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Analyze a real world problem
Design a software solution for that problem
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Zhen Chen
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Solano Community College

Sustainable Manufacturing
Source: David Dornfeld, Ph.D. Will C. Hall Family Professor of Engineering, Director, Laboratory for Manufacturing and Sustainability (LMAS), University of
California, Berkeley

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Sustainability – everyone has a role to play
Source: The University of Toledo – SEED Initiative, http://www.utoledo.edu/sustainability/; accessed 6.9.14

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Who … what … where …?

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There are concrete impactful actions that manufacturers can take
Improve manufacturing process
Cost issue
Technology
1
Energy reduction, harvesting, combined processes, optimization, sustainability budget
Cost issue Improve energy efficiency Green manufacturing
Improve material efficiency system triangle
2
Use clean energy sources
Energy
Manufacturing and energy mix
Reduce embedded energy
3
Material
Cost issue
Use lower impact materials
Material yield, supply chain/source and haz, chemistry/chemical effects
Source: Chris Yingchun Yuan, A System Approach for Reducing the Environmental Impact of
Manufacturing and Sustainability Improvement of Nano-scale Manufacturing, PhD. Thesis,
UC-Berkeley, 2009

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There are concrete impactful actions that manufacturers can take
Process 1
1
Process 2 Process 3
…
Process n
Energy Water Consumables
Material /
Part
Process 1
Part /
Product
Waste
Heat
Air
Emissions
Waste
Water
Solid
Wastes
Source: Robinson, S. “An Environmental and Economic Trade-off Analysis of Manufacturing Process Chains to
Inform Decision Making for Sustainability,” (December 2013), Doctoral Dissertation, UC-Berkeley.

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There are concrete impactful actions that manufacturers can take
Improved
Process 4
Process 2 Cost and environmental impact
Process 3
Process N
Process 1
$
Current
Savings/Value
And extends to tooling and operations also …
Source: Robinson, S., Dornfeld, D. “Leveraging Advanced Manufacturing for Sustainable Production,”
Proc. 2014 International Symposium on Flexible Automation, Awaji-Island, Hyogo, Japan, July 14 – 16, 2014.

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There are concrete impactful actions that manufacturers can take
Real-time data processing is used to collect and process data in parallel to a machine’s operation to save time and data storage

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Data Mining and
Data Mining in Manufacturing
What is data mining?
The process of the "Knowledge Discovery in Databases“
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Enabled by improved computing power, increasing internet availability and decreasing of data storage cost
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Data mining is a fast growing technology in many areas with great potential
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Data mining effort in business, e-commerce and more

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Data Mining in Manufacturing cont.
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Vast amounts of data are available to be collected from manufacturing systems at different levels
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From system-level to the operation-level with varying degrees of complexity
Data analysis can lead to
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System and process optimization
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Informed decision making
Data driven accurate predictions on many aspects:
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Power consumption
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Resource usage
Tool wear …

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Example of Data Mining in Manufacturing
Image source: http://www.qualitydigest.com/sept06/articles/04_article.shtml

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A machine shop has two automatic milling machines.
Machines’ operation output data is in XML format. To improve the energy efficiency of the machines, operation data of power consumption and time stamps for each operation need to be extracted from the XML file. The extracted data will be calculated and then saved for analysis and comparison.
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Find a solution in software for this problem
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Save extracted data into a data file
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Calculate the average power consumption of each operation
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Display and write to an output file the elapsed time and the average power consumption of each operation