Handbook of Environmentally Conscious Manufacturing

Preface
Contents
About the Editor
1: Sustainable Manufacturing: Strategic Issues in Green Manufacturing
1.1 Introduction
1.2 Sustainable Development
1.3 Strategies for Sustainable Manufacturing
1.3.1 Inverse Manufacturing
1.3.2 Recycling
1.3.3 Remanufacturing
1.3.4 Reverse Logistics
1.3.5 Eco-Labelling
1.3.5.1 ISO 14000
1.3.6 Life Cycle Assessment
1.3.7 Design for the Environment
1.4 Case Studies
1.4.1 Kodak Single-Use Camera
1.4.2 Xerox
1.5 Conclusion
References
2: Concepts and Methodologies to Help Promote Industrial Ecology
2.1 Introduction
2.2 Natural Ecosystems as a Paradigm for Industries
2.3 Some Industrial Ecology Tools
2.3.1 Cleaner Production (CP)
2.3.2 Dematerialization
2.3.3 Design for Disassembly (DfD)
2.3.4 Industrial Metabolism (IM)
2.3.5 Life Cycle Assessment (LCA)
2.3.6 Design for Environment (DfE)
2.3.7 Product Life Extension and the Service Economy
2.4 Case Studies in Industrial Ecology
2.4.1 Kalundborg, Denmark
2.4.2 Styria, Austria
2.4.3 The Burnside Eco-Industrial Park, Canada
2.4.4 The Xerox Asset Recycle Management (ARM) Program
2.5 How Is Industrial Ecology Viewed by Industry
2.5.1 Awareness of Industrial Ecology and its Components
2.5.2 What Could Encourage the Practice of IE?
2.6 Conclusions
References
3: Systems Design and Innovations in Circular Economy: The Industry and Business Perspective
3.1 Introduction
3.2 Background
3.2.1 Circular Economy Design
3.2.2 New Business Models
3.2.3 Reverse Cycles
3.2.4 Enablers and Favorable System Conditions
3.3 Designing in a Circular Economy
3.4 From Waste to Wealth
3.5 Design Strategies for Circular Economy
3.5.1 Inverse Manufacturing
3.5.2 Recycling
3.5.3 Remanufacturing
3.5.4 Reverse Logistics
3.5.5 Life Cycle Assessment
3.5.6 Design for the Environment
3.5.7 Eco-Design
3.5.8 Extended Producer Responsibility (EPR)
3.5.9 Eco-Labeling
3.6 Profitability and Competitiveness
3.7 Drive to Circular Economy
3.8 Case Study on Plastics
3.9 Conclusion
References
4: Communicating Product Recovery Activities: Processes, Objectives, and Performance Measures
4.1 Introduction
4.2 Material Recovery Processes
4.3 Value Recovery Processes
4.3.1 Recovery of Components to Reuse in a Different Product
4.3.2 Recovery of some Components within the Product
4.3.3 Thorough Recovery of the Final Product
4.4 Operating Processes
4.5 Marketing Processes
4.6 Design Processes
4.6.1 Measures of Design Efficiency for Recovery Processes
4.7 Conclusion
References
5: Green Design and Quality Initiatives
5.1 Introduction
5.2 The Link Between Quality Management, Environmental Management, and Green Design
5.2.1 Life Cycle Assessment
5.2.2 Environmental Performance Measurement Tools
5.2.2.1 Environmental Management Application: Analysis of the Emissions Associated with Alternative Automobile Car Seat Designs
5.2.3 Environmental Managerial Cost Accounting and Application to a Plastic-Molding Facility
5.2.3.1 Environmental Management Application: Environmental Cost Accounting at a Plastic-Molding Facility
5.2.3.2 Additional Cost Impact of Scrap Production on the Facility
5.2.4 Design for the Environment Strategies: Design for Recycling, Remanufacturing, etc.
5.2.4.1 Environmental Management Application: Example of Reuse/Remanufacture Issues for an Electromechanical Parts Manufacturer
5.3 Summary
References
6: Corporate and Social Responsibility
6.1 Introduction
6.2 Environmentally Conscious Manufacturing and Product Recovery
6.3 Corporate Social and Environmental Responsibility
6.4 A Conceptual Framework for Shared Responsibility
6.5 Conclusion
References
7: Accounting for an Environmentally Conscious Setting
7.1 Accounting in Eco-Management: A Framework
7.2 Environmental Accounting Systems
7.2.1 A Brief Introduction to Financial and Management Accounting
7.2.1.1 Financial Accounting
7.2.1.2 Management Accounting
7.2.2 Eco-Sensitive Financial and Management Accounting
7.2.2.1 Eco-Sensitive Financial Accounting
Treatment of Environmental Expenditures as Assets or as Expenses
Treatment of Environmental Liabilities
Tradable Emission Allowances
Management Discussion and Analysis
7.2.2.2 Eco-Sensitive Management Accounting
Eco-Sensitive Cost Accounting
Eco-Sensitive Cost Management
7.2.3 Ecological Accounting and Auditing
7.2.3.1 Ecological Improvement Concepts and Evaluation
7.2.3.2 Internal Ecological Accounting
7.2.3.3 External Ecological Accounting
7.2.3.4 Ecological Auditing
7.3 Accounting and Environmental Management Systems
7.3.1 The Balanced Scorecard and Environmental Management
7.3.2 Strategic Cost Management and Environmental Management
7.3.2.1 Environmental Accounting Research and Concluding Remarks
Appendix
Costs Relating to Protection of the Environment
Footnote Disclosure
References
8: The Development of Eco-Labelling Schemes: An Economic Perspective
8.1 Introduction
8.2 A Review of Eco-Labelling Schemes
8.2.1 Type 1 Environmental Labels
8.2.2 Type 2 Self-Declaration of Environmental Claims
8.2.3 Type 3 Quantified Product Information Labels
8.2.3.1 Germany’s Blue Angel
8.2.3.2 The European Union’s Ecolabel
8.2.4 The Nordic Council’s White Swan Scheme
8.2.5 Canada’s Environmental Choice Program
8.2.6 Environmental Labels in the USA
8.2.7 Japan’s Eco-Mark
8.2.7.1 Summary
8.3 South Korea’s Environmental Mark Scheme
8.3.1 Transparency in the Operation of the Scheme
8.3.2 The Selection Method for Product Categories
8.3.3 The Development of Assessment Criteria
8.3.4 Consumers’ and Providers’ Current Response
8.4 Green Consumerism
8.5 Conclusions
References
9: Petroleum Production Activities and Depletion of Biodiversity: A Case of Oil Spillage in the Niger Delta
9.1 Introduction
9.2 The Niger Delta Area of Nigeria
9.3 Biodiversity of the Niger Delta
9.4 The Faunal and Floral Compositions of the Niger Delta
9.5 Biodiversity and Oil Exploration and Production
9.6 Impact of Petroleum Production Activities on Biodiversity of the Niger Delta
9.7 Causes of Oil Spillage in the Niger Delta
9.7.1 Socio-Technical Factors
9.7.2 Socioeconomic Factors
9.7.3 Sociopolitical Factors
9.8 Regulatory Frameworks to the Conservation of Biodiversity in the Niger Delta
9.8.1 Oil Pollution Act (OPA) of 1990
9.8.2 Federal Environmental Protection Agency (FEPA)
9.8.3 National Oil Spill Detection and Response Agency (NOSDRA) Act 2006 No. 15 (as Amended)
9.8.4 The Environmental Impact Assessment (EIA) Act (Decree No. 86 of 1992)
9.8.5 Nongovernmental Initiatives
9.8.6 The Challenges
9.9 The Proposed Framework
9.9.1 Environmental Decision Support Systems (EDSSs)
9.9.2 Task Analysis of Environmental Decision-Making
9.9.2.1 The Underlying Mathematical Model
9.9.3 Risk Management Planning
9.10 Conclusions
References
10: A Systematic Framework for Environmentally Conscious Design: Using Fuzzy House of Quality and Analytical Hierarchical Process Techniques
10.1 Introduction
10.2 Literature Review
10.2.1 Environmentally Conscious Design (Green Design)
10.2.2 Design for Disassembly
10.2.3 Life Cycle Design
10.3 Framework
10.3.1 Modified House of Quality
10.3.1.1 Configuration of Modified HOQ
10.3.1.2 Environmentally Conscious Requirements
10.3.1.3 Design Alternatives
10.3.1.4 Importance Ratings
Hierarchic Structure
Pairwise Comparison Matrices
Consistency Check
Synthesis
10.3.2 Systematic Analysis
10.3.2.1 Life Cycle Design Approach
10.3.2.2 The Role of Modified HOQ
Analysis of Raw Material Consumption
Analysis of Manufacture and Assembly
Analysis of Use and Distribution
Analysis of End-of-Life Management
10.3.2.3 The Overall Assessment
The Overall Scores and Defuzzification
10.4 Conclusion and Future Work
References
11: Environmental Attributes of Manufacturing Processes
11.1 Introduction
11.2 Environmental Process Characterization
11.2.1 From Waste Management to Pollution Prevention
11.3 Manufacturing Process Inventory
11.3.1 Casting Operations
11.3.2 Plastics Processing Operations
11.3.2.1 Chemicals
11.3.2.2 Wastewater
11.3.2.3 Pellet Release
11.3.2.4 Fugitive Emissions
11.3.3 Machining Operations
11.3.3.1 Traditional Machining Operations
11.3.3.2 Nontraditional Machining Operations
11.3.4 Forming Operations
11.3.5 Surface Finishing and Treatment Operations
11.3.6 Joining Operations
11.4 Environmentally Responsible Manufacturing
11.4.1 Alternative Process Plan
11.4.2 Alternative Process Sequence
11.4.3 Process Change
11.4.4 By-Product Utilization
11.4.5 Waste Handling
11.4.6 Education/Training
11.5 Summary and Conclusions
References
12: Advances in Environmental Decision Support: Tools for Informed Environmental Management
12.1 Introduction
12.1.1 What Are Environmental Decision Support Systems?
12.1.2 The Need for Environmental Decision Support Systems
12.1.3 Organization of this Chapter
12.2 Foundations
12.2.1 The Nature of Environmental Management Decisions
12.2.1.1 Characteristics of the Problem
12.2.1.2 Implications for Environmental Decision Support
12.2.2 Task Analysis of Environmental Decision-Making
12.2.3 Management of Uncertainty
12.2.3.1 Sources of Uncertainty
12.2.3.2 Stochastic Analysis
12.3 Contributing Disciplines
12.3.1 Environmental Science
12.3.2 Information Systems Engineering
12.3.2.1 Geographic Information Systems
12.3.2.2 Computer Data Representation Via Graphics and Sound
12.3.2.3 Supercomputing and Networking
12.3.2.4 Expert Systems
12.3.3 Decision Science
12.3.3.1 Linear Programming
12.3.3.2 Decision Trees
12.4 Applications of EDSS in Industry
12.4.1 Integrated Factory Decision Support
12.4.2 Risk Management Planning
12.4.3 Design for Environment
12.5 Technology-Driven Advances in Environmental Decision Support
12.5.1 Service-Oriented Architectures and Internet-Enabled Distribution
12.5.2 Social Media and Mobile Technology
12.6 Conclusion
References
13: Decision Models for Reverse Production System Design
13.1 The Evolution of Production Systems
13.2 Features of Reverse Production System Problems
13.3 A Mathematical Model for Strategic Infrastructure Determination
13.4 Industrial Case Studies
13.4.1 Case Study 1: Network Router Recycling
13.4.2 Case Study 2: Carpet Recycling
13.5 Summary and Conclusions
References
14: Environmentally Sound Supply Chain Management: Implementation in the Computer Industry
14.1 Introduction
14.1.1 Industrial Ecology and Environmental Supply Chain Management
14.1.2 The Computer Industry Supply Chain
14.1.3 Our Study
14.2 Incentives for Managing the Environmental Performance of the Supply Chain
14.2.1 Government Regulations
14.2.2 Standards Setting and Developing Market Pressure
14.3 Organizational Responses to Environmental Pressures
14.3.1 The Role of Relational Contracting
14.3.2 Company-Specific Programs
14.3.2.1 Contract Clauses and Metrics
14.3.2.2 Supplier Qualification and Auditing Programs
14.3.2.3 Advanced Programs
Product Improvement
Process Improvement
14.3.3 The Importance of Industry Standards
14.4 Conclusion
Appendix: Interviewed Firms
References
15: Climate Change: Opportunities and Risks for the Manufacturing Sector
15.1 Introduction
15.2 Climate Change Projections and Uncertainties
15.2.1 Assessment of Climate Change Impacts
15.2.2 Net Ecosystem Production (NEP)
15.2.2.1 Ways of Measuring NEP: 1.Eddy Covariance
15.3 Climate Change Mitigation and Control
15.3.1 Agricultural Practices
15.3.2 Genetically Modified Crops
15.4 Global Trends in Renewable Energy
15.5 Risks and Challenges of Fossil Fuels, Biomass, and Nuclear Energy and Larger Dams
15.5.1 Biomass
15.5.2 Coal
15.5.3 Petroleum
15.5.4 Natural Gas
15.5.5 Nuclear Power
15.5.6 Large Hydroelectric Dams
15.6 Global Warming and Climate Change
15.7 Incentives and Opportunities in Investing in Renewable Energy
15.7.1 Renewable Energy Is Inexhaustible
15.7.2 Renewable Energy and Green Economy
15.7.3 Green Jobs
15.7.4 Factors that Affect the Market
15.7.5 Policy Responses to Climate Change
15.8 Conclusion
References
16: Life Cycle Assessment
16.1 Introduction
16.2 Definition
16.3 Three Components of Life Cycle Assessment
16.3.1 Life Cycle Inventory Analysis
16.3.1.1 Problems with Life Cycle Inventory Analysis
16.3.2 Life Cycle Impact Assessment
16.3.2.1 Measuring Environmental Impacts
Classification and Characterization
Analysis of the Use of AHP
16.3.3 Life Cycle Improvement Analysis
16.3.3.1 Design for Environment
16.4 The Use of Life Cycle Assessment
16.5 Strategic Planning for Life Cycle Assessment
16.5.1 Strategic Framework for Life Cycle Assessment
16.5.1.1 Preplanning
16.5.1.2 Evaluation or Impact Assessment
16.5.1.3 Action Implementation/Improvement Analysis
16.6 Life Cycle Cost Assessment
16.7 A Case Study on Life Cycle Assessment
16.8 Conclusion
References
17: Multi-Pathway and Cumulative Risk Assessment: Selecting Optimal Pollution Prevention Strategies
17.1 Introduction
17.2 A Decision Problem
17.3 The Case Study Methodology
17.4 Results
17.5 Discussion
References
18: Reclamation and Recycling of Municipal Waste: A Sludge Dewatering Process
18.1 Introduction
18.1.1 Reclamation
18.1.2 Recycling
18.2 Environmental Protection
18.2.1 Design for Environment (DFE)
18.2.2 Government Regulations
18.2.3 Legal Liabilities
18.2.4 Competition
18.2.5 Product Stewardship
18.3 Recycling Benefits
18.4 Sludge Processing and Disposal
18.5 Dewatering and Recycling of Sludge
18.5.1 Case Study of NYC’s Dewatering Facility [Source: NYCDEP]
18.5.2 Description of the Operation
18.5.2.1 Undewatered Sludge Handling
Centrifuges
Polymer Systems
18.5.2.2 Dewatered Sludge Conveying System
Odor Control Systems
18.6 Conclusion
References
19: Environmental Marketing
19.1 Introduction
19.2 What Is Environmental Marketing?
19.3 Who Is Involved in Environmental Marketing?
19.4 How to Succeed in Environmental Marketing?
19.5 The Future of Environmental Marketing
References
20: Challenging the Future: Ways Towards Sustainable Green Electronics
20.1 Taking up the Challenge: Green Electronics
20.1.1 Environmental Assessment
20.1.2 Environmental Hot Spots in the Life Chains of Electronic Products
20.2 Creating Green Processes in the Electronics Industry
20.2.1 More Environmental Compatibility in Gold Coating
20.2.1.1 Selection of More Environmentally Compatible Substances for a Gold Coating Bath
Model for the Ecological Assessment
Results of the Ecological Assessment
20.2.1.2 Disposal of Cyanide-Free Baths
20.2.1.3 Results: Surface and Bath Properties
20.2.2 Reduced Environmental Impacts by Lead-Free Electronic Assemblies
20.2.2.1 Industrial Activities on the Way to Lead-Free Electronics
20.2.2.2 Studies on the Environmental Compatibility of Lead-Free Solders
Comparison of Different Lead-Free Solders to SnPb
Comparison of Material and Energy Balances of SnPb37 Soldering and Lead-Free Conductive Adhesive Joining
Disposal of Soldered and Adhesive-Joined Circuit Boards
20.3 Considering the Life Cycle: Design for Environment and Product Loops
20.3.1 Why Design for Environment?
20.3.2 What Is DfE?
20.3.2.1 How DfE Affects Product Features: General Principles
20.3.3 Design for Environment and Closed Loops: Two Examples
20.3.3.1 Computers in Loops
20.3.3.2 DfE: The Cradle of Environmentally Friendly Products
20.3.3.3 3 Steps Towards More Sustainability
20.3.4 Green Products: Success Not Only for the Global Players
20.3.4.1 Shared Profits: Innovative Marketing for Innovative Products
Bibliography
With IZM Participation
Further References
21: Recycling as Universal Resource Policy
21.1 Introduction
21.1.1 Why Is Recycling So Boring?
21.1.1.1 Dump Pollution Subsidies
21.1.1.2 Dump Siting Subsidies
21.1.1.3 Dumping Promotion
21.1.1.4 Subsidies for Resource Depletion
21.1.1.5 Subsidies Thru Law and Regulation
21.2 The Technological Basis of Garbage
21.2.1 RDF: Refuse-Derived Fuel
21.2.2 MORFs: Material-Only Recovery Facilities
21.2.3 Incinerators
21.2.4 Dump Liners
21.3 The Legal Right to Destroy Valuable Resources
21.4 Universal Recycling as Resource Policy
21.4.1 We Have Seen Recycling and it Is Inadequate
21.4.2 Recycling Is Not Economic
21.5 Universal Recycling: Opposition
21.6 Universal Recycling: Nuts and Bolts
21.6.1 First Law Arguments
21.6.1.1 First Law of Universal Recycling
21.6.2 Second Law Arguments
21.6.2.1 Second Law of Universal Recycling
21.6.3 Third Law Arguments
21.6.3.1 Third Law of Universal Recycling
21.6.4 Fourth Law Arguments
21.6.4.1 Fourth Law of Universal Recycling
21.6.5 Fifth Law Arguments
21.6.5.1 Fifth Law of Universal Recycling
21.7 Conclusions
Monolog: The Fifth R: Nowhere in Sight
Index