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2

Three examples of manufacturing of parts:

case studies

Material reduction in truck parts

Reducing toxic production m edia usage

Economics and recycling

Remanufacture ofparts

Reduceprocessing media inmanufacturing

Requires energy

input

Reuse parts indesign

Reduce volume ofmaterial i n designs

shred materialreuse materialsreduceconsumption

RecycleReuseReduce

Design

Engineer

Public

view

The 3 Rs of Environmental Design

Recall from t he first lecture:

1

2

Recall the Li fe Cycle Analysis diagram

We will look at two cases:

We will look at two cases:

TruckPilger rol ling

Case 1. Case 2.

1 2

1. Pilger Rolling lubricant flooded the working zone

Environmental impactreduced substantially by

designing betterlubricating nozzles

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3

Required knowledge of fluid flow

Required experimental work

Energy

Material waste

ToxicityFluids

Air q ualit y

UV

Greenhouse gases

Net Result of the Pilger Project

a dramatic reduction in air pollution around the machinery, havinga definite benefit to the health of the people working in that area.

a dramatic reduction in use of toxic coolant; 300 l/min to 30 l/min

an increase in productivity due to less downtime

a reduction in energy use

Truck parts project

Project Goals:

To lighten trucks

To use recyclable material

How? Replace thick grey cast iron partswith thinner high strength nodular cast iron

The use of nodular cast iron is increasing

2

Energy

Material waste

Toxicity

Fluids

Air q ualit y

UV

Greenhouse gases

What was gained

It can be seen that economics playsa role in both foregoing examples

The next example is part of a study inwhich economics pl ayed a major r ole.

Issue: Choosing the number of sheets to be welded in TWBs

Geiger* made a study for the automotive industry

of the economic trade-offs

of how many welds should be made in a side panel.

* From Annals of CIRP; M. Geiger, University o f Erlangen

economicseconomics and recyclingrecycling in choosing the number of diesneeded to make a side door panel for an automobile.

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recycling efficiencyrecycling efficiency: high lowContribution to energy consumpti onenergy consumpti on

EconomicsEconomics: dies are very expensive to make and maintain

QualityQuality requirements can increase costsincrease costs

Both Design and Manufacturing Engineers dealwith the manufacturing process

There is always an environm ental impact in anymanufacturing process

The goal of all design engineers should be toDesign and Manufacture Economically with

Minimum Impact upon the Environment

Remember:

In a Life Cycle Inventory the idea is to account for:

1. All materials

2. All material, fluid and gaseous flows

3. All energy consumption; both source and end

Life Cycle Inventory is a necessary part of an LCA andis something that many companies are busy with.

LCI, Life Cycle InventoryLCI, Life Cycle Inventory

Steps towards an LCI

Life Cycle Inventory, LCI

GOAL(S) SCOPE LCI

One of the most comprehensive, and recent LCIs, called the

United States Automotive Materials Partnership Life CycleAssessment Spec ial To pic s Group [USAMP/LCA]

was conducted by a consortium which included:

Ford, GM, Chrysler, American Iron and Steel Institute,Ameri can Plasti cs Cou nci l and The Alu min um Associat ion.

The following fi gures and tables are from that report andcan be found in the foll owing SAE paper:

SAE paper # Note: Why the emphasis upon automobile manufacturing?Note: Why the emphasis upon automobile manufacturing?

Therefore the automobile has a large impact upon:

the potential for remanufacturing; recycling; local effects;

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Included in the scopeof the LCI were:

The average automobilewas modeled as:

Environmental datacategories were defined as:

Production modelsused for making parts:

Parts that would bechanged in the usephase of the car:

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The USCAR LCI is the most comprehensive available LCIavailable to the public to date.

It provides us with an excellent example of how a complexLCI is conducted.

It can also be seen, that the automobile has a large impact upon:

the potential for remanufacturing; an economic advantage

recycling; this can be either a problem or economic advantage

local effects; more landfills needed; this is a a disincentive

and can be a driving force the emphasis upon the two

foregoing activities.

So, when looking at the traffic jam and parking lot of the future

One can see aproblem to work on

and

think of the potential

for economic activity

and recycling andremanufacturing

opportunities

Finally the end of the lectureFinally the end of the lecture

Thank you for your attentionThank you for your attention