PLManagingRecyclability-Duta-UofM.ppt

UsingPLMformanagingsubstanceregulationsandmeetingrecyclabilitytargets,Dr.DebaDuttaProfessorofMechanicalEngineeringDirector,PLMAllianceUniversityofMichigan,AnnArbor,Frequentlyinthenews,“Over130,000PCsarereplacedeverydayinAmericaalone,andonlyatenthorsoarerecycled”,-RecyclingoldcomputersTheEconomist(27thJan2005),“(EPA)officialsweremovingtoimposestricterrequirementsinthe1991leadandcopperregulationsstartingnextyear,becauseofproblemswithleadindrinkingwaterinWashington,D.C.”,-AmovetowardsstricterleadmonitoringTheNewYorkTimes(8thMar2005),Source:White,et.al.JournalofCleanerProduction,Lifecycleofaproduct,PresentationOverview,Emergenceofproductend-of-liferelatedregulationsTrendsandconcernsforindustryTheEOLresearchprojectAsystemsapproachwithinthePLMframeworkSomeinitialresultsSummary,EnvironmentalconcernsEOL,IncreasedwasteduetoabandonedproductsHazardous/toxicsubstancesFivepoundsofleadineveryCRTmonitor30mgofHgineveryfluorescenttube(4ft)HalogenatedflameretardantsinplasticsLostresourcesEst.lossofresourcesfromelectricalequipmentwasteinEuropein1988:2.4milliontonnesofferrousmetal1.2milliontonnesofplastic652,000tonnesofcopper,Datafrom12SamsungrecyclingcentersinKorea(),EnvironmentalconcernsEOL,ExpensiverecyclingordisposalNeedforspecialisedprocessesVarietyofproductsnoeconomiesofscaleHighcostsofsafedisposalDecreasinglandfillspaceStringentlegalrequirements-ExpensivetobuildsafelandfillsClose-downof“unsafe”landfillsNIMBY(notinmybackyard),ExtendedProducerResponsibility(EPR),Transferoffinancial(sometimesoperational)responsibilityofEOLtreatmenttoproducersTargetsforrecoveryandrecyclingBans/Restrictionsontheuseofhazardoussubstances,ExtendedProducerResponsibility(EPR),LawsandRegulationsEuropeELV,WEEE,RoHSUSARCRAJapanSHARL,WasteTreatmentLawTaiwanResourceRecyclingandReuseAct,WasteDisposalActVoluntary/Co-regulatoryschemesAustraliaandenforcementmechanisms,Studiestofindalternatematl.andrecovery/recyclingtechnology,DevelopmentCycle,Designproductconfigurationforcompliance,env.performanceandprofitability,Specificationsforvendorparts,andinstructionsforATFs,Validationofcomplianceofparts/productandcorrectivemeasures,Analysisofenv.performancereportsandprofitabilityofEOLtreatmentoperations,OperationsCycle,Maintenance/updatesofATFs,physicalprocesses,notificationprocedures,Collectionofsubstanceinformationandreporting/documentation,Trackingofpartreplacementandconfig.changesinproducts(instances),Selection/executionofoptimalEOLtreatmentplan,Reporting/documentationoftreatmentprocesses/costs/etc.,TheEOLProblem,Complexandmulti-facetedStakeholdersinindustry,governmentandsocietyCorporateimageimplications,Pointsolutionswillnotsuffice!,ProductLifecycleManagement,ProductLifecycleManagement(PLM)isanintegratedbusinessapproachtomanagethecreation,disseminationanduseofproductinformationthroughouttheExtendedEnterprise.,Integratespeople,processesandinformationthroughouttheproductlifecycleandacrosstheextendedenterpriseIncludestoolsforinformationsharingbetweenformats,workflowmanagement,validation,alerting,etc.Envisagesdifferentfunctions(CAD/CRM/ERP/SCM)seamlesslyworkingona“singleproductdefinition”,PLM-advantages,EOLProjectResearch,RegulatorycycleDevelopmentcycleOperationscycle,Proactivedesignforcompliancewithsubstanceregulations,ChangeevaluationprocessinECM,Jointdetection&characterisationinCADassemblymodels,Compliancewithsubstanceregulations,StepscurrentlyundertakenbyOEMsStringentandsweepingrestrictionsforallsuppliedpartsUsuallydirecttransferofrestrictionsapplicabletoproductinproportionofthepartweightsMaterial/substancecontentanalysisandvalidationofcomplianceRequiredreportingofdetailedsubstancecontentbysuppliersSearchforalternativematerialse.g.leadfreepaint,leadfreesolder,Compliancewithsubstanceregulations,AvailabletoolsinPLMThird-partytrackingoflatestregulationsandOEMpoliciesOrganisationofcollectedinformationandcompilationofrequiredreportsTrackingofsubstancecontentinpartstocheckforcompliance,Compliancewithsubstanceregulations,InadequacyofcurrenttoolsleadtoLostopportunitytooptimiseonthecostsandqualityofoverallproductUniformrequirementsonallsuppliedpartsputsunduepressureonsomecomponentsTechnicalinfeasibilities,whendetected,mayrequirechangestoothercomponentstoensurecomplianceChangeslateinthedevelopmentcycleareexpensiveandincreasetimetomarket,ProblemStatement,Given:AconceptualproductassemblyconfigurationFind:Setofmaterialspecificationsforeachcomponent(e.g.limitonleadcontent,reqd.recycledmatl.content)Suchthat:ApplicableregulationsaresatisfiedFunctionalrequirementsofproductaresatisfiedCostandtimeforproductionisminimisedQuality/Performanceofproductismaximised,Phasesofthedesignprocess,ConceptualDesignEmbodimentDesign/PreliminaryDesignDetailedDesign,Proposedframework,Optimizationproblemformulation,maximises.t.where,numberofcomponentsinassemblynumberofalternativespecificationsforkthcomponentperformanceratingofkthcomponentifalternativelischosenrelativeimportanceofkthcomponentinassembly,Optimizationproblemformulation,TypesofconstraintsSinglepartconstraintse.g.Pbcontentinalloy,HgcontentsinbulbsMatingpartconstraintsincompatiblematerialsunequalthermalexpansion,unequalwear/corrosionresistancee.g.nylonnutsteelboltConstraintsongroupsofpartse.g.totalamountCrVIinchromiumplatedparts,PbinpiezoelectriccomponentsProductlevelconstraintsappliedtoproductasawholee.g.recyclablecontentrequirement,costconstraint,Preliminaryresults,Valvecarryingcorrosiveliquid,WhichpartsshouldbeCrplated?(limit30mgpervalve),TechnicalChallenges,DrmationQueryandretrievalsystemEstimationoffunctionalpropertiesandcostsforalternativesTranslationofpropertiestoperformancerating(thatallowscomparison),DeterminationofapplicableregulationsEstimationofweightsandsubstancecontentsDeterminationofconstraintsduetomaterialincompatibility,etc.Query/retrievalsystemwithformulationofconstraintequations,Decidingreasonablerisk(probability)toassigntoconstraintsRobustprobabilisticoptimisation,Ongoingwork,Probabilisticprogrammingtotackleuncertaintycomponentpropertiescanbespecifiedasrangeswithprobabilitydistributiondesignercanspecifyprobabilitywithwhichaconstraintmustbesatisfiedallowdesignertomanage“risk”ofviolatingtheconstraintsorrequirements,Designchangechangemanagement,EfficientevaluationofimpactofchangeinECM,EfficientChangeEvaluationinECM,IssuesComprehensiveevaluationofeffectsofaproposedE