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Re: (Thinking) Manufacturing
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Re(thinking) Manufacturing
Robert D. Cormia
Foothill College
Overview
• A new paradigm
• Re => ‘cycling’
• Remanufacturing
• Demanufacturing
• Local manufacturing
• Repair and reuse
The Value of Materials
Materials
Manufacturing
MaterialReprocessing
ProductRecycling
How Would Nature Do It?
• Not like us!• Systems and cycles• Waste = food• Cradle to Cradle• Biomimetic
New Materials Paradigm
• Minimize extraction
• Maximize reuse
• Repurpose by design
• Learn to re: ‘cycle’– Up-cycling– Down-cycling
Re- ‘Cycle’
Reduce
Reuse Repurpose
http://www.mcdonough.com/cradle_to_cradle.htm
Remaking the Way We make Things
Cradle to Cradle
• Roundtrip materials use – ‘end-to-end’
• Manufactured using a minimum of new (virgin) material
• Mandated demanufacturing and recovery of existing material
Waste => Food
• Material waste is the driver of more extraction, more energy use, and more pollution to the environment.
• Deconstruction and reuse is the ‘natural cycle’ approach.
Story of Stuff
Single Use Batteries
Remote controls, toys, flashlights, smoke detectors—these are just some of the products that require batteries in our daily lives. Over three billion dry cell batteries are sold each year in the U.S. Because batteries disposed of in municipal landfills and trash incinerators can disperse significant amounts of heavy metals and other toxic substances into the air and water, battery waste prevention and recycling strategies are essential.
http://earth911.com/hazardous/single-use-batteries/
Material Scarcity
• Declining metal / mineral production across the globe
• Increasing energy to extract metals from lower grade ore
• Competition for scarcer resources
Recycling as an Ethic
• Plastic• Glass• Metal• Paper• Biowaste• Cardboard• Batteries• E-waste• Organs
Benefits of Recycling
• Local jobs
• Local wages
• Balance of payments
• Reuse of material
• Lower energy
• Lower ‘consumption’
• Cheaper than trash
http://www.recycling-revolution.com/recycling-benefits.html
Material Cycling Value
• Down-cycling– Conserving value
• Up-cycling– Adding value
• Re-cycling– Preserving value
duraflame stax / Java Log
Repurposing – Waste => FoodCoffee grinds can be 100% composted
Recycled material => post wasteBlended with renewable materialsLower carbon – cleaner burning
As Good as Wood?
Or Better?
The Green Cycles
• Recycling is processing used materials into new products, which results in less waste of potentially useful materials, less consumption of fresh raw materials, less energy usage and less water and air pollution.
• Precycling is thinking ahead before you buy. This can reduce the buildup of waste, items to landfills and even can save you money.
• Freecycling is giving away items for free instead of throwing them away. A great reusing network can be created.
• Upcycling is creating useful items from recycled material. This results in less waste and even can save money through reusing and not having to buy again.
• Downcycling is reusing or recycling of a product for an alternative lesser-quality purpose to keep it out of landfills or elsewhere.
• E-cycling is the recycling of electronics. E-cycling helps to prevent some e-waste such as lead, mercury, cadmium and other toxins to enter the environment.
http://www.examiner.com/x-17027-Louisville-Green-Living-Examiner~y2009m8d5-The-green-cycles-recycling-precycling-freecycling-upcycling-downcycling-and-ecycling
Industrial Ecologies
http://en.wikipedia.org/wiki/Industrial_ecology
Extended Producer Responsibility
• OEM ‘take it back’– Cradle to grave approach– Efficient ‘reintegration’
• Pooled take-back (consortia)– Leverage best practice– Develop economies of scale
• Third party (vendor) – Specialists– Industrial ecosystems
Remanufacturing Lifecycle
Remanufacturing Institute
http://www.reman.org/
Toner Cartridges
• Most are recycled
• Ten lives or more
• Copiers may someday be ‘downcycled’
Demanufacturing• Demanufacturing is the disassembly
and recycling of obsolete consumer products. The goal is to remove and recycle every component in an appliance. For example, the motherboard and metal parts of a computer are smelted and the metals are recovered. The TV tube in the monitor is recycled and turned into a new TV tube. The computers plastic housing is recovered and turned into new computer housings. The goal of the process is to reuse all of the materials that make up the computer, not throw them away.
http://www.greenbiz.com/feature/2001/07/16/the-demanufacturing-difference
Demanufacturing Jobs
These are good jobs for hardworking people who are both industrious and diligent, doing precision work which often requires a lot of care!
The Value of These Jobs?
• Local employment
• All regions of US
• Growing in number
• All levels of skill
• Transportable
• Open to all walks of life / ‘preparedness’
Remanufacturing
• Rebuilding machines• Reclaiming tools at
end of life• Recondition and
refurbished• Cost effective
replacement parts• Reduce virgin
material extraction
http://www.airbrakecomponents.net/
Industrial Applications
• Electronics
• Automobiles
• PHEV retrofits
• Buildings
• Furniture
• Clothing
• Toys
APRA Automotive Parts Remanufacturers Association
• APRA is a non-profit trade association whose members rebuild/remanufacture automotive and truck related "hard" parts for passenger cars, trucks, off-road, marine, equipment and industrial uses. These parts include, but are not limited to, alternators, armatures, generators, starters, carburetors, clutches, distributors, connecting rods, crankshafts, cylinder blocks, engine assemblies, fuel pumps, brakes, master and wheel brake cylinders, power brakes, starter drives, solenoids, automatic transmissions, regulators, springs, windshield wiper motors and water pumps. http://www.apra.org/
Automotive Parts
• Engines
• Transmissions
• Clutch
• Drive shafts
• Bearing assemblies
• Fuel injection
• Alternators
Engine Reassembly
• Diesel (passenger)
• Diesel (truck)• Older engines• Turbo chargers• Salvage
Engine Reassembly
Engine Reconditioning
Automotive Batteries
• Lead acid batteries• Nickel metal hydride• Lithium ion phosphate• PHEV batteries• EV battery racks• NEV batteries
www.batterymd.com
http://www.intergears.co.uk/
Modular Building Solutions
Almost end of life condition for this building
Almost brand new condition for these buildings
LEED Building – Success!
We are beginning to make progress on both ‘reuse’ and reduction of virgin material
Manufacturing Energy?
Biosynthetic Fuels
• Agrifuels– Diverted food
• Biofuels– Diverted waste
• Biosynthetic fuels– Recycled CO2
Biomimetic Process• Waste = Food• Self-assemble, from the ground up• Evolve solutions, don't plan them• Relentlessly adjust to the here & now• Cooperate AND compete, not just one or the other• Diversify to fill every niche• Gather energy & materials efficiently• Optimize the system rather than maximizing components• The whole is greater than the sum of its parts--design for swarm• Use minimal energy & materials "Don’t foul your nest“• Organize fractally• Chemical reactions should be in water at normal temperature & pressure• Vogel's mechanical-engineering-specific principles
http://www.worldchanging.com/archives/003680.html
Design by Intention
Repair and Reuse
• A second life• Not remanufacturing• Extends original
product value• Adds skilled labor• Builds local labor• Low materials cost• Strong customer
satisfaction
Organ Recycling - Reuse
• There are things which cannot be (re)manufactured (at least not yet).
• Be a blood donor
• Be an organ donor
• Realize the living potential of reuse
The Road Ahead
• Nanomanufacturing
• Human reassembly
• Continuous redesign
• Like software
• Biomimicry
Where to Learn More
• The Remanufacturing Institute - http://www.reman.org/
• ARPA – http://www.arpa.org/
• Battery MD - http://www.batterymd.com/
• Intergears – http://www.intergears.co.uk/
• Green Citizen - http://www.greencitizen.com/
• http://www.recycling-revolution.com/