An integrated approach for the benchmarking of production facilities’ environmental performance: data envelopment analysis and life cycle assessment

Environmental impacts have become an important consideration in the manufacturing industry due to increasing public pressure for environment protection and the requirements of recently launched legislations. Data envelopment analysis (DEA) is a widely adopted methodological approach for the benchmarking of the relative efficiency of different production units. Changes in production efficiency may affect environmental impacts. DEA can be used for identifying the most efficient production facility and hence, the environmental impacts generated from the different production lines can then be benchmarked. Life cycle assessment (LCA) is carried out to quantify the full environmental impacts of a product from ‘cradle to grave’. The integration of LCA with DEA, efficiency and environmental impact of different production processes for a certain family of products can be evaluated and benchmarked. The proposed two-stage approach can help to reduce the aggregate environmental impacts of the manufacturing phase and is used to benchmark the environmental performance of several production lines in a manufacturing company.     

Design for environment as a tool for the development of a sustainable supply chain

In this work, design for environment (DfE) methodologies have been used as a tool for the development of a more sustainable supply chain. In particular by combining life‐cycle assessment (LCA) techniques and by using the quality function deployment (QFD) multi‐criteria matrices, an ‘environmental compromise’ can be reached. In this work, the QFD matrices have been developed in a new way using an iterative process that involves the whole supply chain starting from the product life‐cycle, taking into consideration the machines that make the product and their components. This methodology is compatible with the requirements of the various stakeholders, suppliers, manufacturers and clients, involved in the supply chain. To assess the validity of the proposed approach a specific supply chain was studied concerning packaging systems for liquid food substances (beverage cartons). Firstly all the stages which are most critical from the environmental point of view in the supply chain of packaging systems were identified and assessed. The starting point for the analysis of environmental aspects and impacts which characterise the supply chain was LCA, which proved to be useful for the identification and the environmental assessment of the various stages in a packaging system. Through the use of ‘iterative QFD’ it is possible to arrive at a definition of the engineering characteristics of all the machinery which is involved in the supply chain. In particular in this work the authors have tried to identify the critical points in the design of those machines which either make the beverage cartons or are involved in the filling process.     

Integration of DFE and DFMA for the sustainable development of an automotive component

The recent developments in manufacturing organizations recognize sustainability as an important value addition for survival in the competitive scenario. The design engineers are in search of approaches for creating environmental conscious products. The purpose of this paper is to report a research carried out for ensuring sustainable product design by the integration of Design for Environment (DFE) and Design for Manufacture and Assembly (DFMA) methodologies. In this context, this paper reports a case study carried out in an automotive component. The candidate product is the charge alternator pulley. The existing pulley has been created using Computer Aided Design. Then sustainability analysis was conducted on the existing component for determining environmental impact. This is followed by the engineering analysis of the component using ANSYS. Then conceptual design changes were developed in the proposed product using DFMA concept. Then the environmental impact has been evaluated in terms of carbon footprint, energy consumption and air/water impacts on proposed product. It has been found that the optimized pulley design possesses minimal environmental impact. The result of the case study indicated that the integration of DFE and DFMA concept could initiate new developments in sustainable designs with minimal impact to the environment and it also reduces the product cost.     

Carbon footprint of recycled biogenic products: the challenge of modelling CO2 removal credits

Current carbon footprinting (CF) and life cycle assessment (LCA) methods do not treat recycled biogenic carbon adequately, because the calculation rules for recycled products and biogenic carbon stored in products are defined independently from each other. Therefore, an improved and consistent calculation rule for the CF of product systems containing both recycling processes and carbon stored in products is proposed. The methodological approach consists of the application of the same allocation principles for both greenhouse gas (GHG) releases and GHG removals: (1) explicit accounting of inputs (GHG removals) and outputs (GHG releases) of biogenic carbon flows instead of assuming carbon neutrality per se; (2) consistent application of allocation rules for environmental benefits and environmental burdens. It is shown that the different modelling approaches (e.g. polluter pays, conservative or partitioning) lead to different results in LCA and CF calculations, e.g. the GHG emissions of first life cycle of the product system calculated here range between ? 1.6 units in the polluter pays approach and 4 units in the conservative approach. It is shown that the currently common modelling is an average approach for primary biogenic material, a worst-case approach for recycled biogenic material and a best-case approach for disposed biogenic material. This paper proposes to improve the currently developed standards for CF by adding a requirement to the goal and scope definition phase that ensures the consistent and transparent documentation, how biogenic carbon removal credits are allocated between life cycles.     

Application of QFD for enabling environmentally conscious design in an Indian rotary switch manufacturing organisation

Many businesses are recognising that environmental consciousness is an important concept for survival in today's highly competitive market. This paper presents a project in which quality function deployment (QFD) for environment (QFDE) has been applied to an Indian rotary switch manufacturing organisation to enable environmentally conscious design at the early stage of product development. QFDE consists of four phases. QFDE phases I and II are concerned with the identification of the rotary switch parts that are important in enhancing environmental consciousness. QFDE phases III and IV are concerned with the evaluation of the effect of design improvement on environmental quality requirements. The results obtained from the case study revealed that QFDE could be applied in the early stage of rotary switch product development as it identified the vital components from an environmental perspective and enabled the options for design improvement to be effectively evaluated. The managerial implications of the case study have also been presented.     

Environmental impact assessment of a ceramic tile supply chain – a case study

The beginning of the twenty-first century saw a surge in the growth of construction industry, particularly the housing sector in India. This led to the growing demand of ceramic tiles. This growth is responsible for large-scale consumption of natural resources and generation of solid waste. The objective of this paper is to assess the environmental impact of vitrified ceramic floor tile supply chain by performing life cycle assessment (LCA) following international standards of ISO 14040 series guidelines. The impact has been determined by conducting a LCA using Umberto NXT software (eco-invent 3.0 database) with ReCiPe endpoint and midpoint methods. It has been found that the manufacturing stage of supply chain is generating highest impact on environment in all the categories. Impact analysis of different input resources/material shows that red oxide used in glaze preparation, electricity in manufacturing, packaging material, distribution by trucks, installation of tiles using concrete and disposal of packaging material are responsible for most of the environmental impact. This study will offer the essential quantitative assessment to recognise the phases and materials which are highly responsible for the degradation of environment so that appropriate interventions by the different stakeholders can be planed.     

Treating design uncertainty in the application of Eco-indicator 99 with Monte Carlo simulation and fuzzy intervals

In incremental eco-design improvements, design engineers attempt to modify an existing product via some eco-design measures to reduce the product’s environmental impacts (e.g. reduction of material usage and energy consumption). In this process, several design concepts can be proposed, and concept selection is required to allocate resources sensibly to promising design concepts only. In this context, the research purpose is to estimate the environmental impacts of each concept given the uncertainty of design information. In the proposed methodology, the fuzzy interval arithmetic is used to specify and propagate imprecise design information. Then, the centroid concept is applied to model different views of imprecision (i.e. pessimistic, balanced and optimistic) associated with fuzzy impact assessment. Accordingly, a decision scheme is developed to support concept selection and suggest the potential areas for further eco-design improvements. A coffee maker is used as an example to demonstrate the proposed methodology. Also, the Monte Carlo Simulation is applied for the same example to compare the numerical outcomes by the fuzzy interval approach.     

LCCA and environmental LCA for highway pavement selection in Colorado

The roadway network in the USA earned a grade of D representing poor condition in the latest report card from the American Society of Civil Engineers. To maintain economic and environmental sustainability during the roadway network development and rehabilitation, it is critical to apply sustainable materials and intelligent design. A good estimation on project-level life-cycle costs and environmental impacts is one of the important steps in the highway investment decision-making process. This article examines the current life-cycle cost analysis (LCCA) practice employed by the Colorado Department of Transportation (CDOT) in their pavement investment decision-making process, and proposes a regional environmental life-cycle assessment (LCA) model to evaluate the greenhouse gas (GHG) emissions associated with Colorado highway pavements. Both LCCA and LCA are performed for a highway reconstruction project with Portland cement concrete pavement (PCCP) and hot-mixed asphalt (HMA) alternatives. The LCCA is 7.4% in favour of HMA. Since the difference is less than 10%, it indicates equivalent designs. However, in the LCA, the GHG emission from PCCP is 26% less than the HMA over the 40-year analysis period. The vehicle fuel consumption will increase due to the deterioration of pavements. But the increased user cost is not included in the current LCCA employed by CDOT as well as user cost due to crashes and nonuser costs. The LCA can be an optional criterion for the selection of the preliminary pavement type.     

CAD and DFM: enablers of sustainable product design

Sustainability has been regarded as an important concept for survival in the contemporary scenario. Modern design engineers are in need of approaches for creating sustainable products. In this context, this paper reports a case study carried out in an Indian modular switches manufacturing organisation. The existing handle of the switch has been modelled using computer-aided design (CAD). Then, the sustainability analysis has been carried out for determining the environmental impact. This is followed by the redesign of the handle using design for manufacturability (DFM) principles. The sustainability has been measured in terms of carbon footprint, energy consumption and air–water impacts. It has been found that the redesigned handle possesses minimal environmental impact. It could be inferred from the results of the case study that CAD and DFM could lead to the development of sustainable product design with minimal impact on the environment.     

A sustainable method for optimizing product design with trade-off between life cycle cost and environmental impact

In today’s competitive market, corporations have learned that taking sustainability issues into account can significantly improve their public image. Modern producers therefore must simultaneously reduce the environmental impact of their products and make economic gains. Therefore, making trade-offs between economic and environmental issues is required to ensure a company’s continuity. In doing so, companies have attached a great deal of importance to the new product design phase. However, optimization at the design stage becomes very complex for a product with a large number of parts, which can have several design alternatives with similar forms and functionality, but different costs and environmental impacts. In the automobile, shipbuilding and aircraft industries, if the conventional complete enumeration method is applied, the time required for selecting the optimal combination of design alternatives with respect to life cycle cost and environmental impact may exceed a human’s natural life span. To overcome this limitation, this paper introduces an optimization method for use as a design aid tool that enables a designer to assess the life cycle cost and environmental impact of his/her design very early in the product development process. To support the developed method, an illustration is provided using a case study on a locally manufactured automobile.     

The environmental impact assessment of wheat and barley production by using life cycle assessment (LCA) methodology

This study was conducted to assess the impact of cereals (wheat and barley) production on environment under rainfed and irrigated farming systems in northeast of Iran. Life cycle assessment (LCA) was used as a methodology to assess all environmental impacts of cereal grain production through accounting and appraising the resource consumption and emissions. The functional unit considered in this study was one ton grain yield production under different rates of nitrogen application. All associated impacts of different range of N fertilizer application were evaluated on the basis of the functional unit. In this study, three major impact categories considered were climate change, acidification, and eutrophication. In order to prepare final evaluation of all impacts on environment, the EcoX was determined. Results represented that, under low consumption of N fertilizer, the environmental impacts of both rainfed farming systems of wheat and barley was less than irrigated farming systems. Considering grain yield as response factor to different fertilizer application level, irrigated farming systems of wheat and barley with the range of 160–180 and?>220 (Kg?N?ha^?1) showed the maximum impact on environment. It seems LCA is an appropriate method to quantify the impact of utilized agricultural inputs and different managements on environment.     

Life cycle assessment part 1: framework, goal and scope definition, inventory analysis, and applications

Sustainable development requires methods and tools to measure and compare the environmental impacts of human activities for the provision of goods and services (both of which are summarized under the term "products"). Environmental impacts include those from emissions into the environment and through the consumption of resources, as well as other interventions (e.g., land use) associated with providing products that occur when extracting resources, producing materials, manufacturing the products, during consumption/use, and at the products' end-of-life (collection/sorting, reuse, recycling, waste disposal). These emissions and consumptions contribute to a wide range of impacts, such as climate change, stratospheric ozone depletion, tropospheric ozone (smog) creation, eutrophication, acidification, toxicological stress on human health and ecosystems, the depletion of resources, water use, land use, and noise-among others. A clear need, therefore, exists to be proactive and to provide complimentary insights, apart from current regulatory practices, to help reduce such impacts. Practitioners and researchers from many domains come together in life cycle assessment (LCA) to calculate indicators of the aforementioned potential environmental impacts that are linked to products-supporting the identification of opportunities for pollution prevention and reductions in resource consumption while taking the entire product life cycle into consideration. This paper, part 1 in a series of two, introduces the LCA framework and procedure, outlines how to define and model a product's life cycle, and provides an overview of available methods and tools for tabulating and compiling associated emissions and resource consumption data in a life cycle inventory (LCI). It also discusses the application of LCA in industry and policy making. The second paper, by Pennington et al. (Environ. Int. 2003, in press), highlights the key features, summarises available approaches, and outlines the key challenges of assessing the aforementioned inventory data in terms of contributions to environmental impacts (life cycle impact assessment, LCIA).     

Environmental assessment of a Palette Modular Device for gold recovery from PVD

The novel “Palette Modular Device” (PMD) technology, addressing the recovery of wastes from Physical Vapour Deposition (PVD) maintenance, is evaluated according to a Life Cycle Assessent (LCA) approach. The PMD recovery technology was recently developed with the aim of an easier and more sustainable separation of the film layers used in PVD, with a particular emphasis on multi-material film productions, frequently adopted in the electronic industry. The PMD is briefly presented in the paper, along with three implementations for industrial purposes. Each implementation adopts a different light solvent for the metal recovery like acetone and formic acid. The usage of light solvents is a peculiar feature enabled by the system considered, as an alternative to traditional approaches. The LCA starts with the objectives and prosecutes with inventories of all material and energy flows for each different scenario considered. Additionally, a global impact assessment is provided in a specific section, in order to enable a quantitative comparison of the potential effects on the environment in every scenario. The results of this study allow the industrial designer to perform an overall environmental evaluation of the three strategies proposed and to compare the performances of the novel technology. The research, furthermore, highlights some critical points in the adoption of the PMD and suggests how to improve the implementation of this recovery process.     

Selection of green product design scheme based on multi-attribute decision-making method

The function, cost and environmental performance are the primary decision-making factors for scheme selection in green design. For the comprehensive and accurate decision-making in selecting green product design scheme, a quantitative analysis method of multi-attribute decision-making (MADM) is presented. With analysing the multi-attribute of scheme selection, the MADM model is established, which takes environmental impact of materials, disassembly performance, recycling performance, energy efficiency, noise, pollutants to environmental and functional values. Fuzzy technique for order performance by similarity to ideal solution method is applied to solve this model for the feasible solutions. Finally, a case study is given to validate the application of this methodology as a useful design guideline for scheme selection in green design.     

Construction of an optimum system design method considering product lifecycle

This paper proposes an optimum system design method that especially considers product lifecycles and aims to help designers make effective decisions during the product design phase. By considering and estimating all lifecycle factors of cost and environmental impact in addition to the product performance, this method facilitates development of optimum design solutions that incorporate requirements pertaining to the product's entire lifecycle. Furthermore, quantitative estimation of lifecycle factors enables the numerical expression of optimum solutions, rather than depending primarily on experiment and designer intuition. To demonstrate the effectiveness of the proposed method, this paper develops an optimum system design method for a milling machine as an example of a machine product designed for long term use. The lifecycle cost and the lifecycle environmental impact are generally expressed as the summation of each value during manufacturing phase, usage phase, disposal phase and recycling phase. In this example model, Eco-indicator 99 is used to evaluate environmental impact. In the proposed lifecycle design optimisation method, the relationships among the product performance, the lifecycle cost and the lifecycle environmental impact are evaluated as a multi-objective optimisation problem. Analysis of the obtained Pareto optimum solution sets subsequently enables designers to pursue breakthrough product design solutions.     

Construction of evolving models for the environmental evaluation of innovative sub-systems based on a hierarchical agglomerative clustering

This paper deals with simplifying the environmental evaluation of an innovative sub-system related to the future complex system that will include it, by using evolving generic models built on a limited number of characteristics. For a complex system range, the evolving approach of the environmental modelling aims to generate a learning dynamics, to avoid the paralysing complexity induced in design by the valuation of many components according to many impact categories. Applied to the automotive sector, dendrograms are made with results of life cycle assessments (LCA) of 17 vehicles for 4 environmental indicators and on 3 life cycle steps. In an iterative process, a limit condition threshold on the resulting relative errors aims to cluster the vehicles. First, several calculation methods of dendrograms are tested. Second, the influence of the limit condition on the models is observed. Lastly, by simulating the vehicle population increase, the modelling capacity to evolve is tested. Five vehicle characteristics are sufficient to identify a model to be equivalent to the future vehicle. While the number of clusters is increased to simplify their identification with the system characteristics, the relative error variability increases too. The generic models are stable when adding LCA's results.     

Life cycle assessments of municipal solid waste management systems: A comparative analysis of selected peer-reviewed literature

Life cycle assessment (LCA) is a popular tool used to evaluate the environmental performance of municipal solid waste (MSW) management systems. Although reviews of LCAs of MSW have been undertaken to assess the validity of the ‘waste hierarchy,’ a recent review of the goal, scope and results of LCAs of mixed-material MSW management systems has yet to be performed. This paper is a comparative analysis of 20 process-based LCAs of MSW published between 2002 and 2008 in a total of 11 English-language peer-reviewed journals. It quantifies the methodological transparency of the studies and the frequency of use of particular system boundaries, types of data sources, environmental impact categories, impact weightings, economic valuations, sensitivity analyses, and LCA computer models. Net energy use (NEU), global warming potential (GWP), and acidification potential (AP) values for various types of MSW management systems are also compared using statistical indicators.The reviewed LCAs differ substantially in their system boundaries. Half or more of the LCAs either do not mention or are unclear in whether or not life cycle emissions from energy inputs or capital equipment are included in the calculation of results. Only four impact categories are common to more than half of the reviewed LCAs. The human and ecological toxicity impact categories are much less common than global warming potential, acidification, and eutrophication.A financial life cycle costing is present in eight of the reviewed LCAs, while an economic valuation of the environmental impacts is observed in five. Explicit sensitivity analyses are present in 4/20 of the studies, although many more LCAs evaluate the effects of varying model parameters by increasing the number of waste management scenarios. There is no consensus on whether or not to use the marginal or average source of electricity in calculating environmental impacts. Eight out of the 20 do not mention this source while the remaining LCAs are evenly split between the marginal and average electricity source. One quarter of the reviewed LCAs supply weighted results for the overall environmental performance of MSW management scenarios. All but one of these concurred with the ‘hierarchy of waste’ that the environmental performance of landfilling is lower than that of all the other treatment methods, and that thermal treatments are inferior to recycling.The comparative analyses of the NEU, GWP and AP results are based on 37, 45, and 42 MSW management scenarios, respectively. As measures of statistical dispersion, the interquartile ranges of the NEU, GWP and AP values are lowest for the landfilling (AP, NEU) and thermal treatment (GWP) scenarios. The results of the statistical analysis of the NEU, AP and GWP values appear to indicate that thermal treatment scenarios have a better environmental performance than landfilling, while the results for mixed treatment scenarios are less obvious. A comparison of the relative environmental performances of MSW treatment scenario types within each study did not provide a clear confirmation or repudiation of the waste hierarchy.This paper concludes that many recently published LCAs do not ensure that the methodological assumptions are made clear to the reader. Lack of transparency makes the results difficult to interpret, and hampers meaningful comparisons between the LCA results. A convergence in the adoption of particular assumptions that are more representative of MSW management systems would facilitate the comparison of the results.     

Sustainable product design using CAD: a case study in an Indian rotary switches manufacturing organisation

Sustainability is gaining importance in contemporary manufacturing organisations. Modern design engineers need approaches for creating environmentally friendly products. In this context, this paper reports a case study carried out in an Indian rotary switches manufacturing organisation. A component of the rotary switch has been modelled using computer-aided design. Then, the sustainability analysis has been carried out for determining the environmental impact. The environmental impact has been measured in terms of carbon footprint, energy consumption and air/water impacts. The handle design has been modified to minimise the environmental impact. The results of this case study indicate that appropriate modifications in design could lead to the development of sustainable design with minimal environmental impact.     

Life cycle assessment of second generation (2G) and third generation (3G) mobile phone networks

The environmental performance of presently operated GSM and UMTS networks was analysed concentrating on the environmental effects of the End-of-Life (EOL) phase using the Life Cycle Assessment (LCA) method. The study was performed based on comprehensive life cycle inventory and life cycle modelling. The environmental effects were quantified using the IMPACT2002+ method. Based on technological forecasts, the environmental effects of forthcoming mobile telephone networks were approximated. The results indicate that a parallel operation of GSM and UMTS networks is environmentally detrimental and the transition phase should be kept as short as possible. The use phase (i.e. the operation) of the radio network components account for a large fraction of the total environmental impact. In particular, there is a need to lower the energy consumption of those network components. Seen in relation to each other, UMTS networks provide an environmentally more efficient mobile communication technology than GSM networks. In assessing the EOL phase, recycling the electronic scrap of mobile phone networks was shown to have clear environmental benefits. Under the present conditions, material recycling could help lower the environmental impact of the production phase by up to 50%.     

Environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method

This paper presents a methodology for environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method. An ‘environmental impact assessment index’ is proposed that evaluates and ranks the manufacturing processes for producing a given engineering product or component. The index is obtained from an ‘environmental impact assessment factors function’ considering environmental impact assessment factors and their relative importance for the considered application. An example is included to illustrate the approach.