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Sustainable Manufacturing Innovation and Competitiveness

－Scheme of Minimal-Manufacturing－

○H. Kita, K. Masui, S. Hara, T. Yamaguchi, K.H. Park, T. Ohji and K. Igarashi

National Institute of Advanced Industrial Science and Technology (AIST)

WORKSHOP ON SUSTAINABLE MANUFACTURINGPRODUCTION AND COMPETITIVENESSCopenhagen, Denmark, 21-22 June 2007

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Contents

Minimal Manufacturing (MM) and the Working Group at AIST

Task Assignments

MM Methodologies

・ Utilization of Exergy and Entropy

・ Analytical Results of Case Study

・ Competitiveness

Examples of Minimal-Manufacturing Technologies in AIST

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Minimal Manufacturing for Sustainability

It aims at the high-performance manufacturing of products with maximal functionalities by use of minimal resources and minimal energies with the by-production of minimal wastes.

Traditional Minimal ManufacturingLow environmental load（Conservation of energy

and resources)

Frontier technology（novel & high functionality）

Practical technology（High efficiency by low cost）

Trade-off

Minimal resourcesMinimal energiesMinimal wastes

High manufacturing efficiencyLow cost

Maximal functionality

Let the exclusive technologies be compatible

Trade-off

Trade-off

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Advisors and Lecturers outside AIST

K. UedaUniv. of Tokyo, Prof.F. KimuraUniv. of Tokyo, Prof.E. H. IshidaTohoku Univ. Prof.K. HaraGenesis Res. Inst., Executive managing Director

A. MatsuyamaDaicel Chemical Industries, Tsukuba Research Center, GM

AIST committee

T. IshidaResearch and Innovation Promotion OfficeT. MikiResearch and Innovation Promotion OfficeT. TokizakiResearch and Innovation Promotion OfficeSecretariatY. ShimoiNanotechnology Research InstituteJ. TakahashiTechnology Information DepartmentM. SawakiTechnology Information DepartmentS. NakahamaResearch CoordinatorK. IgarashiResearch CoordinatorS. HaraNanoelectronics Research InstituteN. KoshizakiNanoarchitectonics Research CenterK. YoshimuraMaterials R.I. for Sustainable DevelopmentK. MurataNanotechnology Research InstituteK. MasuiAdvanced Manufacturing Research InstituteT. OhjiAdvanced Manufacturing Research InstituteMembersH. KitaAdvanced Manufacturing Research InstituteT. YamaguchiNanotechnology Research InstituteCo-ChairS. SasakiAdvanced Manufacturing Research InstituteChair

Minimal Manufacturing Working Group, AIST

Secretariat

Chief

Advanced Manufacturing R.I.J. Akedo

Innovation Promotion OfficeT. IshidaInnovation Promotion OfficeT. Tokizaki

Nanotechnology R.I.H. MaedaAdvanced Manufacturing R.I.N. Mishima

R.I. Innovation in Sustainable Chemistry

M. NakaiwaNanoelectronics R.I.S. HaraichiTechnology Information Dept.K. -H. ParkNanotechnology R.I.W. MizutaniAdvanced Manufacturing R.I.K. MasuiNanotechnology R.I.K. MurataAdvanced Manufacturing R.I.H. KitaNanoelectronics R.I.S. Hara

Pj. Chief

Pj. Director

Advanced Manufacturing R.I.

K. MasuiNanotechnology R.I.K. MurataNanoelectronics R.I.S. Hara

Nanotechnology R.I., Director

H. Yokoyama

Chief

Advanced Manufacturing R.I.K. MasuiAdvanced Manufacturing R.I.H. KitaNanotechnology R.I.T. Yamaguchi

"Minimal Manufacturing & Maximum Servicing" President, Dr. H. Yoshikawa

Organization in FY2006

Task force of Technologiesfor Minimal Manufacturing

Task force of Indices for Minimal Manufacturing

Investigation on Production Innovation by Nanotechnology (NEDO mini fund FY2005)

Research Coordinator, Dr. K. Igarashi

Collabo-ration

Minimal Manufacturing Working Group at AIST

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Demand

Production

ResourcesWaste Materials and Lost Energy

Economical

Economical

SystemSystem

Market

Task AssignmentsEnvironment

(Ecological System)

“Producing high performance products which meet the market demand while using the minimum amount of resources and wasting the minimum amount of materials and energy.”■Task1 ： Standard of “the Minimum” and evaluation criteria considering competitiveness in economic activities.■Task2： AIST’s potential technologies for the minimal manufacturing.

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Entropy Production

Entr

opy

Prod

uctio

n

Time

The goal is to retard the Entropy Production rates, while meeting the society / industry demands in total.

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5 10 30 50

Environmental Impact

Waste

& Exhau

stInput Energy

Water

Input Resource

Environmental Efficiency

Social Cost

Resource

use ef

ficien

cyRare Resource usage

Amount of waste

Hazardous Chemicals

Cyclic Time (years) Long TermShort Term

Uni

vers

al S

pace

Glo

bal M

inim

alLo

cal M

inim

al

Entr

opy

Prod

uctio

nR

ate

Min

imal

M

anuf

actu

ring.

Universal Space - Cycle Time Chart

Fuel

Amount of material usage

Material YieldManufacturing efficiency

Intermediate Products/ Materials

Expenditure on R&DTime Schedule on R&D

Instruments Size

Capital Investment

Start-up speedArea of factory

Production lead time

Manufacturing cost

Goods in Process / Amount of Stock

Delivery Due

Processes Steps

YieldDistribution

Enterpris

e

Enterpris

e

Society

Society

Ecosy

stem

Ecosy

stem

The Erat

h

The Erat

h

Nation/

Nation/

Country

Country

Consumer

Consumer

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Energy & Resources(Electric power, Heat, etc)

Dis

posa

l

Environmental Impact byProduct Manufacturing

Maintenance management cost(Energy)

⑩

Customer SatisfactionReliability, DurabilityYield

Environmental Impact by Product Usage

Environmental Impact by Product Deletion

Waste energyWaste and Exhaust,

waste energy

Man

ufac

turig

Part

s &

C

ompo

nent

s

Prod

ucts

Raw

Mat

eria

ls

& M

iner

als

Reu

se &

R

ecyc

le

Production (Manufactory) Usage & Disposal (Consumer)

Supply chainLogistic

Disposal process cost(Energy)

Usa

ge

Purc

hase

Inpu

t

Cost ⇔ Value

Proc

ess

&

Out

put

Was

te

Design, Architecture & IP Knowledge & Information

Knowledge & Information

Waste and Exhaust, waste energy

Product Life Cycle and Environmental Impact

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Manufactory Level

Specific Process Level

Society Level

Nested Open Systems in Manufacturing and Exergy

Exergy: “Quantity of State” commonly dealing with energy, resources, products, etc. going out, coming in and fixed in the stages of production, usage, and disposal.

In- and out-puts of resources, products, energies, and wastes in each system stage.

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Environment Standard:

Earth Resources0

Artificial Product A

Prod

uctio

n：Co

nsum

ing

Exer

gy

Use and Disposal Waste A

Environment Impact Degree

Exe

rgy

Artificial Product B

Waste B

Concept of Exergy

Ex = (H-H0) – T0 (S-S0)T0:Environmental temperature

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How Can We use “Exergy and Entropy” for Minimal Manufacturing?

1) Process Design

2) Resources Consumption Evaluation through Life Cycle

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EXE

RG

Y

INPUT EXERGY

LOST EXERGY

EXERGY FIXED IN PRODUCTS

Efficiency of Process The ratio of the fixed energy in the products to the input energy.

Analysis Objects Quantification of resources, products and energy in common scale.

Practical use for index of process design Exergy in steady state can be the index for the optimal process.

Exergy Analysis

OUT( Products and wastes）

IN (Resources and Energy)

Environmental Index

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Example: Efficiency of Process in Ceramic Parts

Calculated for a product of 5 kg

OUTPUT (Products、Wastes)

FixedFixed

INPUT (Resources, Energy)

Efficiency of Process (Fixed Ex / Input Ex) is about 7%.

Process

Exer

gy (M

J)

-800

-600

-400

-200

0

200

400

600

800

1000

1200

Powder Mixing

Granulation Press Forming Dewax Sintering Sum

Raw materials, Sub raw materials Electric power LPG

Waste Waste exergy Product, Intermediate product

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Waste (surplus)

Reference standard

Artificial Product

Exergy of state (used in the calculation.)

Exergy required for chemical reaction (not used in the present calculation.)

Real Input Exergy

Minimal exergy evaluated from exergy of state

Use and Issues of Exergy in Process Design

Scheme to reduce input exergy “Exergy of state”is an index for the minimum.

Minimization in Process Design

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Practical Using Time (Months)Practical Using Time (Months)

Thic

knes

s o

f H

eate

r Tu

be (m

m)

Enh

ance

men

t E

ntro

py (

MO

ns)

(Controlling the Entropy Production due to the reactions with Molten Aluminum)Decreased Entropy By Using of Ceramic Heater Tube

Decreased Entropyof Heater TubeFour-teen Steel Heater Tubes

One Ceramic Heater Tube

This result suggests that entropy does not increase in a ceramic heater, whereas reaction between molten aluminum and steel increases the entropy in a steel heater.

Four-teen Steel Heater Tubes

One Ceramic Heater Tube

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Al Factory(17 MOns=1.24MOns×14P)

(22 MOns=21.5MOns×1P)Al Factory

5,287 MOns

4,089 MOns

Steel Heater Tubes

Ceramic Heater Tube

Al- Product(Fe Contamination)～4300 ton

Al- Product (No Contamination)～4300 ton

Entropy Production

Entropy Production 1,198 MOns

Decreased Entropy

1 Piece

14 Pieces

Ordinary Process

Improved Process

Decreased Entropy By using Ceramic Heater Tube on the Aluminum Melting Process (Estimation for 7 years)

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• Competitive Index (CI) =Customer value

Supply price

• Environmental Index (EI) = Exergy loss through the life-cycle that consists of production, use and disposal stages

EI

CI

Minimal Manufacturing Index

AB

CD

Region A: Ideal directionRegion B: CI improves more than the

increase of EI. It is hoped that technologies will move to region A via region B.

Region C: Environmental aspect is improved, but competitiveness becomes lower.

Region D: Allowed in no way.

Manufacturing cost, R&D expenses, producer’s and

supplier’s profits

Present value of benefit that a customer

receives through the product life-cycle

>1

Current status

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AOKup+-Enhancing recycle

Lower recycle cost

Easy assembly/disassembly

product

Bbadup+++More functions

Multi-functional mobile phone

AOKup+++Feeling spacious

Contributing to water saving

Lower water cost

Water-saving lavatory

A orCOKdepen

ds++Feeling secure

Preventing soil and water pollution

Lead-free product

COKdowneven+Contributing to oil saving

Plant-derived plastics

COKdowneven+Preventing air pollution

Higher fuel cost

Diesel car with PM filter

n/aup++Feeling healthyHealthy tea

++

Cus-tomervalue

+

Sup-ply

price

up

CI

AOKFeeling

envi.benign

Contributing to energy saving

Lower fuel costHybrid car

Emotional value

Environmental value

Economic value

RegionEICustomer value

Examples

Classification of Customer Values and Effects on the Index

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Concepts of Values,Economical, Environmental, and Emotional Values

（Example : Automobile）

Economical ValueEnvironmental ValueEmotional Value

User ClassificationWealth (common or rich)Use (play or work)Age (young or aged) Other factors (family members, region, character, etc.)

Commercial Vehicle（CV)

Passenger Vehicle（PV)

Popular car

Luxury car

Owners are not drivers.

Owners are drivers

Economical Value is the most important.

The value of automobile depends on types of vehicles and users.

Emotional Value

Economical Value

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From Weight Basis to Function Basis

Use and Issues of Exergy in Material and Structure Design

Material and Structure Design Based on Integration and SimplificationMinimization in

Material and Structure

Reference standard (B)

Artificial Product (A)

Artificial Product (B)

1.Integrating functions by nano-technology

2.Using abundant, natural resources

3.Light weight products of optimaized structure, etc.

4.Re-use design, etc.

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InflexibilityInflexibility

ComplexityComplexity

LocalMinimization

LocalMinimization

Processes

Materials

Device

Products

Systems

Mapping of technologies suitable for MM is being updated in AIST.

Issues ofPresent

Industries

ME

MS

ME

MS

On-site Production

3D devices

(WLC

SP

, ...)3D

devices(W

LCS

P, ...)

Flexible Function(FP

GA

, ...)Flexible Function

(FPG

A, ...)

micro-TA

Sm

icro-TAS

Cell P

roductionC

ell Production

Desktop factory

Desktop factory

mini FA

Bm

ini FAB

Co-P

roductionC

o-Production

Co-G

enerationC

o-Generation

SC

MS

CM

SC

MS

CM

Printed P

roductsP

rinted Products

Micro P

lasma

Micro P

lasma

Laser Annealing

Laser Annealing

Mask-less

Mask-less

Stereo-FabricM

odelingS

tereo-FabricM

odeling

InkjetInkjet

Desktop Furnace

Desktop Furnace

Com

binatorialC

ombinatorial

Com

binatorialC

ombinatorial

Self-O

rganizationS

elf-Organization

Micro-R

eactor M

icro-Reactor

Catalysis

Catalysis

Aerosol D

epositionA

erosol Deposition

Post

Silicon W

aferP

ostS

ilicon Wafer

IntelligentM

aterialsIntelligentM

aterials

InitializingC

ontamination C

onditionInitializing

Contam

ination Condition

Equipm

ent Sharing

Equipm

ent Sharing

Vacuum

FreeV

acuum Free E

ncapsulatedP

roduction System

Encapsulated

Production S

ystemE

ncapsulatedP

roduction System

Encapsulated

Production S

ystem

Technologies Suitable for Minimal Manufacturing

M.M.concept

FlexibilityFlexibility

SimplificationSimplification

UnificationUnification