Toward the development of process plans with reduced environmental impacts

doi:10.1007/s11465-012-0334-3

Front Mech Eng

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Issue () : 231-246 https://doi.org/10.1007/s11465-012-0334-3

FEATURE ARTICLE

Toward the development of process plans with reduced environmental impacts

Fu ZHAO¹(

), Vance R. MURRAY¹, Karthik RAMANI¹, John W. SUTHERLAND²

1. School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA; 2. Environmental and Ecological Engineering, Purdue University, West Lafayette, IN 47907, USA

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Abstract

Manufacturing process planning serves as a pivotal link between design and manufacturing. Process planning decisions play a critical role in determining the cost and environmental impacts associated with manufacturing. Past efforts to address environmental issues during process planning are briefly reviewed and potential approaches that can achieve reduced environmental impacts are then discussed. A proposed method is presented for environmentally conscious process planning. The method begins with an existing process plan, and then identifies impactful process steps, and associated design features, in terms of manufacturing cost and environmental impact. Alternative processes that can achieve these features are then considered to generate alternative process plans. These alternatives are then evaluated in terms of economic and environmental performance. The results of these evaluations are then used to generate a set of process plans that are non-dominated with respect to manufacturing cost and environmental impact objectives to produce a Pareto frontier. The proposed method is demonstrated using the manufacturing of a prosthetic hip shell as a case study.

Keywords process planning life cycle assessment (LCA) sustainable manufacturing prosthetic hip shell

Corresponding Author(s): ZHAO Fu,Email:fzhao@purdue.edu

Issue Date: 05 September 2012

Cite this article:

Fu ZHAO,Vance R. MURRAY,Karthik RAMANI, et al. Toward the development of process plans with reduced environmental impacts[J]. Front Mech Eng, 0, (): 231-246.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-012-0334-3
https://academic.hep.com.cn/fme/EN/Y0/V/I/231

Fig.1 Conceptual model of a prosthetic hip shell

Fig.2 Conceptual model of a prosthetic hip assembly

Tab.1 The process plan for the prosthetic hip shell

Tab.2 Variables for the cost of each process in the process plan for the hip shell (all variables have units of $/part)

Tab.3 Variables for the calculation of the energy related carbon footprint for each process in the process plan (all energy terms have units of kW·h/part, is in kg COe/kW·h, and is in kg COe/part)

Tab.4 Variables for the calculation of the mass related carbon footprint (all mass terms have units of kg/part, is in kg COe/kg, and is in kg COe/part)

Tab.5 The SimaPro/Ecoinvent database entry and related notes for each α

Tab.6 Variables for the calculation of the total carbon footprint of each process (all variables have units of kg COe/part)

Fig.3 Percent of total manufacturing cost and carbon footprint by process

Fig.4 Impactful Feature 2, a shell with a threaded hole

Fig.5 Impactful Feature 4, a porous metal coating

Fig.6 FPN for the impactful feature of a hip shell with a threaded hole

Tab.7 Values for the manufacturing cost ($/part) of each process in the FPN for the hip shell

Tab.8 Values for the total carbon footprint (kgCOe/part) of each process in the FPN for the hip shell

Fig.7 The cost and the carbon footprint of the manufacture of the prosthetic hip shell for the original process plan and the three alternate process plans

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