Powerpoint format of lectures in MECH 424, 2005 edition.

The contents of this lecture are the sole copyright of J. Jeswiet, Professor of Mechanical Engineering. They are intended for use only by students in MECH 424, Life Cycle Engineering, Queens University, Kingston, ON, Canada. Working for the environment

Lecture 3

J. Jeswiet

MECH 424 Life Cycle Engineering Topics: 1. The latest on drivers, 2. Three small examples, 3. Automotive LCI. Gday. Gday.

Unlicensed use of the contents of this lecture outside MECH 424 is illegal. Inquiries should be addressed to: J. Jeswiet, Mechanical Engineering, McLaughlin Hall, Queens University, Kingston, ON, Canada K7L 3N6 Fax: 613-533-6489 [email protected]

Drivers behind the changes that are occurring: Changes have occurred in the corporate sector over the past decade. Companies now need to meet the requirements of the Kyoto Protocol [3] on climate change. The following are just a few examples of changes that are occurring and which are acting as drivers. Companies have become concerned about their environmental image and how this will have an impact upon sales of their brand. Branding has become an important tool for companies as indicated by Forbes magazine in their 2004 ratings of company branding [4]. It is predicted that the cost of doing business will increase; for instance higher interest rates may be charged by banks when environmental programs are not in place. In another example [6], an oil company has been holding secret meetings with environmental groups worldwide in an effort to change its hardnosed public image on the environment.

Some energy companies have gone ahead and made it part of their mandate to decrease their production of greenhouse gases [7]. For instance in 1997 one oil company [7] recognized the global warming problem and announced target reductions of 10% compared to their 1990 levels by 2010, but actually were able to do this by 2001. Their net savings were $650,000. In two cases energy companies have become involved in solar energy research [7, 8]. With all the foregoing changes in branding and changes in industry attitudes toward environmental impact and reporting impacts, other needs have arisen. Jeswiet and Hauschild [11] indicate that companies not only need to change their image in many cases, but there is a need for tools which can be used to assess both their old and new product lines, and whether a new area of endeavor can be both profitable and environmentally responsible.

Part of that assessment will require an Environmental Risk Analysis, which will probably be included in the future tools used by the designer. The ongoing changes will eventually have an effect upon product designers.
References:
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] Boothroyd G. and Alting, L. Design for assembly and disassembly, Annals of CIRP, 41/2/1992; 625. Jovane F., Alting L., Armillotta A., Eversheim W., Feldmann K., Seliger G. and Roth N., (1993) A key issue in product life cycle: disassembly, Annals of CIRP 42/2/1993; 651. United Nations Kyoto Protocol, Kyoto, Japan, on 11 December 1997. How companies manage intangibles like brands...is tough to quantify. Until now. Forbes Magazine 2004. Australian Broadcasting Corporation radio interview, 0815, June 1, 2004. Macalister, T. Exxon seeks to clean up is image as global villain. Guardian Weekly, October 16 22, 2003, page 7. BP 2003 Sustainability report. The Economist, Oct. 2003, Profits and Principles, is there a choice? Shell Oil advertising. Neftegaz.RU interview with L. Taylor, Minister of the Environment, Alberta Canada. Eurasia summit, 24 September 2003, New York. EU automobile take back directive; Directive 2000/53/EC, 18 September 2000, on the EOL of vehicles. Jeswiet, J., and Hauschild, M. EcoDesign and Future Environmental Impacts. Journal of Machines and Design. Accepted September 2004 Graedel, T.E. and Allenby, B.R. Industrial Ecology. 2003 by AT&T, published by Prentice Hall, New Jersey. Product Design for Manufacture and Assembly. Boothroyd, Dewhurst and Knight. 1994 Marcel Dekker, NY.

Three examples of manufacturing of parts: case studies Material reduction in truck parts Reducing toxic production media usage Economics and recycling

Recall from the first lecture:

The 3 Rs of Environmental Design Reduce reduce consumption Reuse reuse materials Recycle shred material
Public view

Recall the Life Cycle Analysis diagram

Reduce volume of Reuse parts in material in designs design Reduce Remanufacture of processing media in parts manufacturing

Requires energy input

Design Engineer

We We will will look look at at two two cases: cases: Pilger rolling Truck

1.

Pilger Rolling lubricant flooded the working zone

Environmental impact reduced substantially by designing better lubricating nozzles

Case 1.

Case 2.

Required experimental work

Truck parts project

Net Result of the Pilger Project

Project Goals: To lighten trucks To use recyclable material

a dramatic reduction in air pollution around the machinery, having

a definite benefit to the health of the people working in that area.

Required knowledge of fluid flow

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

How? Replace thick grey cast iron parts with thinner high strength nodular cast iron

The use of nodular cast iron is increasing

Energy Material waste Toxicity Fluids Air quality UV Greenhouse gases

It can be seen that economics plays a role in both foregoing examples The next example is part of a study in which economics played a major role.

economics and recycling in choosing the number of dies needed to make a side door panel for an automobile. Issue: Choosing the number of sheets to be welded in TWBs Geiger* made a study for the automotive industry

What was gained

Energy Material waste Toxicity Fluids Air quality UV Greenhouse gases

of the economic trade-offs of how many welds should be made in a side panel.

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

Remember: Both Design and Manufacturing Engineers deal with the manufacturing process There is always an environmental impact in any manufacturing process The goal of all design engineers should be to Design and Manufacture Economically with Minimum Impact upon the Environment

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

recycling efficiency: high low Contribution to energy consumption Economics: dies are very expensive to make and maintain Quality requirements can increase costs

SAE paper # Life Cycle Inventory, LCI Steps towards an LCI GOAL(S) SCOPE LCI

Note:Why Whythe theemphasis emphasis upon uponautomobile automobilemanufacturing? manufacturing? Note:

One of the most comprehensive, and recent LCIs, called the United States Automotive Materials Partnership Life Cycle Assessment Special Topics Group [USAMP/LCA] was conducted by a consortium which included: Ford, GM, Chrysler, American Iron and Steel Institute, American Plastics Council and The Aluminum Association. Therefore the automobile has a large impact upon: the potential for remanufacturing; recycling; local effects; The following figures and tables are from that report and can be found in the following SAE paper:

Included in the scope of the LCI were:

Environmental data categories were defined as:

Production models used for making parts:

The average automobile was modeled as:

Parts that would be changed in the use phase of the car:

The USCAR LCI is the most comprehensive available LCI available to the public to date. It provides us with an excellent example of how a complex LCI 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 a problem to work on and think of the potential for economic activity and recycling and remanufacturing opportunities Thank Thank you you for for your your attention attention

Finally the end of the lecture