SUSTAINABLE

MANUFACTURING Novita Sakundarini

University of Nottingham Malaysia

Delivered for The 6 Summer Course Smart

th

Agroindustry, Universitas Gadjah Mada

9 August 2024

Private and Confidential

Lecture Outline
• What and Why Sustainable?
• Sustainable Manufacturing
• Challenges and enablers
• Sustainable Manufacturing Solution
• Business case from industries
• Global Outlook of SM – New landscape, Near Zero Emission,
Decarbonization
• Key takeaway messages
What and Why
“Sustainable”
EARTH
EARTH
EARTH
EARTH
“Humanity has the ability to make development sustainable-to
ensure that it meets the needs of the present without
compromising the ability of future generations”
(Brundland Report, 1987)

The Origin of Sustainability

Sustainability – The underlying concept

Sustainability focuses on meeting the needs of the present

without compromising the ability of future generations to meet
Triple bottom line
their needs.
Why – Sustainable?
What is the consequences?
What is the consequences?
Projection 2050 – Industry vs Sustainability

Can we do this??
What is the consequences?
Being unsustainable is bad?

Intergovernmental Panel on
Climate Change (IPCC) , 2007

Temperature is rising

Global CO2 levels have increased

Climate Change
What is the consequences?
 How wasteful we are?
Stuff: Japan: 9000
Source: Svenningsen, UNEP

Anthony SF Chiu ([email protected]) 18

 How wasteful we are?
Stuff: Thailand: 218
Source: Svenningsen, UNEP

Anthony SF Chiu ([email protected]) 19

 How wasteful we are?

Source: Svenningsen, UNEP

Stuff: India: 22

Anthony SF Chiu ([email protected]) 20

 Malaysia’s food waste

According to the Solid Waste Management and Public Cleansing Corporation (SWCorp), by
2020 the total amount of food waste can certainly fill up 16 of the twin towers. Here’s
another fact: Malaysians waste about 16,688 tonnes of food per day, an amount that can
easily feed around 2.2 million people, three times a day! (The Strait Times, 2019)
Solid Waste in Malaysia

Malaysia currently produces 38,000 metric tonnes of waste daily,

with the national recycling rate a mere 33.17% – still shy of the
40% target set for 2025
(SWCorp, 2023)
Then…how industries must respond?
Earth Carrying Capacity
 Sustainable
Manufacturing
What is the consequences
to the industries?

SUSTAINABLE
MANUFACTURING –
“the creation of the
manufactured
products that use
The Sustainable processes that
Development emerged: minimize negative
environmental
“Humanity has the impacts, conserve
ability to make energy and natural
development resources, are safe for
sustainable-to ensure employees,
INDUSTRIES that it meets the needs communities,
of the present without consumers, and planet
Extract more resources, compromising the
generate emissions, species, and are
ability of future economically sound”
climate change issues, generations”
waste generation (International Trade
(Brundland Report, Administration, 2007)
1987)
Categorization of Sustainable Manufacturing

Sustainable product design and

1 development

2 Sustainable Manufacturing Process

3 Sustainable Supply Chain

4 Sustainable End of Life Management

 Sustainable Product Design and Development

• Eliminate the use of hazardous materials - Zsidisin and Siferd (2001); Hang et al.
(1997)
• Design products which will facilitate disassembly of retired products, separation of
parts according to materials, as well as reprocessing of materials - Duflou et
al.(2012); Lin et al. (2001)
• Design products which will facilitate repair, rework and refurbishment - Carter
and Ellram (1998); lvarez-Gil et al. (2007); Beamon (1999)
• Design products which will reduce material use - Pajunen et al. (2012)
• Design products which will reduce energy consumption - Kara and Li (2011);
Asian Productivity Organization (2004)
• Use environmental-friendly materials (e.g. recyclable materials) - Zhu et al.
(2007)
• Design products which incorporate recovery of obsolete products (e.g. product
leasing) - Manzini and Vezzoli (2003); Mont (2003); Hirschl et al.(2003)
• Design products which support maintenance - Baines et al. (2007)
• Design products which will prolong the life of materials - Lee et al. (2001);Sarkis
(1998)
 Sustainable Product Design and Development

• Material recovery (e.g. use wastes as internal resources such as metal

swarf and chips) - Thiede et al. (2012); Pajunen et al. (2012)
• Waste recovery (e.g. use coolants and transport solid wastes from the
factory for use as resources in other manufacturing processes) - Jawahir
et al. (2007); Kara and Li (2011); Duflou et al. (2012)
• Energy savings - Fang et al. (2011); Despeisse et al. (2012); Jayal et al.
(2010)
• Reduce CO2 emissions - Ball et al. (2009)
• Improve manufacturing and machine efficiency - Granados et al. (2009);
Newman et al.(2012); Usavec et al. (2010); Bi and Wang (2012); Jawahir
et al. (2007); Kara and Li (2011); Duflou et al. (2012); Millar and Russel
(2011); Fairfield et al. (2011)
• Adopt lean production systems - Miller et al. (2010); Baines et al. (2007
 Sustainable Supply Chain

• Adhere to environmentally-conscious programmes, standards or regulations - Rachuri et al.

(2009)
• Set environmental targets and objectives - Hamner (2006)
• Measure and audit material flows or wastes - Westkamper et al. (2001); Callenbach et al.
(1993)
• Select green suppliers - Bowen et al. (2001); Rao (2002)
• Influence suppliers to practise green initiatives - Hines and Jones (2001); Walton et al.
(1998)
• Collaborate with suppliers - Bowen et al. (2001); Vachon and Klassen (2006); Zhu and
Sarkis (2004); Hall (2000)
• Training suppliers - Bowen et al. (2001); Rao (2002)
• Influence customers to accept green practices, services or products - Canning and Hanmer-
Lloyd (2001)
• Use less, cleaner or reusable packaging - James et al. (2005); Jahre and Hatteland (2004)
• Adopt energy-efficient transportation - Kam et al. (2006)
• Adopt energy-efficient logistics (e.g. warehouse location and routes) - Wu and Dunn (1995);
Kam et al. (2006);
 Sustainable End of Life Management

• Prolong the service life of products or materials by providing

maintenance and support services to customers - Seliger (2007); Fiksel
(2009)
• Provide hazardous waste treatment in the plant for products after
recovery from the market - Frios (1999)
• Provide and manage product warranty returns - Kleyner and Sandborn
(2008)
• Provide and manage product recalls (e.g. reconditioning, reselling) –
Abdul Rashid et al (2017)
• Provide recycling support using components and material coding
standards - Hamner (2006); Lee and Na (2010)
Challenges and
Enablers
Challenges:
• Poor legislation
• Lack of infrastructure and resources
• Market demand
• Complexity in the design of the system
• Technological risk
• Resistance to change

Enablers
• Competition
• Public pressure
• Cost effectiveness
• Technological advancement
• Organization image
• Compliance to Environmental Audit
 The implementation steps of the sustainable
manufacturing approach (Kishawy et al, 2018)
• Developing practice and maintenance
(housekeeping)
• Process optimization
• Raw materials substitution
• New technologies
• New product design
 Sustainable
Manufacturing
Solution
The sustainable manufacturing solutions can be classified
into four different areas:
• Manufacturing technologies - approaches focused on “how things
are manufactured”, i.e. whose object of research lies in processes and
equipment, including machine-tools or facilities. Examples of such
approaches are among other things: development of new or improved
manufacturing processes, predictive maintenance of production equipment,
determination of process resource consumption, process chain simulation, or
energy-efficient facility building.
• Product lifecycles - approaches focussed on “what is to be produced”,
i.e. whose object of research is the product definition (where product can be
understood as a good or a service). Examples of such approaches are among
others: asset and product lifecycle management, intelligent product,
simplified product sustain ability assessment.
• Value creation networks - approaches focused on the organisational
context of manufacturing activities, i.e. whose objects of research are
organisations such as companies or manufacturing networks. Examples of such
approaches are among others: resource efficient supply chain planning, industrial
ecology.
• Global manufacturing impact - approaches focused on the transition
mechanisms towards sustainable manufacturing, i.e. whose objects exceed the
conventional scope of engineering. Examples of such approaches are among
others: development of sustainability assessment methods, education and
competence development, development of standards.
Business Case
NIKE INC
Ajinomoto Malaysia’s Initiatives in
Sustainable Food Manufacturing
Global Outlook:
New Landscape
Near Zero
Emissions
Decarbonization
 New Landscape for SM+IR4/IR5 Integration
Research Trend (RT) Relationship with citation score analysis Topic Based on Keywords Future Research Direction
Co-occurance

RT1 Sustainable Value Stream Mapping of Digitalization Focus on better exploring the research on how humans
The application of IR4, machine learning, big Industry 4.0 in Manufacturing Process Industry 4.0 and machines are collaborating in the manufacturing
data, digitalization in manufacturing to improve Reconfiguration: A case study in apparel Machine Learning ecosystem with the addition of sustainability aspects.
sustainability company (Phuong, N.A., Guidat, T., 2018) Resource Efficiency
Sustainability
Big Data
RT 2 A human centered sustainable additive Additive Manufacturing How Industry 4.0/ 5.0 could help reducing waste with
The use of technology such as additive manufacturing tool for early design stage 3D Printing the use of more advance technology.
manufacturing, smart manufacturing (using IR4 (Rocheton B.; Segonds F.; Laverne F.; Perry Circular Economy
technology) to support circular economy N., 2020) Product Design
Smart Manufacturing
RT3 Investigation into energy efficiency of Cryogenic Machining Focus on developing more advanced twin transition and
Optimization in tooling and machining to reduce outdated cutting machine tools and Energy Consumption Industry 4.0/5.0 and on how digital transition can foster
energy consumption with the support of IoT identification of improvement potentials to Minimum Quantity Lubricants sustainability.
promote sustainability (Kianinejad K.;
Uhlmann E.; Peukert B., 2015)

RT4 Tribological investigations on the application Energy Efficient How Industry 4.0/ 5.0 could help with more sustainable
Energy efficiency and tribology of oil-miscible ionic liquids additives in Tribology production processes, such as using renewable energy
modified Jatropha-based metalworking fluid sources. Energy efficient method and formulation using
(Amiril S.A.S.; Rahim E.A.; Embong Z.; simulation including a real time monitoring of energy
Syahrullail S., 2018) usage and evaluation technique can be the area of focus.
RT5 Towards the development of digital Sustainability Assessment Focus on exploring new model that leverage the
Development of sustainable assessment which manufacturing ecosystems for sustainable IoT capabilities of Industry 4.0/5.0, as well as examining
integrate real time with IoT support performance: learning from the past two Life Cycle Analysis the challenges and opportunities associated with their
decades of research (Shahatha adoption.
Al‐Mashhadani A.F.; Qureshi M.I.; Hishan
S.S.; Md Saad M.S.; Vaicondam Y.; Khan N.,
2021)
RT6 Sustainable manufacturing: re-contouring of Optimization How Industry 4.0/ 5.0 could help with more sustainable
Eco efficiency in manufacturing process laser cladding restored parts by machining Machining technology production processes to achieve cost efficiency by reducing
method with cutting energy management Tooling the waste, efficient use of energy and optimization of
Sustainable Manufacturing – moving forward… Near Zero Emission&Decarbonization
 Thank you and Save the Earth !

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