Nicole Gonzalez

1
Green Manufacturing

• Presented by
• Nicole Gonzalez
• Amrit Mohanani
• Eric Taub

2
Todays Agenda

• What is Green Manufacturing?
• Green Factory
• Economics and Market Place
• Manufacturer's Responsibilities
• Green Manufacturing Processes
• Metal Cutting Process
• Safety Considerations and operating environment
• Example
• Technology
• Clean-Tech
• Examples
• Companies / Industries served
• Advantages and Disadvantages
• Future Practices and Recommendations
• Benefits of Energy Conservation
• Case Study Example
• Conclusion

3
What is Green Manufacturing?

• Manufacturing that takes into consideration
  environmental impact at all stages of the
  production processes including resource savings,
  release of pollutants and recycling of components
• The purpose use materials that will not harm the
  ecosystem as much in the design, production,
  on-site applications and end of life disposal of
  the products

4
Green Factory
5
Economics and Market Place

• In mid 2007, it was reported that the cost to
  convert into Green Manufacturing was 4,850 per
  employee for the U.S. manufacturers
• Market is projected to grow from 65.4 billion
  in 2008 to 226.5 billion by 2016

6
Manufacturer's Responsibilities

• Reduce release of pollutants
• Reduce consumption of energy
• Reduce waste related to the manufacturing
  processes
• Develop products with small environmental impact
• Optimize processes
• Material reduction
• Water saving
• Paper recycling
• Prevention of potential hazards to the
  environment
• Develop advanced fabrication techniques
• Change Metal cutting techniques

7
Manufacturing Processes

• JIT Manufacturing
• Continuous cost reduction and quality improvement
• Zero Emission Strategy
• Elimination of all environmentally damaging by
  products from the production process
• 16 of companies are actively pursuing zero
  emissions
• 85 of companies are pursuing reduced emission
  strategies

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Manufacturing Processes cont.

• Switch to water based enzymes, rather than
  chemicals
• Eliminates the use of some solvents
• 15,000/year cost saving in raw material
• Substitute plants for petroleum as a raw material
• Corn can be used to create plastics
• Make castings from recycled metal products
• Conserves resources
• Requires 95 less energy

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Manufacturing Processes Metal Cutting

• Laser cutting
• cutting, welding, heat treating
• Metal Stamping
• presses a metal blank with a powerful die into
  the desired shape
• metal formed must be malleable enough to bend
  into shape without breaking.
• Deep drawn metal stamping draws the metal shape
  through progressive passes through the stamping
  die (produces long final metal stampings)

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Safety Considerations and operating environment
Metal Cutting
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Benefits of Converting to Green

• Murray Ohio Manufacturing
• Produces lawn mowers
• Used a chlorinated oil with an additive of
  graphite to increase lubricity
• The results
• Scrap metal went from 9 to 1
• Tool life increased 30-50

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Technology

• Clean-Tech technologies
• uses energy, water and other raw materials more
  efficiently
• brings superior performance
• improves customer profitability by reducing costs
• creates less waste and toxicity compared to
  current technologies

13
Technology Clean-Tech

• Energy
• oil reduction
• Solar Power
• usable energy from sunlight
• Wind
• wind power - Clean source of energy
• Biofuels
• Derived recently living organisms or their
  metabolic byproducts, such as corn and soybeans,
  sugar cane or palm oil.
• Form of solar energy
• Geothermal
• Provided by the heat of the earth
• Water
• Hydroelectric plants

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Example of Clean Tech in Construction industry

• - Green roofs absorb 75 of rainfall
• during the summer (70- 100)
• during the winter (40-50)
• absorb also 95 of cadmium, lead, copper
• absorb also 16 of zinc

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Companies/Industries Served

• Companies

• Nissan Green Plan

• GE
• Dupont (chemical)
• Toyota (automobile)
• Nissan (automobile)
• IBM (consumer tech)
• Sony (consumer tech)
• Nokia (telecommunication)
• Pitney Bowes (communications)

• "As part of our Nissan Green Program, we don't
  want to spread our resources so thin we can't
  develop anything, but at the same time, we're
  trying to keep our doors open so that we can
  choose technology that we can react to," he says.
  For example, if diesel fuel catches on, Nissan
  can react quickly by promoting its diesel-based
  systems. Similarly, if the company's hybrid
  utility vehicles -- the so-called HUVs --
  increase in popularity, Nissan can push its HUV
  systems.

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Advantages

• Saves valuable resources
• Minimizes waste and pollution
• Higher quality and reliability
• Energy efficient
• Elimination of waste through the production
  process
• Accessibility from loans from the government
• Development of innovative manufacturing systems
  and designs
• Recycling
• Reducing cost zero emission strategy

17
Disadvantages

• Increase in product cost
• Converting cost
• Price of raw material
• Less choice, less suppliers
• Research cost
• Lack of availability and information

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Future Practices/ Recommendations

• Companies like IBM, Sony, Nokia and others are
  opening environmentally-oriented patents to the
  public domain.
• The objective of this is to further develop
  their consumer or industrial products, processes
  and services in an environmentally responsible
  manner.
• http//www.industryweek.com/ReadArticle.aspx?Artic
  leID15684

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Benefits of Energy Conservation
Viewpoint -- The Secret Benefits of Energy
Conservation Beyond the Utility

• Conservation programs are worth 18 to your
  business -- and that's a conservative estimate.
• Non-utility benefits can be expressed many ways,
  but generally fall into the following four
  quantifiable categories
• A. extended equipment life B. reduced
  maintenance costs C. reduced risk to energy
  supply price spikes and D. the ability to sell
  carbon credits.
• In addition, there are strategic benefits (which
  are site-specific and not quantified here)
• A. enhanced public image and B. reduced risk
  to environmental/legal costs.

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Case Study
http//www.industryweek.com/ReadArticle.aspx?Artic
leID15730SectionID25

• Assume large facility with 10,000 light fixtures
• Common to reduce consumption 25
• Assume the fluorescent lights are relatively new
  and consume 60 watts per 2-lamp fixture and
  operate 5,000 hours per year. Our baseline energy
  consumption is
• (5,000 hrs/year)(.060 kW/fix)(10,000 fix.)
  3,000,000 kWh/year

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Case Study Continued

• If the school pays approximately .08/kwh, then
  the dollars spent on electricity for this
  lighting system
• 240,000/year.
• Thus, a 25 reduction from the baseline usage
  would equal 750,000 kWh/year, or 60,000/year in
  savings.

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Case Study Continued (Extended Equipment Lives)

• If lights are used 25 less, the lighting system
  (ballasts) should last about 25 longer. A
  lighting ballast is rated for 60,000 hours of
  operation. If the school operates the lights
  5,000 hours per year, they would need to replace
  the ballasts at the 12th year and dispose of the
  old ballasts. If there are 5,000 ballasts, each
  costing 25 to 55 (material, installation and
  disposal costs vary by geographic location), the
  replacement cost (minimum) at the 12th year would
  be
• (25/ballast)(5,000 ballasts) 125,000

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Case Study Continued

• Annualized replacement cost would be
• 125,000)(1/12 years) 10,417/year
• With a use rate of only 3,750 hours/year (a 25
  reduction), the ballasts should last 16 years.
  This would reduce the annualized replacement cost
  to
• (125,000)(1/16 years) 7,813/year

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Case Study Continued

• Thus, the Annualized Savings, (calculated as the
  difference between the original replacement cost
  minus the reduced replacement cost) are
• 10,417/year - 7,813/year 2,604/year (at
  25 per ballast)
• Using the same equations, at 55/ballast, the
  annualized savings, (from replacing at 16 years
  instead of 12 years) would be
• 5,729 per year.
• Thus, due to extended equipment life, we have
  reduced the annualized replacement cost by a
  minimum of 2,604/year to a maximum of
  5,729/year.

25
Conclusion

• Green manufacturing is not characterized by a
  specific machine, but by processes
• Green manufacturing minimizes the environmental
  impact caused by industry
• Maximizes raw material uses
• Minimizes waste
• Go Green!