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Environmentally Conscious Design & Manufacturing

Explore motivations, design issues, and recycling concepts in sustainable manufacturing for a greener future. Learn about closed-loop recycling, materials hierarchy, preference tools, and expert systems.

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Environmentally Conscious Design & Manufacturing

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  1. Environmentally Conscious Design & Manufacturing Class6: Reuse / Recycle Prof. S. M. Pandit

  2. Reuse / Recycle Agenda • Motivation • Design issues & inverse manufacturing • Discrete product recycling • Tools • Expert systems

  3. Motivation • 1991Carnegie Mellon Report Projection: • 150,000,000 obsolete PCs by 2005 • None with readily recoverable materials • Landfilled! • Cost: $ 400,000,000 • What about washing machines, refrigerators, etc.?

  4. Design Issues - 1 Inverse Manufacturing Not limited to reusing and recycling -- Develop methods for the creation of designs with thought given to reuses and recycling from the very early stage -- Improve the functions of a product along with prolonging its product life through use and maintenance -- Lower the amount of abandoned artifacts. http://amstel.t.u-tokyo.ac.jp/~umeda/yoshikawa.html

  5. Design Issues - 2 • Green Design • -- How to arrange the information for design and development leading to the formation of an artifact system symbiotic with the environment. • -- New artifacts born out of this sort of methodology will have considerable effect in creating the new industries of the future.

  6. Design Issues - 3 • Extension of Reuse / recycle concepts: Maintenance Issues -- The manufacturing industry will turn into a life cycle industry -- The artifacts produced will quantitatively decrease -- But they will, instead, have • A long life and • Give rise to higher added values and the manufacturing industry will become sustainable.

  7. Design Issues - 4 • Reuse / Recycling in sustainable manufacturing -- Develop methods serving toward the creation of designs with thought given to reuse and recycling from the very early stage -- Improve the functions of artifacts, while decreasing the production volume but maintaining the level of economic activities.

  8. Recycling - Options & Hierarchy • Maintenance • Recycle subassemblies • Recycle components • Recycle materials

  9. Hierarchy of Preference in Recycling - 1

  10. Hierarchy of Preference in Recycling - 2

  11. Hierarchy of Preference in Recycling - 3

  12. Closed-loop Recycling

  13. Open-loop Recycling

  14. Recycling Materials - 1 • Avoid • -- Too many different materials • -- Toxic materials • -- Joining dissimilar materials hard to separate • Metals • -- Dilution factors affect price (of Extraction)

  15. Relation between Dilution and Price

  16. Recycling Materials - 2 • Plastics • -- Composition affects chemistry for recycling • • Tag with symbol • Fastening methods

  17. Recycling Materials - 3 • Priorities for recycling: • -- Reduce materials content • -- Reuse / refurbish • -- Remanufacture • -- Recycle • -- Incinerate • -- Dispose of as waste Preference

  18. Tools - 1 • Hierarchy for recycling / Reprocessing • -- pairwise comparison techniques • Look at available technology • Feasibility of developing technology • Cost and time factors

  19. Tools - 2 • Choosing between alternatives: • -- Reprocessability index for products & • subassemblies • -- Pairwise comparison

  20. Tools - 3 • Disassembly options (operations planning) • Engineered materials • Adsorb/ absorb contaminants • Bio- degradation • Experimental & analytic tools • -- Effluent gases, caloric values, incineration • options

  21. Tools - 4

  22. Recycling Program Steps • Evaluation • Design & Development • Education • Implementation • Monitoring & Management • Transportation, Processing & Marketing

  23. Expert Systems • Inference Engine • Tree structure “If-Then-Else” Rules • Analytic models • Hybrids • Empirical models • Learning algorithms • Imprecision “fuzzy” External Data Inputs Output Processor Structured Data Base

  24. Homework #2 The following problems are out of the textbook “Industrial Ecology” 1. Problem 2.3 Answer: (Example of aluminum) year Pop(billion) Al(million tons) Al per capita (g/person) 1950 2.5 1.25 450 1960 3.2 2.60 740 1970 2.8 7.0 1670 1980 4.7 11.0 2130 1985 5.0 11.5 2090 2. Problem 2.4 Answer: 2000: 23; 2010: 14 g; 2020: 6.2 g SO2/dollar Hint: Use extrapolation beyond the curves of Fig. 2.8)

  25. Homework #2 3. Problem 3.2 Answer: 1.5%(current fraction), 1.0%( 2020 fraction). 4. Problem 4.1 Answer:Draw a vertical line from 1.1 mg/l, and picture moving all of the curves to the right by half a division (i.e., factor of three in the log). The intersection is with the log probit curve. The Weibull model would have given approximately 2*104 µg/l as the standard, the logit model approximately 0.3 µg/l, and the multistage model approximately 30 µg/l.

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