Transcript ME 4171 - Environmentally Conscious Design & Manufacturing

Product Life Cycle(s)
Georgia Institute of Technology
Systems Realization Laboratory
Module Objective
Having read this, you should know the following:
1. Basic product life-cycle stages
2. Different terminology used by different organizations
and stakeholders
3. Be able to draw a product life-cycle diagram
Georgia Institute of Technology
Systems Realization Laboratory
Our Linear Production System
Materials Extracted
from Biosphere
Material
Processing
Materials Mined
from Lithosphere
Product
Manufacture
Distribution
Use
Disposal
Resources are mined, wastes are
generated, products are disposed
Georgia Institute of Technology
Systems Realization Laboratory
Cyclical Production System
Materials Extracted
From Biosphere
Manufacture
Material
Processing
Materials Mined
From Lithosphere
Product
Manufacture
4
3
Distribution
2
1
Use
Disposal
Demanufacture
Material
Demanufacture
Product
Demanufacture
Product
Take-Back
1=
Energy recovery
with incineration
Clean fuel
production via
pyrolysis
2=
3=
4=
Direct reuse
Remanufacture of reusable components
Reprocessing of recycled material
Monomer/raw material generation
Engineering decisions in design and manufacturing can have
profound implications throughout the entire product life cycle,
from raw materials production, through the use phase of the
product and into it’s end of life treatment.
Georgia Institute of Technology
Systems Realization Laboratory
Stages of the Product Life Cycle
(Office of Technology Assessment)
Environmental impacts occur at all stages of a product’s life cycle. Design can be employed to reduce
these impacts by changing the amount and type of materials used in the product, by creating more efficient
manufacturing operations, by reducing the energy and materials consumed during use, and by recovery of
energy and materials during waste management. (OTA)
Georgia Institute of Technology
Systems Realization Laboratory
A Product’s Life Cycle – From Cradle to Re-Incarnation
Manufacture
Material
processing
Mining
Environment:
air, sea, land
4
Product
manufacture
3
2
Distribution
1
Demanufacture
Disposal
Material demanufacture
Product
demanufacture
Use
+
Service
Product
take-back
1 = Direct recycling / reuse
Energy
recovery with
incineration
Clean fuel
production
via pyrolysis
2 = Remanufacture of reusab le components
3 = Reprocessing of recycled material
4 = Monomer / raw material regeneration
The term “demanufacture” is used to characterize the process opposite to manufacturing
involved in recycling materials and products.
Georgia Institute of Technology
Systems Realization Laboratory
Automobile Life-Cycle
material and parts specifications
materials
Material
Supplier
Tier 1 Part
Molder/Suppliers
Vehicle
Platform
parts
vehicles
vehicles
Assembly
Plant(s)
Dealer
parts
Tier 2 Part
Molder/Suppliers
scrap parts
OEM
Tier 2 Part
Molder/Suppliers
remanufact.
parts
parts
Material
Supplier
materials
Parts Remanufacturer
Tier 3 Part
Molder/Suppliers
recyclable nonmetallic materials
cores
reusable
parts
junked
vehicles
cores
Vehicle
Dismantler
scrap
vehicles
Supplier Base
Recycler(s)
metals
Mills
Consumer
Auto
Shredder
• Many modern products like automobiles are assembled by OEMs (Original
Equipment Manufacturers) from components manufactured by numerous
suppliers, creating a complicated network of interactions.
Georgia Institute of Technology
Systems Realization Laboratory
Examples of undesired releases and consumptions
Product life cycle stage
Some examples
of harmful ene rgy and matter
consumption and e missions
Manufacturing
Energy inefficient manufacturing processes.
Manufacturing waste material.
Hazardous chemicals.
Waste heat.
Large energy consumption.
Deployment
Packaging materials.
Transportation energy.
Operation and service
Increased emissions and energy consumption due
to loss
of peak performance.
Worn components which are replaced and discarded.
Retirement
Energy for (garbage) collection.
Scrap products.
The above names for life cycle stages
are often used in Defense related
industries and products.
Georgia Institute of Technology
Systems Realization Laboratory
Generic High Level Life-Cycle Activities
I n p u ts
L i f e- cy cl e S ta g e s
O u tp u t s
R a w M ate r ial s A cq u i si t io n
A t m o s p h er i c
E m i s s io n s
M a n u f ac tu ri n g
R aw
M a t e ri a ls
M a te r i a ls M a n u fa c t ur e
W a t e rb o rn e
Wa ste s
For a mechanical product.
(Source: EPA)
P r o d u c t F a br i ca t io n
S o li d
W a s t es
F ill in g/ P a ck a gi n g / D is tr ibu t ion
E n e rg y
C o p r o d u ct s
U s e / R e u s e / M a i n te n a n c e
O t h er
R el e as e s
R e cy cl e / W ast e M an a g e m e n t
Georgia Institute of Technology
Systems Realization Laboratory
Some Aspects of an Environmentally Benign Product
Product Life Cycle
Produc tion and
Distribution
Use
Pos t Us e
low ene rg y an d mate rial
cons ump tio n
low ene rg y an d mate rial
cons ump tio n
us e of en viro nme ntally
be nign (e .g . re cycle d)
material
few and environ men tally
be nign emiss ions
few and en viro nmen tally
be nign (recyclable )
emiss ion s / wa ste
long prod uct life
= ea sy to :
insp ect, mainta in,
re pa ir, up date
us efuln ess
Rec ycling
Dispos al
de grada bility
Ma te rial Rec ycling
high re cyclin g va lu e
of the materials
se parab ility o r comp atibility of materials
Inc iner ation
no h aza rd ous
emiss ions
Produc t Re cycling
(Re use of the pro du ct o r its p arts )
high re us e valu e
disa ss embla bility
The terms “material” and “product” recycling are used in Germany and the German
engineering standard VDI 2243 – “Designing Technical Products for Ease of Recycling”
Georgia Institute of Technology
Systems Realization Laboratory