Improving the environmental performance of bedding products by using life cycle assessment at the design stage

Improvement of the environmental performance of processes and products is a common objective in industry, and has been receiving increased attention in recent years. The main objective of this work is to evaluate the potential environmental impact of two bedding products, a polyurethane foam mattress (PFM) and a pocket spring mattress (PSM). These two types are the most common mattresses used in Europe. A Life Cycle Assessment (LCA) shows that the PFM has a higher environmental impact than the PSM. For both products the main cause of environmental impact is the manufacturing process, respectively the polyurethane foam block moulding process for the PFM, and the pocket spring nucleus process for the PSM. A scenario analysis shows the possibility of reducing the environmental impact of the products’ life cycle using an alternative End-of-Life scenario, resorting to incineration rather than landfill. Two strategies were also studied in order to reduce the environmental impact of the PFM: (1) reutilization of foam that was sent to the waste system management, and (2) a 20% weight reduction of the polyurethane foam. The second strategy has proven to be the most effective.

Certification and integration of environment with quality and safety – a path to sustained success

According to Wright [1] certification of products and processes began during the 1960’s in the manufacturing industry, as a tool to control and assure the quality/conformity of products and services provided by suppliers to customers/consumers. Thus, the series of ISO 9000 was published first time, in 1987 and it was been created with a flexible character, to be reviewed periodically. Later, were published others normative references, which highlight the ISO 14001 in 1996 and OHSAS 18001 in 1999. This was also, the natural sequence of the certification processes in the organizations, i.e., began with the certification of quality management systems (QMS) followed by the environmental management systems (EMS) and after for the Occupational Health and Safety Management System (OHSMS). Hence, a high percentage of organizations with an EMS, in accordance with the ISO 14001, had also implemented, a certified QMS, in accordance with ISO 9001. At first the implementation of a QMS was particularly relevant in high demanding activity sectors, like the automotive and aeronautical industries, but it has rapidly extended to every activity sector, becoming a common requisite of any company worldwide and a factor of competitiveness and survival. Due to the increasingly demanding environmental legislation in developed countries, companies nowadays are required to seriously take into consideration not only environmental aspects associated to the production chain itself, but also to the life cycle of their products.

A generic model for integration of Quality, Environment and Safety Management Systems

Purpose – The purpose of this paper is to propose a generic model of Integrated Management System of Quality, Environment and Safety (IMS-QES) that can be adapted and progressively to assimilate various Management Systems, of which highlights: ISO 9001 for Quality; ISO 14001 for Environment; OHSAS 18001 for Occupational Health and Safety. Design/methodology/approach – The model was designed in the real environment of a Portuguese Organization and 160 employees were surveyed. The rate response was equal to 86 percent. The conceived model was implemented in a first phase for the integration of Quality, Environment and Safety Management Systems. Findings – Among the main findings of the survey the paper highlights: the elimination of conflicts between individual systems with resources optimization; creation of added value to the business by eliminating several types of wastes; the integrated management of sustainability components in a global market; the improvement of partnerships with suppliers of goods and services; reducing the number of internal and external audits. Originality/value – This case study is one of the first Portuguese empirical researches about IMS-QES and the paper believes that it can be useful in the creation of a Portuguese guideline for integration, namely the Quality Management Systems; Environmental Management Systems and Occupational Health and Safety Management Systems among others.

Dashboard services for pragmatics-based interoperability in cloud and ubiquitous manufacturing

The real Cloud and Ubiquitous Manufacturing systems require effectiveness and permanent availability of resources, their capacity and scalability. One of the most important problems for applications management over cloud based platforms, which are expected to support efficient scalability and resources coordination following SaaS implementation model, is their interoperability. Even application dashboards need to easily incorporate those new applications, their interoperability still remains a big problem to override. So, the possibility to expand these dashboards with efficiently integrated communicational cloud based services (cloudlets) represents a relevant added value as well as contributes to solving the interoperability problem. Following the architecture for integration of enriched existing cloud services, as instances of manufacturing resources, this paper: a) proposes a cloud based web platform to support dashboard integrating communicational services, and b) describe an experimentation to sustain the theory that the effective and efficient interoperability, especially in dynamic environments, could be achieved only with human intervention.

An Electromagnetic Tracker System for the design of a dental superstructure

Nowadays, different techniques are available for manufacturing full-arch implant-supported prosthesis, many of them based on an impression procedure. Nevertheless, the long-term success of the prosthesis is highly influenced by the accuracy during such process, being affected by factors such as the impression material, implant position, angulation and depth. This paper investigates the feasibility of a 3D electromagnetic motion tracking system as an acquisition method for modeling such prosthesis. To this extent, we propose an implant acquisition method at the patient mouth, using a specific prototyped tool coupled with a tracker sensor, and a set of calibration procedures (for distortion correction and tool calibration), that ultimately obtains combined measurements of the implant’s position and angulation, and eliminating the use of any impression material. However, in the particular case of the evaluated tracking system, the order of magnitude of the obtained errors invalidates its use for this specific application.

MDAI: Model based Design in Automobile Industry

It is proposed a new approach based on a methodology, assisted by a tool, to create new products in the automobile industry based on previous defined processes and experiences inspired on a set of best practices or principles: it is based on high-level models or specifications; it is component-based architecture centric; it is based on generative programming techniques. This approach follows in essence the MDA (Model Driven Architecture) philosophy with some specific characteristics. We propose a repository that keeps related information, such as models, applications, design information, generated artifacts and even information concerning the development process itself (e.g., generation steps, tests and integration milestones). Generically, this methodology receives the users' requirements to a new product (e.g., functional, non-functional, product specification) as its main inputs and produces a set of artifacts (e.g., design parts, process validation output) as its main output, that will be integrated in the engineer design tool (e.g. CAD system) facilitating the work.

Grid Integration of Offshore Wind Farms Using Modular Marx Multilevel Converters

This paper proposes the use of a Modular Marx Multilevel Converter, as a solution for energy integration between an offshore Wind Farm and the power grid network. The Marx modular multilevel converter is based on the Marx generator, and solves two typical problems in this type of multilevel topologies: modularity and dc capacitor voltage balancing. This paper details the strategy for dc capacitor voltage equalization. The dynamic models of the converter and power grid are presented in order to design the converter ac output voltages and the dc capacitor voltage controller. The average current control is presented and used for power flow control, harmonics and reactive power compensation. Simulation results are presented in order to show the effectiveness of the proposed (MC)-C-3 topology.

A Service Integration Platform for Collaborative Networks

Integrated manufacturing constitutes a complex system made of heterogeneous information and control subsystems. Those subsystems are not designed to the cooperation. Typically each subsystem automates specific processes, and establishes closed application domains, therefore it is very difficult to integrate it with other subsystems in order to respond to the needed process dynamics. Furthermore, to cope with ever growing marketcompetition and demands, it is necessary for manufacturing/enterprise systems to increase their responsiveness based on up-to-date knowledge and in-time data gathered from the diverse information and control systems. These have created new challenges for manufacturing sector, and even bigger challenges for collaborative manufacturing. The growing complexity of the information and communication technologies when coping with innovative business services based on collaborative contributions from multiple stakeholders, requires novel and multidisciplinary approaches. Service orientation is a strategic approach to deal with such complexity, and various stakeholders' information systems. Services or more precisely the autonomous computational agents implementing the services, provide an architectural pattern able to cope with the needs of integrated and distributed collaborative solutions. This paper proposes a service-oriented framework, aiming to support a virtual organizations breeding environment that is the basis for establishing short or long term goal-oriented virtual organizations. The notion of integrated business services, where customers receive some value developed through the contribution from a network of companies is a key element.

Self-optimization for dynamic scheduling in manufacturing systems

Scheduling is a critical function that is present throughout many industries and applications. A great need exists for developing scheduling approaches that can be applied to a number of different scheduling problems with significant impact on performance of business organizations. A challenge is emerging in the design of scheduling support systems for manufacturing environments where dynamic adaptation and optimization become increasingly important. In this paper, we describe a Self-Optimizing Mechanism for Scheduling System through Nature Inspired Optimization Techniques (NIT).

MASDSheGATS – Scheduling System for Dynamic Manufacturing Environments

This chapter addresses the resolution of scheduling in manufacturing systems subject to perturbations. The planning of Manufacturing Systems involves frequently the resolution of a huge amount and variety of combinatorial optimisation problems with an important impact on the performance of manufacturing organisations. Examples of those problems are the sequencing and scheduling problems in manufacturing management, routing and transportation, layout design and timetabling problems.

Addressing the facilities layout design problem through constraint logic programming

One of the most difficult problems that face researchers experimenting with complex systems in real world applications is the Facility Layout Design Problem. It relies with the design and location of production lines, machinery and equipment, inventory storage and shipping facilities. In this work it is intended to address this problem through the use of Constraint Logic Programming (CLP) technology. The use of Genetic Algorithms (GA) as optimisation technique in CLP environment is also an issue addressed. The approach aims the implementation of genetic algorithm operators following the CLP paradigm.

Scheduling in holonic manufacturing systems

This chapter presents some of the issues with holonic manufacturing systems. It starts by presenting the current manufacturing scenario and trends and then provides some background information on the holonic concept and its application to manufacturing. The current limitations and future trends of manufacturing suggest more autonomous and distributed organisations for manufacturing systems; holonic manufacturing systems are proposed as a way to achieve such autonomy and decentralisation. After a brief literature survey a specific research work is presented to handle scheduling in holonic manufacturing systems. This work is based on task and resource holons that cooperate with each other based on a variant of the contract net protocol that allow the propagation of constraints between operations in the execution plan. The chapter ends by presenting some challenges and future opportunities of research.

Optimização do tratamento de um efluente aquoso resultante da utilização de cola nas máquinas de produção de placas de madeira

O presente trabalho teve como principais objectivos, estudar e optimizar o processo de tratamento do efluente proveniente das máquinas da unidade Cold-press da linha de produção da Empresa Swedwood, caracterizar a solução límpida obtida no tratamento e estudar a sua integração no processo, e por fim caracterizar o resíduo de pasta de cola obtido no tratamento e estudar a possível valorização energética deste resíduo. Após caracterização inicial do efluente e de acordo com os resultados de um estudo prévio solicitado pela Empresa Swedwood a uma empresa externa, decidiu-se iniciar o estudo de tratabilidade do efluente pelo processo físico-químico a coagulação/floculação. No processo de coagulação/floculação estudou-se a aplicabilidade, através de ensaios Jar-test, dos diferentes agentes de coagulação/floculação: a soda cáustica, a cal, o cloreto férrico e o sulfato de alumínio. Os melhores resultados neste processo foram obtidos com a adição de uma dose de cal de 500 mg/Lefluente, seguida da adição de 400 mg/Lefluente de sulfato de alumínio. Contudo, após este tratamento o clarificado obtido não possuía as características necessárias para a sua reintrodução no processo fabril nem para a sua descarga em meio hídrico. Deste modo procedeu-se ao estudo de tratamentos complementares. Nesta segunda fases de estudo testaram-se os seguintes os tratamentos: a oxidação química por Reagente de Fenton, o tratamento biológico por SBR (sequencing batch reactor) e o leito percolador. Da análise dos resultados obtidos nos diferentes tratamentos conclui-se que o tratamento mais eficaz foi o tratamento biológico por SBR com adição de carvão activado. Prevê-se que no final do processo de tratamento o clarificado obtido possa ser descarregado em meio hídrico ou reintroduzido no processo. Como o estudo apenas foi desenvolvido à escala laboratorial, seria útil poder validar os resultados numa escala piloto antes da sua implementação industrial. A partir dos resultados do estudo experimental, procedeu-se ao dimensionamento de uma unidade de tratamento físico-químico e biológico à escala industrial para o tratamento de 20 m3 de efluente produzido na fábrica, numa semana. Dimensionou-se ainda a unidade (leito de secagem) para tratamento das lamas produzidas. Na unidade de tratamento físico-químico (coagulação/floculação) os decantadores estáticos devem possuir o volume útil de 4,8 m3. Sendo necessários semanalmente 36 L da suspensão de cal (Neutrolac 300) e 12,3 L da solução de sulfato de alumínio a 8,3%. Os tanques de armazenamento destes compostos devem possuir 43,2 litros e 96 litros, respectivamente. Nesta unidade estimou-se que são produzidos diariamente 1,4 m3 de lamas. Na unidade de tratamento biológico o reactor biológico deve possuir um volume útil de 6 m3. Para que este processo seja eficaz é necessário fornecer diariamente 2,1 kg de oxigénio. Estima-se que neste processo será necessário efectuar a purga de 325 litros de lamas semanalmente. No final da purga repõe-se o carvão activado, que poderá ser arrastado juntamente com as lamas, adicionando-se 100 mg de carvão por litro de licor misto. De acordo com o volume de lamas produzidos em ambos os tratamentos a área mínima necessária para o leito de secagem é de cerca de 27 m2. A análise económica efectuada mostra que a aquisição do equipamento tem o custo de 22.079,50 euros, o custo dos reagentes necessários neste processo para um ano de funcionamento tem um custo total de 508,50 euros e as necessidades energéticas de 2.008,45 euros.

Mix design process of polyester polymer mortars modified with recycled GFRP waste materials

In this study, the effect of incorporation of recycled glass fibre reinforced plastics (GFRP) waste materials, obtained by means of shredding and milling processes, on mechanical behaviour of polyester polymer mortars (PM) was assessed. For this purpose, different contents of GFRP recyclates, between 4% up to 12% in weight, were incorporated into polyester PM materials as sand aggregates and filler replacements. The effect of the addition of a silane coupling agent to resin binder was also evaluated. Applied waste material was proceeding from the shredding of the leftovers resultant from the cutting and assembly processes of GFRP pultrusion profiles. Currently, these leftovers as well as non-conform products and scrap resulting from pultrusion manufacturing process are landfilled, with additional costs to producers and suppliers. Hence, besides the evident environmental benefits, a viable and feasible solution for these wastes would also conduct to significant economic advantages. Design of experiments and data treatment were accomplish by means of full factorial design approach and analysis of variance ANOVA. Experimental results were promising toward the recyclability of GFRP waste materials as partial replacement of aggregates and reinforcement for PM materials, with significant improvements on mechanical properties of resultant mortars with regards to waste-free formulations.

Integration of an automatic storage and retrieval system (ASRS) in a discrete-part automation system

This technical report describes the work carried out in a project within the ERASMUS programme. The objective of this project was the Integration of an Automatic Warehouse in a Discrete-Part Automation System. The discrete-part automation system located at the LASCRI (Critical Systems) laboratory at ISEP was extended with automatic storage and retrieval of the manufacturing parts, through the integration of an automatic warehouse and an automatic guided vehicle (AGV).