A concept of water usage efficiency to support water reduction in manufacturing industry

Increasing pressures on freshwater supplies, continuity of supply uncertainties, and costs linked to legislative compliance, such as for wastewater treatment, are driving water use reduction up the agenda of manufacturing businesses. A survey is presented of current analysis methods and tools generally available to industry to analyze environmental impact of, and to manage, water use. These include life cycle analysis, water footprinting, strategic planning, water auditing, and process integration. It is identified that the methods surveyed do not provide insight into the operational requirements from individual process steps for water, instead taking such requirements as a given. We argue that such understanding is required for a proactive approach to long-term water usage reduction, in which sustainability is taken into account at the design stage for both process and product. As a first step to achieving this, we propose a concept of water usage efficiency which can be used to evaluate current and proposed processes and products. Three measures of efficiency are defined, supported by a framework of a detailed categorization and representation of water flows within a production system. The calculation of the efficiency measures is illustrated using the example of a tomato sauce production line. Finally, the elements required to create a useable tool based on the efficiency measures are discussed

Discrete Event Simulation Modelling for Dynamic Decision Making in Biopharmaceutical Manufacturing

With the increase in demand for biopharmaceutical products, industries have realised the need to scale up their manufacturing from laboratory-based processes to financially viable production processes. In this context, biopharmaceutical manufacturers are increasingly using simulation-based approaches to gain transparency of their current production system and to assist with designing improved systems. This paper discusses the application of Discrete Event Simulation (DES) and its ability to model the various scenarios for dynamic decision making in biopharmaceutical manufacturing sector. This paper further illustrates a methodology used to develop a simulation model for a biopharmaceutical company, which is considering several capital investments to improve its manufacturing processes. A simulation model for a subset of manufacturing activities was developed that facilitated ‘what-if’ scenario planning for a proposed process alternative. The simulation model of the proposed manufacturing process has shown significant improvement over the current process in terms of throughout time reduction, better resource utilisation, operating cost reduction, reduced bottlenecks etc. This visibility of the existing and proposed production system assisted the company in identifying the potential capital and efficiency gains from the investments therefore demonstrating that DES can be an effective tool for making more informed decisions. Furthermore, the paper also discusses the utilisation of DES models to develop a number of bespoke productivity improvement tools for the company

A concept of water usage efficiency to support water reduction in manufacturing industry

Increasing pressures on freshwater supplies, continuity of supply uncertainties, and costs linked to legislative compliance, such as for wastewater treatment, are driving water use reduction up the agenda of manufacturing businesses. A survey is presented of current analysis methods and tools generally available to industry to analyze environmental impact of, and to manage, water use. These include life cycle analysis, water footprinting, strategic planning, water auditing, and process integration. It is identified that the methods surveyed do not provide insight into the operational requirements from individual process steps for water, instead taking such requirements as a given. We argue that such understanding is required for a proactive approach to long-term water usage reduction, in which sustainability is taken into account at the design stage for both process and product. As a first step to achieving this, we propose a concept of water usage efficiency which can be used to evaluate current and proposed processes and products. Three measures of efficiency are defined, supported by a framework of a detailed categorization and representation of water flows within a production system. The calculation of the efficiency measures is illustrated using the example of a tomato sauce production line. Finally, the elements required to create a useable tool based on the efficiency measures are discussed

A framework for modelling and reduction of water usage in the manufacturing industry

This thesis reports on the research undertaken to reduce the water usage within manufacturing through modelling and improving the water efficiencies at both process and production system levels. The primary objectives of this research are: to develop a framework which classifies the various water usages within a manufacturing facility, to define a number of efficiency ratios to highlight the water inefficient activities, and to develop a decision support tool to aid with the selection of the most effective solutions for reduction of water usage within manufacturing applications. The research undertaken in the past three years is divided into four main parts. The first part reviews the relevant literature on water availability and distribution, the role of water in manufacturing, and relevant legislations and policies governing the water usage in manufacturing industries. [Continues.

A decision tool for improving manufacturing water usage efficiency

The environmental drivers for improving the efficiency of water usage in manufacturing industry are strong. However, while a water reduction programme can initially produce worthwhile benefits with moderate effort, further significant reductions require change to product, process or operational planning. The investment risk represented by such changes may act as a disincentive for companies to proceed with water conservation efforts. To improve the situation a methodology and a supporting simulation tool for decision making in water reduction investment is introduced in this work. The methodology is based on the concept of water usage efficiency introduced in previous work, which allows identification of hotspots where the maximum gains from intervention can be achieved. The tool further supports a structured approach to ranking the feasibility and benefits of proposed interventions. A report is presented on application of the tool to the operations of a food manufacturing company in India. The area with the greatest potential for improvement was identified as being water directly involved in the process of rice cooking, with the corresponding highest ranked intervention option being pre-soaking the rice. This option delivers the desired efficiency benefits while being lower cost than more technically involved interventions such as introducing water treatment equipment

How to Manufacture a Sustainable Future for 9 Billion People in 2050

There is a growing body of evidence which increasingly points to serious and irreversible ecological consequences if current unsustainable manufacturing practices and consumption patterns continue. Recent years have seen a rising awareness leading to the generation of both national and international regulations, resulting in modest improvements in manufacturing practices. These incremental changes however are not making the necessary progress towards eliminating or even reversing the environmental impacts of global industry. Therefore, a fundamental research question is: ’How can we meet the long term demand of our growing global population, and in this context, what are the key challenges for the future of manufacturing industry?’ A common approach adopted in such cases is to utilise foresighting exercises to develop a number of alternative future scenarios to aid with long-term strategic planning. This paper presents the results of one such study to create a set of ’SMART Manufacturing Scenarios’ for 2050