Leveraging Technology for a Sustainable World: Proceedings of the 19th CIRP Conference on Life Cycle Engineering, University of California at Berkeley, Berkeley, USA, May 23 - 25, 2012 PDF
Preview Leveraging Technology for a Sustainable World: Proceedings of the 19th CIRP Conference on Life Cycle Engineering, University of California at Berkeley, Berkeley, USA, May 23 - 25, 2012
Leveraging Technology for a Sustainable World David A. Dornfeld (cid:129) Barbara S. Linke Editors Leveraging Technology for a Sustainable World Proceedings of the 19th CIRP Conference on Life Cycle Engineering, University of California at Berkeley, Berkeley, USA, May 23–25, 2012 ABC Editors Prof.DavidA.Dornfeld Dr.BarbaraS.Linke LaboratoryforManufacturingandSustainability(LMAS) LaboratoryforManufacturingandSustainability(LMAS) UniversityofCaliforniaatBerkeley UniversityofCaliforniaatBerkeley Berkeley,CA Berkeley,CA USA USA ISBN978-3-642-29068-8 e-ISBN978-3-642-29069-5 DOI10.1007/978-3-642-29069-5 SpringerHeidelbergNewYorkDordrechtLondon LibraryofCongressControlNumber:2012935109 (cid:2)c Springer-VerlagBerlinHeidelberg2012 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartofthematerialisconcerned,specificallytherightsof translation,reprinting,reuseofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionorinformation storageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilarmethodologynowknownorhereafterdeveloped.Exemptedfrom thislegalreservationarebriefexcerptsinconnectionwithreviewsorscholarlyanalysisormaterialsuppliedspecificallyforthepurposeofbeingenteredand executedonacomputersystem,forexclusiveusebythepurchaserofthework.Duplicationofthispublicationorpartsthereofispermittedonlyunderthe provisionsoftheCopyrightLawofthePublisher’slocation,initscurrentversion,andpermissionforusemustalwaysbeobtainedfromSpringer.Permissions forusemaybeobtainedthroughRightsLinkattheCopyrightClearanceCenter.ViolationsareliabletoprosecutionundertherespectiveCopyrightLaw. 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Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface Welcometo the 19th CIRP Conference on LifeCycle Engineering hosted bythe University ofCalifornia,Berkeley!The Berkeleycampus is boththeUniversityofCalifornia’sflagshipcampusaswellasarenownedresearchcenterthatcontinuesalegacyofinnovationinengineering, science,society,culture,andpolitics.WehopethatthisenvironmentwillleadtoaproductivediscussionwithinourLifeCycleEngineering(LCE) community. The 19th CIRP LCE conference continues a strong tradition of scientific meetings in the areas of sustainability and engineering. The theme forthisyear’sconference isLeveraging Technologyfora SustainableWorld.Asresourceshave become increasinglyscarce andthe environmentalimpactofbusinessandindustryhasgrown,ithasbecomevitalforengineerstoprovideleadershipindevelopingthoseinnovations thatwillenablegreenbusinessesandindustriesthatremainsociallyresponsibleandeconomicallysuccessful.Itisourgoalthatthisconference will serve as an international forum for researchers to review and discuss the current developments, technology improvements, and future researchdirectionsthatwillallowengineerstomeetthissocietalneed. Theconferenceincludesover100technicalpapersthathavebeenacceptedafterarigorouspeerreviewandrevisionprocess.Theresearch coversBusinessesandOrganizations,CaseStudies,EndofLifeManagement,LifeCycleDesign,MachineToolTechnologiesforSustainability, Manufacturing Processes, Manufacturing Systems, Methods and Tools for Sustainability, Social Sustainability, Supply Chain Management. KeynotetalkswillbegivenbyDr.JulianAllwoodoftheUniversityofCambridge,Dr.MichaelOvercashofWichitaStateUniversity,Mr.Richard HellingofDowChemical,Ms.KarenHuberofCaterpillar,andMr.AdamHanselofDTL/MoriSeiki.Wehopethatthesepresentationsandthe proceedingswillserveasavaluablesourceofinformationonthestateofLCE. Wewouldliketothankalloftheparticipantsfortheircontributionstotheconferenceprogramandproceedings,aswellastheorganizing teamattheLaboratoryforManufacturingandSustainabilityfortheirsupport.Wewouldalsoliketoextendourgratitudetothemembersofthe ScientificCommitteesfortheircontinuedsupportinhelpingtomakethisasuccessfulconference! Theconference programwould notbe possiblewithoutthe generousfinancial supportofourindustry sponsorswho,at the time ofthis writing,include:Samsung,MoriSeiki/DMG,EspritbyDPTechnologies,andDowChemical.InadditionourthanksgototheNationalScience FoundationNSF,whoprovidedfinancialsupportforgraduatestudentsandpostdoctoralresearchersattendingtheconference. Thankyouagainforyoursupportofthe19thCIRPLCEconferenceandwelookforwardtoagreatmeeting! DavidA.Dornfeld BarbaraS.Linke Organization Chairs Prof.DavidA.Dornfeld Dr.-Ing.BarbaraS.Linke OrganizingCommittee Mr.AntoineChaignon Dr.HyunseoupLee Ms.Yi-FenChen Ms.JenniferMangold Mr.JoshuaChien Ms.KatherineMcKinstry Mr.SeungchounChoi Ms.JoannaNoble Mr.LeeClemon Ms.EmilyRice Ms.NancyDiaz Ms.StefanieRobinson Mr.MoneerHelu Ms.KathySchermerhorn-Cousens Ms.YuchuHuang Mr.AntonSudradjat Dr.MargotHutchins Dr.KarlWalczak Mr.DaeyoungKong InternationalScientificCommittee Prof.S.Ahn/KR Prof.T.Lien/NO Prof.L.Alting/DK Prof.C.Luttropp/SE Prof.F.Badurdeen/US Prof.H.Meier/DE Prof.A.Bernard/FR Prof.N.Nasr/US Prof.H.Bley/DE Prof.A.Nee/SG Prof.B.Bras/US Prof.R.Neugebauer/DE Prof.D.Brissaud/FR Prof.J.F.G.Oliveira/BR Prof.G.Byrne/IE Prof.A.Ometto/BR Prof.W.Dewulf/BE Prof.M.Overcash/US Prof.F.Doyle/US Prof.G.Reinhart/DE Prof.J.Duflou/BE Prof.O.Romero-Hernandez/MX Prof.H.ElMaraghy/CA Prof.G.Seliger/DE Prof.W.ElMaraghy/EG Prof.M.Shpitalni/IL Prof.K.Feldmann/DE Prof.W.Sihn/AT Prof.J.Greene/US Prof.S.Skerlos/US Prof.T.Gutowski/US Prof.R.Steinhilper/DE Prof.K.Haapala/US Prof.J.Sutherland/US Prof.M.Hauschild/DK Prof.S.Takata/JP Prof.C.Herrmann/DE Prof.S.Tichkiewitch/FR Prof.J.Hesselbach/DE Prof.T.Tomiyama/NL Prof.J.Issacs/US Prof.J.Twomey/US Prof.I.S.Jawahir/US Prof.Y.Umeda/US Prof.J.Jeswiet/CA Prof.H.vanBrussel/BE Prof.H.Kaebernick/AU Prof.F.vanHouten/NL Prof.S.Kara/AU Dr.A.Vijayaraghavan/US Prof.F.Kimura/JP Prof.E.Westka¨mper/DE Prof.T.Kingsbury/US Prof.C.Yuan/US Prof.F.Klocke/DE Prof.H.Zhang/US Prof.G.Lanza/DE Table of Contents Keynotes UnitProcessLifeCycleInventory(UPLCI)–AStructuredFrameworktoCompleteProductLifeCycleStudies....................... 1 MichaelOvercash,JanetTwomey Businesses and Organizations QualityInformationManagementforAdvancedQualityPlanninginSmallandMedium-SizedCompanies ........................... 5 SophieGro¨ger,ToniEiselt MakingtheBusinessCaseforEco-DesignandSustainableManufacturing.................................................... 11 AlirezaVeshagh,SalvadorMarval,TimWoolman GoalProgramming-BasedApproachtoIdentifySustainableProductServiceSystemDesigns .................................... 19 AihuaHuang,KenWijekoon,FazleenaBadurdeen SupportingScenarioDesigninPlanningLong-TermBusinessStrategiesBasedonSustainabilityScenarios ........................ 25 YusukeKishita,MakiHirosaki,YujiMizuno,HarunaWada,ShinichiFukushige,YasushiUmeda ExploitingLifeCycleInnovation ....................................................................................... 31 J.E.ParadaPuig,S.Hoekstra,L.A.M.vanDongen Businesses and Organizations − Product Service Systems RiskManagementofIndustrialProduct-ServiceSystems(IPS2)–HowtoConsiderRiskandUncertaintyovertheIPS2Lifecycle?...... 37 JohannesKeinegen.Schulte,MarionSteven Product-ServiceSystemTypesandImplementationApproach .............................................................. 43 BrittaPergande,PaulaL.A.Nobre,AndersonC.Nakanishi,EduardoS.Zancul,LeandroLoss,LucasC.Horta LifeCycleOrientedQualityAssessmentofTechnicalProduct-ServiceSystems ................................................ 49 SebastianWaltemode,CarstenMannweiler,JanC.Aurich Case Studies for Automotive Applications AFrameworktoAnalyzetheReductionPotentialofLifeCycleCarbonDioxideEmissionsofPassengerCars........................ 55 ChristophHerrmann,KarstenKieckha¨fer,MarkMennenga,StevenSkerlos,ThomasStefanSpengler,JulianStehr,VineetRaichur, GritWalther MaterialSubstitutionforAutomotiveApplications:AComparativeLifeCycleAnalysis............................................ 61 LauraMarretta,RosaDiLorenzo,FabrizioMicari,JorgeArinez,DavidDornfeld DecisionMakingMethodologytoReduceEnergyinAutomobileManufacturing................................................. 67 KatherineC.McKinstry,JorgeArinez,StephanBiller,DavidDornfeld WaterConsumptioninaVehicleLifeCycle .............................................................................. 73 FranciscoTejada,JohnZullo,TinaGuldbergTejada,BertBras SimplifiedLifeCycleAnalysisofaFormingToolintheAutomotiveIndustry.................................................... 79 F.Klocke,G.Schuh,B.Do¨bbeler,M.Pitsch,R.Schlosser,D.Lung,D.Assmann,C.Hein,R.Malek X TableofContents Case Studies for Selected Applications LCAApplication:TheCaseoftheSugarCaneBagasseElectricityGenerationinBrazil.......................................... 85 DiogoA.LopesSilva,IveteDelai,MarianaMaiadeMiranda,MaryLauraDelgadoMontes,AldoRobertoOmetto EnergyEfficiencyPotentialforChina’sCementIndustry:ABottom-UpTechnology-LevelAnalysis ................................. 91 AliHasanbeigi,WilliamMorrow,DavidFridley,EricMasanet,TengfangXu,JayantSathaye,NinaZheng,LynnPrice DriversandBarriersofEnvironmentallyConsciousManufacturing:AComparativeStudyofIndianandGermanOrganizations ......... 97 VarinderKumarMittal,KuldipSinghSangwan,ChristophHerrmann,PatriciaEgede,ChristianWulbusch StimulatingStudentstoExperienceSustainableEngineering:TheCQSGroupTRacingTeam ................................... 103 NicolasDekeyser,SietzeSwolfs,GeertWaeyenbergh,WimDewulf ReducingEnergyDemandsofPrintingMachinesbyEnergyReuseOptionsandOptimization .................................... 107 ReimundNeugebauer,MatthiasPutz,CarstenKeller,SaschaFa¨lsch EnvironmentalFootprintofMagnetiteNanoparticleApplication:IronOxideCase ............................................... 113 SuphunnikaIbbotson,SamiKara ModularServer–Client–Server(MSCS)ApproachforProcessOptimizationinEarlyR&DofEmergingTechnologiesbyLCA ......... 119 EvaZschieschang,PeterPfeifer,LiselotteSchebek LifeCyclePerspectivesforBiosensors.................................................................................. 125 AliHakimian,PegahN.Abadian,JacquelineA.Isaacs LifeCycleforEngineeringtheHealthcareServiceDeliveryofImaging........................................................ 131 JanetTwomey,MichaelOvercash,SeyedSoltani DefiningandMappingLCANetworks:InitialResults ...................................................................... 137 AndersBjørn,MikołajOwsianiak,AlexisLaurent,ChristineMolin,TorbjørnB.Westh,MichaelZ.Hauschild End of Life Management ObsolescenceManagementasaToolforEffectiveSparePartsManagement.................................................. 143 SvenSchulze,ChristianEngel,HenningLeichnitz AssessmentofAutomationPotentialsfortheDisassemblyofAutomotiveLithiumIonBatterySystems.............................. 149 ChristophHerrmann,AnnikaRaatz,MarkMennenga,JanSchmitt,StefanAndrew Remanufacturing:AnAlternativeforEndofUseofWindTurbines ........................................................... 155 KatherineOrtegon,LoringF.Nies,JohnW.Sutherland AStudyonanE-WasteManagementStrategyConsideringGlobalInverseSupplyChain ........................................ 161 KunikoMishima,NozomuMishima,MasaruNakano SeparatingManufacturingMetalChipsforRecyclingthroughaCombinedHydrodynamicandElectromagneticApproach.............. 167 QiangZhai,ChrisYuan AFrameworkforUsingCognitiveRoboticsinDisassemblyAutomation ....................................................... 173 SupachaiVongbunyong,SamiKara,MauricePagnucco RecyclabilityEvaluationofLCDTVsBasedonEnd-of-LifeScenarios ........................................................ 179 TakahiroMizuno,EisukeKunii,ShinichiFukushige,YasushiUmeda StrategicDecisionMakingforEnd-of-LifeManagementofFuelCells......................................................... 185 E.I.Wright,S.Rahimifard TableofContents XI Life Cycle Design ImpactofTechnologyonProductLifeCycleDesign:FunctionalandEnvironmentalPerspective................................... 191 SeungJinKim,SamiKara AConceptualFrameworkforSustainableEngineeringDesign .............................................................. 197 KaiLindow,RobertWoll,RainerStark Prioritizing‘DesignforRecyclability’Guidelines,BridgingtheGapbetweenRecyclersandProductDevelopers ...................... 203 HarmA.R.Peters,MartenE.Toxopeus,JuanM.Jauregui-Becker,Mark-OlofDirksen HolisticApproachforJointlyDesigningDematerializedMachineToolsandProductionSystemsEnablingFlexibility-OrientedBusiness Models ........................................................................................................... 209 GiacomoCopani,MarcoLeonesio,LorenzoMolinari-Tosatti,StefaniaPellegrinelli,MarcelloUrgo,AnnaValente,JuanjoZulaika LeanDfd:ADesignforDisassemblyApproachtoEvaluatetheFeasibilityofDifferentEnd-of-LifeScenariosforIndustrialProducts ...... 215 ClaudioFavi,MicheleGermani,MarcoMandolini,MarcoMarconi MappingtheLifeCycleAnalysisandSustainabilityImpactofDesignforEnvironmentPrinciples................................... 221 LoraOehlberg,CindyBayley,ColeHartman,AliceAgogino Machine Tool Technologies for Sustainability DevelopmentofanEmpiricalModeltoDescribetheServiceLifeofBallScrewsforMachineToolsunderConsiderationofJerk Influences......................................................................................................... 227 ChristianBrecher,Tu¨rkerYagmur SimulationoftheEnergyConsumptionofMachineToolsforaSpecificProductionTask.......................................... 233 EberhardAbele,ChristianEisele,SebastianSchrems EnergyEfficientCoolingSystemsforMachineTools ...................................................................... 239 ChristianBrecher,StephanBa¨umler,DavidJasper,JohannesTriebs SimulationandPredictionofProcess-OrientedEnergyConsumptionofMachineTools .......................................... 245 S.Braun,U.Heisel MappingEnergyConsumptionforIndustrialRobots....................................................................... 251 Pa˚lYstgaard,ToneBeateGjerstad,TerjeKristofferLien,PerAageNyen PrototypicalImplementationofaRemanufacturingOrientedGrindingMachine................................................. 257 EraldoJannonedaSilva,AldoRobertoOmetto,HenriqueRozenfeld,DiogoA.LopesSilva,DanielaCristinaAntelmiPigosso, ViniciusRiccoAlvesReis Manufacturing Processes − Casting, Forming, Injection Molding, Joining AssessmentofEnergyConsumptioninInjectionMouldingProcess .......................................................... 263 IneˆsRibeiro,PauloPec¸as,ElsaHenriques UnitProcessEnergyConsumptionModelsforMaterialAdditionProcesses:ACaseoftheInjectionMoldingProcess ................. 269 FarhanQureshi,WenLi,SamiKara,ChristophHerrmann DynamicTotalCostofOwnership(TCO)CalculationofInjectionMouldingMachines............................................ 275 SebastianThiede,TimSpiering,StephanKohlitz,ChristophHerrmann,SamiKara AMaterialandEnergyFlowOrientedMethodforEnhancingEnergyandResourceEfficiencyinAluminiumFoundries ................ 281 MichaelKrause,SebastianThiede,ChristophHerrmann,FranzFriedrichButz Multi-objectiveAnalysisonJoiningTechnologies ......................................................................... 287 JoshuaM.Chien,KatherineC.McKinstry,ChulBaek,ArpadHorvath,DavidDornfeld XII TableofContents Manufacturing Processes − Machining LifeCycleAnalysisofGrinding ........................................................................................ 293 BarbaraLinke,MichaelOvercash TotalCostAnalysisofProcessTimeReductionasaGreenMachiningStrategy ................................................ 299 MoneerHelu,BenjaminBehmann,HaraldMeier,DavidDornfeld,GiselaLanza,VolkerSchulze EnergyAnalysisofMicro-drillingProcessUsedtoManufacturePrintedCircuitBoards........................................... 305 Hae-SungYoon,BinayakBhandari,Jong-SeolMoon,Chung-SooKim,Gyu-BongLee,KwangWookPark,Chul-KiSong, Sung-HoonAhn UsingJatrophaOilBasedMetalworkingFluidsinMachiningProcesses:AFunctionalandEcologicalLifeCycleEvaluation ............ 311 MariusWinter,GerlindO¨hlschla¨ger,TinaDettmer,SuphunnikaIbbotson,SamiKara,ChristophHerrmann EvaluationofTwoCompetingMachiningProcessesBasedonSustainabilityIndicators .......................................... 317 JulianoBezerradeAraujo,Joa˜oFernandoGomesdeOliveira UsingaNewEconomicModelwithLCA-BasedCarbonEmissionInputsforProcessParameterSelectioninMachining ............... 323 KadraBranker,JackJeswiet EvaluationofAbrasiveProcessesandMachineswithRespecttoEnergyEfficiency............................................. 329 JanC.Aurich,MarinaCarrella,ManfredSteffes Manufacturing Systems − Factory Planning and Peripheral Systems AnApproachforthePlanningandOptimizationofEnergyConsumptioninFactoriesConsideringthePeripheralSystems ............. 335 HolgerHaag,Jo¨rgSiegert,ThomasBauernhansl,EngelbertWestka¨mper DevelopmentofaProcedureforEnergyEfficiencyEvaluationandImprovementofProductionMachinery........................... 341 RolfSteinhilper,StefanFreiberger,FrankKu¨bler,JohannesBo¨hner CompressedAirLeakDetectionUsingMicrophoneArrayTechniques ........................................................ 347 PetrEret,CraigMeskell AutomatedHandlingofLimpFoilsinLithium-Ion-CellManufacturing ......................................................... 353 J.Fleischer,E.Ruprecht,M.Baumeister,S.Haag ALifeCycleOrientedEvaluationofChangeableManufacturingandAssemblySystems ......................................... 357 JochenHartung,BarbaraBaudzus,JochenDeuse EnergyEfficiencyinPneumaticProductionSystems:StateoftheArtandFutureDirections ...................................... 363 PaulHarris,GarretE.O’Donnell,TomWhelan Manufacturing Systems − Process Planning and Control InterfaceRequirementsandPlanningFrameworkfortheIntegrationofNon-conventionalProcessesinProductionLines .............. 369 JochenBo¨ck,Jo¨rgSiegert,ThomasBauernhansl,EngelbertWestka¨mper Simulation-BasedAssessmentoftheEnergyConsumptionofManufacturingProcesses......................................... 375 EberhardAbele,SebastianSchrems,ChristianEisele,PhilippSchraml AutomatedProvisionandExchangeofEnergyInformationthroughouttheProductionProcess.................................... 381 PhilippEberspa¨cher,HolgerHaag,RaphaelRaha¨user,JanSchlechtendahl,AlexanderVerl,ThomasBauernhansl, EngelbertWestka¨mper AutomatedLinkageofConsumptionModelsandControlInformationinControlSystems......................................... 387 JanSchlechtendahl,PhilippSommer,PhilippEberspa¨cher,AlexanderVerl TableofContents XIII SustainableInterlinkedManufacturingProcessesthroughReal-TimeQualityPrediction ......................................... 393 DanielLieber,BenediktKonrad,JochenDeuse,MarcoStolpe,KatharinaMorik Energy-SensitiveProductionControlinMixedModelManufacturingProcesses ................................................ 399 ReimundNeugebauer,MatthiasPutz,AndreasSchlegel,TinoLanger,EnricoFranz,So¨renLorenz AnEco-ImprovementMethodologyforReductionofProductEmbodiedEnergyinDiscreteManufacturing........................... 405 H.O¨zgu¨rU¨nver,M.UralUluer,Ays¸egu¨lAltin,Yig˘itTas¸ciog˘lu,S.EnginKilic¸ CostandEnergyConsumptionOptimizationofProductManufactureinaFlexibleManufacturingSystem ........................... 411 NancyDiaz,DavidDornfeld ConceptofEnergy-EfficientJobSequencingforHeatTreatmentProcesses ................................................... 417 DanielBu¨cker,JochenDeuse Methods and Tools for Sustainability ResourceEfficiencyAssessmentSystem ............................................................................... 423 ThomasLundholm,MichaelLieder,GuidoRumpel DevelopingaSimpleCarbonFootprintCalculationToolwiththeCriteriaofInventoryDataSelection ............................... 429 JahauLewisChen,Yi-HsingWen AMetrics-BasedMethodologyforEstablishingProductSustainabilityIndex(ProdSI)forManufacturedProducts ..................... 435 X.Zhang,T.Lu,M.Shuaib,G.Rotella,A.Huang,S.C.Feng,K.Rouch,F.Badurdeen,I.S.Jawahir ModelingGapsandOverlapsofSustainabilityStandards .................................................................. 443 AnnaE.D’Alessio,PaulWitherell,SudarsanRachuri AForecastingModelfortheEvaluationofFutureResourceAvailability ....................................................... 449 MarkMennenga,SebastianThiede,JanBeier,TinaDettmer,SamiKara,ChristophHerrmann ReductionofWaterConsumptionwithinManufacturingApplications ......................................................... 455 MadhuSachidananda,ShahinRahimifard WaterFootprintQuantificationofMachiningProcesses .................................................................... 461 JonathanOgaldez,AshleyBarker,FuZhao,JohnWilliamSutherland Methods and Tools for Sustainability in Aerospace Manufacturing MethodologyforEcologicalandEconomicalAircraftLifeCycleAnalysis ...................................................... 467 MarkusGroßeBo¨ckmann,RobertSchmitt LifeCycleEngineeringinPreliminaryAircraftDesign...................................................................... 473 KatharinaFranz,RalfHo¨rnschemeyer,ArthurEwert,MartinaFromhold-Eisebith,MarkusGroßeBo¨ckmann,RobertSchmitt, KatjaPetzoldt,ChristophSchneider,JanErikHeller,Jo¨rgFeldhusen,KerstinBu¨ker,JohannesReichmuth LifecycleImpactProfileforEfficientProductDevelopment–JetEngineExample............................................... 479 PatrickAnsgarHacker,Gu¨ntherSchuh,FrankvonCzerniewicz SurveyofCommonPracticesinSustainableAerospaceManufacturingforthePurposeofDrivingFutureResearch................... 485 YuriyRomaniw,BertBras Methods and Tools for Sustainability in Process Chains EnergyEfficientandIntelligentProductionScheduling–EvaluationofanewProductionPlanningandSchedulingSoftware ........... 491 AgnesPechmann,IlkaScho¨ler,ReneHackmann
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