A Software Tool for Unit Process-Based Sustainable Manufacturing Assessment of Metal Components and Assemblies

2014 ◽  
Author(s):  
Ian C. Garretson ◽  
Christopher J. Eastwood ◽  
Michael D. Eastwood ◽  
Karl R. Haapala
Keyword(s):  
Manufacturing Process ◽  
Impact Analysis ◽  
Sustainability Assessment ◽  
Sustainable Manufacturing ◽  
Software Tool ◽  
Supply Chain Design ◽  
Process Models ◽  
Inventory Analysis ◽  
Unit Process ◽  
Cradle To Gate

While environmental impact analysis is standard in accordance with ISO 14040:2006 using life cycle assessment software, such as GaBi and SimaPro, software tools supporting broader sustainability assessment are limited. Recent research has developed methods for sustainable manufacturing assessment and has led to unit manufacturing process models that can be used to quantify sustainability metrics. In spite of these advances, engineering designers must apply such methods in an ad hoc manner, which increases engineering analysis time and limits the utility of sustainability assessment in early design. Thus, manufacturing process models and supporting software tool are developed to assist design for manufacturing efforts pursuing sustainability performance improvement. The software is constructed using Visual Basic to create a graphical user interface for an MS Excel calculation engine. Using unit manufacturing process models, a product sustainability assessment can be generated by chaining together a sequential manufacturing process flow. In this way, cradle-to-gate assessments can support decisions made during product, process, and supply chain design. The method combines upstream inventory analysis and in-house unit process modeling to perform cradle-to-gate sustainability assessment. The utility of the approach is demonstrated for the assessment of an aircraft-like metal product assembly.

scholarly journals A Review of Engineering Research in Sustainable Manufacturing

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Karl R. Haapala ◽  
Fu Zhao ◽  
Jaime Camelio ◽  
John W. Sutherland ◽  
Steven J. Skerlos ◽  
...  
Keyword(s):  
Decision Making ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Sustainable Manufacturing ◽  
Supply Chain Design ◽  
Planning And Scheduling ◽  
Engineering Research ◽  
Challenges And Opportunities ◽  
Recent Developments ◽  
Planning Development

Sustainable manufacturing requires simultaneous consideration of economic, environmental, and social implications associated with the production and delivery of goods. Fundamentally, sustainable manufacturing relies on descriptive metrics, advanced decision-making, and public policy for implementation, evaluation, and feedback. In this paper, recent research into concepts, methods, and tools for sustainable manufacturing is explored. At the manufacturing process level, engineering research has addressed issues related to planning, development, analysis, and improvement of processes. At a manufacturing systems level, engineering research has addressed challenges relating to facility operation, production planning and scheduling, and supply chain design. Though economically vital, manufacturing processes and systems have retained the negative image of being inefficient, polluting, and dangerous. Industrial and academic researchers are re-imagining manufacturing as a source of innovation to meet society's future needs by undertaking strategic activities focused on sustainable processes and systems. Despite recent developments in decision making and process- and systems-level research, many challenges and opportunities remain. Several of these challenges relevant to manufacturing process and system research, development, implementation, and education are highlighted.

Towards a Standards-Based Methodology for Extending Manufacturing Process Models for Sustainability Assessment

2018 ◽  
Author(s):  
Arvind Shankar Raman ◽  
Karl R. Haapala ◽  
K. C. Morris
Keyword(s):  
Manufacturing Process ◽  
Sustainability Assessment ◽  
Building Blocks ◽  
Cnc Machining ◽  
Process Models ◽  
Machining Processes ◽  
Complex Processes ◽  
Information Models ◽  
Computer Numerically Controlled ◽  
Application Specific

Over the past decade, several efforts have characterized manufacturing processes from a sustainability perspective. In addition, frameworks, methodologies, and standards development for characterizing and linking unit manufacturing process (UMP) models to construct manufacturing system models for supporting sustainability assessment have been pursued. In this paper these research efforts are first briefly reviewed, and then, ASTM standards derived from this work are described and built upon. The contribution of this research is to demonstrate how more formalization of these prior efforts will facilitate systematic reuse of developed models by encapsulating different aspects of complex processes into reusable building blocks. The research proposes a methodology to define template UMP information models, which can further be abstracted and customized to represent an application-specific, upgraded manufacturing process. The methodology developed is based on the ASTM standards of characterizing manufacturing process for sustainability characterization. The approach is demonstrated for analyzing manual and computer numerically controlled (CNC) machining processes.

A Desktop Application for Sustainability Performance Assessment of Composed Unit-Based Manufacturing Systems

2017 ◽  
Author(s):  
Matteo M. Smullin ◽  
Zahra Iman ◽  
Karl R. Haapala
Keyword(s):  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Sustainability Assessment ◽  
Information Modeling ◽  
Process Models ◽  
System Level ◽  
Manufacturing Processes ◽  
Modeling Framework ◽  
Process Flow ◽  
Desktop Application

Life cycle assessment software packages such as SimaPro, GaBi, and Umberto have become well-established tools for conducting environmental impact analysis. However, applications for broader sustainability assessment are limited. Recent research has developed an information modeling framework to compose models of unit manufacturing processes for sustainability assessment and has led to the definition of unit manufacturing process information modeling concepts. An engineer can use the framework to conduct manufacturing system-level sustainability assessments by composing models of unit manufacturing processes. Assessment results can aid engineers in selecting the superior manufacturing process flow for a given product. To demonstrate usefulness of the information framework, a prototype desktop application has been developed. The application was implemented in Windows Project Foundation (WPF) using C# as the coding language to create a graphical user interface. Mathworks MATLAB serves as the calculation engine. Unit manufacturing process models follow the framework and are read by the application, which produces a sustainability assessment for the manufacturing process flow. A manufacturing process flow for an automobile-like metal product acts is used to demonstrate the software application.

On a Process Modeling Framework for Sustainable Manufacturing: A Machining Perspective

2007 ◽  
Author(s):  
Anshu D. Jayal ◽  
A. K. Balaji
Keyword(s):  
Life Cycle ◽  
Manufacturing Process ◽  
Product Life Cycle ◽  
Sustainable Manufacturing ◽  
Research Work ◽  
Process Models ◽  
Metalworking Fluids ◽  
Modeling Framework ◽  
Chemical Action ◽  
Processing Level

Sustainability and economic factors are increasingly pushing industry towards environmentally friendly manufacturing methods. However, the implications of processing level changes, which are being introduced at a significant rate, for overall, environmental impact need better characterization. In the first half of this paper, a simplified framework for enhancing sustainability in manufacturing, by enabling rapid assessment of approximate life-cycle implications of competing process-level alternatives, is introduced. This framework relies on developing or enhancing manufacturing process models in such a way that a superior quantitative evaluation of the environmental and economic impacts of decisions made in manufacturing process planning can be established. In the second half of this paper, the specific case of metal machining is presented. In machining the maximum attention has been directed towards reducing the traditional profligate use of metalworking fluids. Consequently, a significant quantity of research work has been directed towards developing dry and near-dry, or Minimal Quantity Lubrication (MQL), machining techniques. A review of available literature shows that several outcomes of these techniques for product life-cycle assessment need to be addressed — i.e., some environmental tradeoffs are often involved in their implementation. Avenues for further research in sustainable machining, including some ideas for advancing dry and near-dry machining without resorting to chemical action for extreme-pressure lubrication, are also presented.

Toward Metamodels for Composable and Reusable Additive Manufacturing Process Models

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Paul Witherell ◽  
Shaw Feng ◽  
Timothy W. Simpson ◽  
David B. Saint John ◽  
Pan Michaleris ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Powder ◽  
Manufacturing Process ◽  
Process Model ◽  
Model Development ◽  
Process Models ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Future Work ◽  
Am Processes

In this paper, we advocate for a more harmonized approach to model development for additive manufacturing (AM) processes, through classification and metamodeling that will support AM process model composability, reusability, and integration. We review several types of AM process models and use the direct metal powder bed fusion AM process to provide illustrative examples of the proposed classification and metamodel approach. We describe how a coordinated approach can be used to extend modeling capabilities by promoting model composability. As part of future work, a framework is envisioned to realize a more coherent strategy for model development and deployment.

Sustainability assessment in the manufacturing industry: a review of recent studies

2018 ◽  
Vol 25 (8) ◽  
pp. 3162-3179 ◽  
Author(s):  
Shamraiz Ahmad ◽  
Kuan Yew Wong
Keyword(s):  
Manufacturing Industry ◽  
Sustainability Assessment ◽  
Manufacturing Sector ◽  
Social Indicators ◽  
Sustainable Manufacturing ◽  
Manufacturing Industries ◽  
Bottom Line ◽  
Content Type ◽  
The Status ◽  
Different Levels

Purpose The purpose of this paper is to review and analyze the recent sustainability assessment studies in the manufacturing industry from the triple-bottom-line (TBL) perspective. This paper aims to depict the status quo of practical sustainability assessment, summarize the different levels and boundaries of evaluation, and highlight the difficulties and further improvements needed to make the assessment more effective in the manufacturing industry. Design/methodology/approach Four keywords, namely, sustainability assessment, sustainable manufacturing, TBL and green production, were used to explore and find the relevant articles. First, this paper systematically reviewed the studies and analyzed the different levels and boundaries of sustainability assessment. Following this, the reviewed studies were critically discussed along with their merits and shortcomings. Findings The review showed that most of the sustainability assessment studies were conducted on product, company and process levels in the manufacturing industry. Nevertheless, there is still a need to focus more on plant and process level assessments to achieve the TBL objectives. Environmental assessment is comparatively matured in manufacturing industries. However, from the economic and social viewpoints, only cost analysis and workers’ safety, respectively, were considered in most of the studies. The economic and social indicators need to be more inclusive and should be validated and standardized for manufacturing industries. Originality/value Unlike previous sustainability assessment reviews in manufacturing industries which were mostly based on life cycle assessment, this paper has included environmental, social and economic aspects in one comprehensive review and focused on recent studies published from 2010 to 2017. This paper has explored the recent sustainability assessment trends and provided insights into the development of sustainability assessment in the manufacturing sector.

scholarly journals Investigations on Temperature Fields during Laser Beam Melting by Means of Process Monitoring and Multiscale Process Modelling

2014 ◽  
Vol 6 ◽  
pp. 217584 ◽  
Author(s):  
J. Schilp ◽  
C. Seidel ◽  
H. Krauss ◽  
J. Weirather
Keyword(s):  
Process Monitoring ◽  
Manufacturing Process ◽  
Computation Time ◽  
Simulation Models ◽  
Process Models ◽  
Temperature Fields ◽  
Transient Temperature ◽  
Transient Temperature Field ◽  
Laser Beam Melting ◽  
Simulation Based

Process monitoring and modelling can contribute to fostering the industrial relevance of additive manufacturing. Process related temperature gradients and thermal inhomogeneities cause residual stresses, and distortions and influence the microstructure. Variations in wall thickness can cause heat accumulations. These occur predominantly in filigree part areas and can be detected by utilizing off-axis thermographic monitoring during the manufacturing process. In addition, numerical simulation models on the scale of whole parts can enable an analysis of temperature fields upstream to the build process. In a microscale domain, modelling of several exposed single hatches allows temperature investigations at a high spatial and temporal resolution. Within this paper, FEM-based micro- and macroscale modelling approaches as well as an experimental setup for thermographic monitoring are introduced. By discussing and comparing experimental data with simulation results in terms of temperature distributions both the potential of numerical approaches and the complexity of determining suitable computation time efficient process models are demonstrated. This paper contributes to the vision of adjusting the transient temperature field during manufacturing in order to improve the resulting part's quality by simulation based process design upstream to the build process and the inline process monitoring.

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