. page 309). A tool life–cycle emphasis is required to that manufacturing is pursued while explicitly considering activities across all four life-cycle stages and the impacts (Kiritsis et al. 2011. page 309). Besides. 2011. 2011. Reuse. The evolution of manufacturing strategies over the years and their impact on the stakeholder value (much broader than shareholder value) is shown in Figure 5. 2011. Multi–lifecycle emphasis is needed to ensure closed-loop material flow from the post-use stage of one life-cycle to the pre-manufacturing of the next. page 309). current more advance thinking also emphasises on the need for active integration of business partners who contribute to the sustainability stakes of a product (Kiritsis et al. and Recycle. page 309). page 309). This kind of approach requires two important considerations: a tool life–cycle emphasis and multi– lifecycle emphasis (Kiritsis et al. 2011. manufacturing. 2011. All four product life – cycle stages and impacts (economic. environmental. Since manufacturing is the core operation in a supply chain (limiting the focus to physical products). page 309).There are four stages activities involved in the life – cycle of a product: pre – manufacturing. and social) must be clearly stated and integrated to ensure sustainability in the supply chain. From Figure 5. Green manufacturing practices. 2011. gained significant popularity over the last several years (Kiritsis et al.1: The exponential shareholding growth of innovation-based sustainability 16 . 2011. which is mandatory for sustainable manufacturing (Kiritsis et al. Figure 5. the value addition to the wider group of stakeholders was very limited (Kiritsis et al. page 309). 2011.1 (Kiritsis et al. Subsequent practice of lean manufacturing by Toyota’s Production System. page 309).1. and post – use (Kiritsis et al. page 309). page 309). designing the system and promoting sustainability in its operations must centre on a sustainable manufacturing approach (Kiritsis et al. advocates environmentally-benign practices through the 3R approach of Reduce. use. focused on waste – reduction (one ‘R’) and was able to deliver more value to customers while also appreciating the role of team members (Kiritsis et al. 2013). Processesand Systems for Next Generation Manufacturing. define. 2013). University of Kentucky. 2013). and systems in its core (Jawahir.0 DESIGN OF SUSTAINABILITY 17 . which includes sustainable products. all contributing to the sustained growth through the economic sustainability component. Sustainable Manufacturing: The Driving Force for Innovative Products. and society (Jawahir. A significant effort has been undertaken by various groups from a range of disciplines to characterize. 2013). with its three major functional elements (innovative product development—value design. Continued progress in sustainable development heavily depends on sustained growth.Source: Jawahir. economy. has been discussed (Jawahir. processes. A relatively less-known and significantly impacting element of sustainability is sustainable manufacture. primarily focusing on three major contributing areas of sustainability: environment. 6. 2013). and value recovery). This integral role of sustainable manufacture. and formulate different forms and means of sustainable development (Jawahir. manufacturing processes—value creation. The understanding of the integral role of these three functional elements of sustainability in product manufacture is important to develop quantitative predictive models for sustainable product design and manufacture (Jawahir. and design for sustainability. Designing for Energy Efficiency. Designing for Serviceability. There are ten designs of sustainability proposed by Jawahir (n. Design and Manufacture for Reduced Costs. The design practices for sustainable manufacturing system and supply chain design must consider a variety of interactions between the methods and technical models. the adaptive and emergent behaviour of the system designed with all other interactive systems.1 Design for Environment and Life Cycle Assessment (LCA) 18 . Designing for Reduced Materials Use. Evaluating the system performance from these aspects therefore will require comprehensive sustainability metrics at the plant. design for resources and energy. including design for environment. Reuse and Recycling. Designing for Remanufacturing . all the stakeholders who have an influence on the system or can be influenced by the system as well as the complex dependencies between these aspects and the natural environment. and also many tools may use to support such effort have been developed and applied. Designing for Product Disassembly.): Designing for Repair. Designing for Product Demanufacturing. and Sustainable Design and Manufacture (Designing for Sustainability). during all phases of the design process. Some of these are described in this section. enterprise and supply chain levels.Sustainability can be included into design. must be assessed through predictive models 6.d. Designing for Waste Minimization. materials. Energy sustainability involves the supplying of energy services in a sustainable manner. LCA is a tool for improving the environmental performance of processes and systems. impact assessment and interpretation (Rosen.3 Design for Sustainability 19 . 2012). recycling. and acceptable to communities and people.2 Resource and Energy Sustainability Sustainability has been applied to many fields related to manufacturing. To develop a holistic and comprehensive understanding of environmental impacts. life-cycle inventory analysis. 6. which in turn necessitates that energy services be provided for all people in ways that. are sufficient to provide basic necessities by means which are affordable and not detrimental to the environment. All these observations contribute to the development of life cycle assessment (LCA). in part by enhancing resources conservation and efficiency. including energy and resource use. In LCA. processes. but it is in actuality more complex and involved. reuse. and is often used in sustainability work (Rosen. Consumption of energy and other resources and environmental discharges of material and energy wastes are examined in LCA for existing process and design alternatives (Rosen. and final disposal can be obtained with LCA. A life cycle assessment consists of four steps: goal and scope definition. From the perspective of resource utilization. LCA is incorporated into the ISO series 14040 standards and is often used in conjunction with evaluation of toxicity and risk potential to promote manufacturing sustainability (Rosen. LCA is also used in pollution prevention and green design efforts (Rosen. 2012). 2012). the full life cycle of a product or process normally is needed (Rosen. Smith and Rees (1998) describe sustainable development as a pattern of resource use that aims to meet human needs while preserving the environment so that these needs can be met now and in future generations. with the objective of reducing environmental damage. the environmental impacts of a product or service are analysed through all phases of its life. 2012). 2012). Strategies for the design/selection of products. 6.Design for environment involves the consideration of environmental impact throughout the design process. and forms an integral component of designing for sustainability. 2012). now and in the future. Rosen and Abu Rukah (2010) shows the concept of energy sustainability can be viewed as the application of the general definitions of sustainability to energy. An EcoDesign approach (Figure 6. Figure 6.Design for sustainability involves the incorporation of sustainability objectives in design activities. noting that companies like Honda and Toyota use such an approach. life cycle analysis and TRIZ into a methodology for environmentally conscious design is described by Sakao. (2012). Practices and Needs. This approach permits design alternatives to be examined throughout the product development process. Sustainable Manufacturing and Design: Concepts. Although in its infancy. The relationship between quality function deployment. Several approaches aimed at design for sustainability have been reported. 6. including the following: A triple bottom line approach to design for sustainability is described by McDonough and Braungart (2002). are examined by Braungart et al (2007). and allows the costs and benefits of design for sustainability issues to be 20 .1) is described by Karlsson and Luttropp (2006).1: EcoDesign approach for designing for sustainability Source: Rosen et al. in which firms balance traditional economic objectives with social and environmental concerns. and that numerous improvements are needed. Eco-efficient strategies. life cycle analysis and contingent valuation is investigated by Borea and Wang (2007). This approach seeks to assist the design engineer in employing eco-design principles without significant economic tradeoffs (2008). Some examples follow: Morgan and Liker (2006) suggest an engineering approach within lean product development systems for managing product development. A product development approach using design for X (DFX) tools. such as life cycle analysis and theory of inventive problem solving (TRIZ) is discussed by Grote et al. and these factors are compared with customer willingness to pay for environmentally benign products. interest in design for sustainability is growing.4 Needs for Enhanced Design for Sustainability Many feel that methodologies for design for sustainability are not advanced. Integration of quality function deployment. which focus on maintaining or increasing the value of economic output while decreasing the impact on ecological systems. These benefits in part stem from the fact that lean product development focuses on key customer needs and manufacturing capabilities. Johnson and Srivastava (2008) indicate that engineering tools for design for sustainability need better capabilities to evaluate the complex trade-offs between process parameters. and to permit evaluation of the effect of sustainability on product cost. First of all. A simplified diagram of the manufacturing process can be organized and associated with the each steps. typical product life and end of life path. redesigning a product should last in the market for a good period of time. the distribution and typical transport information. it is very likely to have a target product in mind. or where there is competition from products claiming to be more sustainable. Third. Generally the product should fit the following characteristics in that it should be in a market where it’s environmental or social characteristics are under scrutiny. the market information. as well as environmental and other constraints. and tends to avoids errors and improve quality. Start by listing environmental and social issues which are currently important in the particular region and market. customer needs. Experience has shown that selection of the first test product should be made carefully. The information will lead to design and manufacturing of the products. project complexity and process design in a more holistic and data driven manner. Review the competing products in your dossier to 21 . quality function deployment and design structure matrix. or modified versions of them. It is very important to be sensitive to emerging issues. The product and its usage need to be understand in term of its history. Johnson and Srivastava (20080 also suggest that a more sophisticated inclusion of environmental and sustainability issues in constraints and design parameters is needed to yield a broader range of design alternatives.evaluated. Johnson and Srivastava [9] feel sustainability is not suitably considered using engineering design tools. review the important Environmental and social impacts area in the market. for customers. such as design for manufacturing and assembly. The second step is to prepare a product dossier. design for Six Sigma. presumably because market intelligence suggest that there are environmental and social characteristics of that product that are becoming critical to its future success. The key components and sourcing of the components can be determined and come out with a material list. and that these tools must be usable in a straightforward manner by design teams.5 Steps to improve and design Sustainable Product There are nine simple steps to improving the products and design it to be more sustainable. 6. Aware of societal or market pressures which could impact the reputation of company. Use the two blank sections of the dossier to collect observations and ideas about the product characteristics and possible areas of improvement. As in step 8. the range of possibilities to improve the product and reduce its overall life cycle impact is identified. prioritize is needed. For the ideas selected there will still be different degrees of difficulty and cost as well as different degrees of environmental (and social) gains. Step 7 is a redesign option which is focus on the creativity of the design. social and market value. After redesign the product. A design for sustainability methodology relates the different design approaches to the environmental and social impacts of the particular product. It is useful to identify any missing information for in the dossier. Use it as a way to start thinking critically and creatively about possible product improvements. step 8 is prioritizing ideas and concepts of sustainability. Therefore. Most of the information needed is collected and proceed to identifying design for sustainability strategies and design responses that address the life cycle phases and product characteristics requiring focus. therefore. Design For Sustainability A Step-by-Step Approach. a case for undertaking a full pilot project within the company or organization. providing a way to select those that will be relevant and fruitful. Consult company personnel about standards and regulations in the market.check what priorities are expressed. Step 5 is to develop a quick picture of the product’s impact profile by taking social and ethical issues into account. 2009) 22 . Return to this list later when begin to select appropriate improvement option for the product. The last step is to make a case for design for sustainability work in the company by getting resources and support for a pilot project. Step 6 is to define the product’s improvement targets and design approaches by a simplified design brief. (UNEP. Fourth steps is reflect the product in light of simple design for sustainability assessment. There are a series of ideas with some estimation of their environmental. light weighting using plastics. There are three case studies about how the introduction of new materials will brings adverse environmental impacts on other parts of the materials use and reuse systems. chemicals and other resources (Nambiar. and increased customer consciousness. its product sustainability metrics need to be considered. safe and secure technologies. It should always maintain to be toxic-free. 2010). increased market-share and increased profits. improving health-care and sanitation facilities. minimal use of energy. the product designer is restricted with additional responsibility of considering the environmental impact of his/her decisions (Nambiar. Then under process innovation for sustainable manufacturing. hazardless. it should always be environmentally friendly or responsible manufacturing process development. 2010). the introduction of electric steel mills will cause upsetting existing reuse and recycling systems for glass and steel scrap. 2010). and raising literacy levels among other indicators. 2010). government regulations and international standards.0 TECHNOLOGICAL CHALLENGES FOR SUSTAINABLE MANUFACTURING Research has shown that companies that adopt sustainable practices are able to achieve increased product quality. The choice of materials and processes has a significant bearing on the environmental impact (Nambiar. Furthermore. it will cause far less attention to unexpected impacts. Thus. When there are introduction of new materials. there is a general misconception about the true meaning of sustainability and companies often end up focusing only on single aspect especially in energy consumption. it becomes imperative for the designer to first adapt himself/herself with the various issues concerning sustainability (Nambiar. Other than product innovation. Limited attention has been granted to the social dimension of sustainability as visualised by United Nations Division for Sustainable Development (UNDSD) such as fostering equity both economic and gender-related. 23 . the product innovation for sustainable manufacturing is one of the challenges for sustainable manufacturing. The challenges for energy consumption associated with reducing the carbon footprint. The factors motivating companies to embark upon sustainable development include social responsibility and investor demands. with increased focus on sustainable manufacturing. For product innovation for sustainable manufacturing. 2010). For example.7. Researchers also have tended to focus more on the environmental aspects of sustainable development. process innovation for sustainable manufacturing also is one of the challenges will face by sustainable manufacturing. Besides. water including metal working fluids. However. One of the technological challenges for sustainable manufacturing is where it requires new materials technologies for sustainable products to reduce material waste and optimize the usage of the material. The ability of the product design of transforming from 1R to 3R to 6R also needed (Nambiar. the stakeholder value will decrease (Jawahir. (Jawahir. Therefore without economic analysis and business care. public policy and regulatory issues need to be considered as always. Safety is very important. sustainable supply chain operations and sustainable quality systems for manufacturing need to be considered time by time (Jawahir. health. training courses in a manufacture company need to be carried out as always to maintain worker’s capability to produce sustainability products (Jawahir. 2008). 24 . ELV and etc. EuP. 2008). This is important challenges faced by sustainable manufacturing. During sustainable manufacturing. safety. Other than that. the production of sustainable manufacturing need to compliance with regulations such as REACH. 2008). RoHs. Besides that. WEEE. 2008). This is because consumer’s need or trend are changing time by time. 2008). This is to remain the reputation of the manufacturing company. The integrated manufacturing systems for sustainability. For example. Besides that education and training issues need to be considered as well (Jawahir. economic analysis and business case for sustainable manufacturing need to be determined time by time.Skill of innovation and creativity in supply or value chain operations also is one of the challenges that sustainable manufacturing face. S. (n. What is Sustainable Manufacturing? Retrieved on 20th May 2015. P. from http://www. and Wagner. Kalpakjian. Retrieved on 20th May 2015. Chico. Retrieved on 20th May 2015. State University. Retrieved on 20th May 2015. from http://www. Total Quality Management (TQM). Editor. (2000). (2006). Retrieved on 20 th May 2015. Thomson Course Technology. from http://www.d. Overview of sustainable manufacturing. (2015).oecd. (n.html Improsys.).rit. Manufacturing Engineering and Technology.htm OECD.in/SQC_training.html Rochester Institute of Technology (R. B.M.). Statistical Quality Control.uk/what-is-concurrent-engineering/ Swamidass. from http://www.edu/gis/cesm/whatis.8. 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