Handbook of Environmentally Conscious Manufacturing

Description

Manufacturers, under pressure from their major stakeholders, integrate environmental issues in the design and management of their products. These stakeholders include customers, regulators, employees, communities, and interest groups who have a common stake in protecting the earth from pollution and in limiting the exploitation of earth's limited natural resources. Manufacturers recognize that being environmentally responsible also offers competitive advantage to the firm. The Handbook of Environmentally Conscious Manufacturing is written as a state-of-the-art reference to guide environmentally conscious manufacturing (ECM). All the contributors have done extensive research and/or practice work in the field of ECM. The Handbook covers all the major topics in Environmentally Conscious Manufacturing. There are specific chapters to deal with sustainable manufacturing, recycling, eco-labelling, life cycle assessment, and ISO 14000 series of standards, as well as decision-making aspects of Environmentally Conscious Manufacturing. Decision-oriented topics on supply chain, decision models, quality initiative, environmental costing and decision support systems are also covered. The influence of ECM on marketing imperative is also covered. 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