My PLM/Digital design and manufacturing challenge, my collaborative companies and my plans for collaborating with them in order to develop, innovate and bring to the market my new sustainable green product/process design”
Name: Dhananjay Mahesh Bhati
eLearning Pack ID: IE655-Spring2017-18-18
My Virtual company name: Harit Disposal Solutions LTD.
Collaborating Companies
SMTCL
Shenyang Machine Tool Co. LTD. (SMTCL) is the world’s largest machine tool builder. It was founded in 1995. In 2004, SMTCL purchased SCHIESS of Germany, which was a heavy duty machine builder with 150 machine building experience. This acquisition provided SMTCL with Design Centres and Manufacturing Campuses across China and Germany.
SMTCL makes Milling, Boring, Turning, and Drilling machines for a variety of industries including Automotive, Aerospace, Defence, Medical, Energy, Construction, and Consumer Goods. It produces 80,000 machines per year and has 18,000 employees.
KENNAMETAL
KENNAMETAL was founded in 1938. Kennametal delivers productivity to customers seeking peak performance in demanding environments by providing innovative custom and standard wear-resistant solutions. Their portfolio of well-respected brand names and broad global presence enable them to help customers of all sizes in virtually every geography, drive success at every stage of their value chain. Kennametal’s products and services are strategically aligned across two core businesses – Industrial and Infrastructure – due to which they touch almost every manufacturing process.
The company is headquartered in Pittsburgh, Pennsylvania, USA. They have more than 12,000 employees across 60 countries. Kennametal is a global market leader in tooling for the mining and highway construction industries
Niagara Cutter
Niagara Cutter, LLC is a leader in cutting tool technology. A wholly owned subsidiary of Seco Tools, LLC, Niagara Cutter has provided high-performance, high-value solid tooling to the aircraft, power generation and general metalworking industries since 1954. Made to accommodate all types of workpiece materials and cutting parameters, the company’s vast product selection comprises solid-carbide, high-speed steel and diamond-coated end mills as well as solid carbide multi-purpose thread milling solutions.
Main services and technologies provided by Niagara Cutter are:
- Application and Design Technology related to Milling
- Machining, Heat Treat and Grinding Technology used to Manufacture Cutting Tools
- Cleaning and Tool Preparation Technology related to Cutting Tools
- Vacuum Technology in PVD Thin Film Coatings related to Cutting Tools
MITSUBISHI Materials
The roots of MITSUBISHI Materials lie in a parent mining company called Tsukumo Shokai, which was a coal and mineral mining company. It was in 1990 that Mitsubishi Metal and Mitsubishi Mining & Cement merged to form Mitsubishi Materials Corporation. The company has around 30,000 employees and has a net annual sales of USD 12.32 billion.
The Advanced Materials & Tools Business conducts its business in two primary categories – Cemented Carbide products and sintered parts.
The Cemented Carbide products department provides an extensive array of cutting tools used in processes including lathe turning, milling, and drilling, as well as abrasion-resistant tools and construction tools. The department manufactures these products in Japan and overseas, sells them in global markets, and has a leading share of the Japanese market.
They also undertake the recycling of tungsten, a rare metal, and focusing on the recovery of used cemented carbide tools.
In the sintered parts department, the company produces sintered parts for automobile engines and transmissions at five locations around the world, helping to meet the growing need to increase fuel efficiency for eco-cars and other vehicles and shift toward the use of electric cars.
Cutting is a Metal-working operation wherein a metal is formed into a specific shape by chipping or cutting away excess metal using different tools and lathe machines. This operation yields two results – a finished product that meets the requirements and huge amounts of waste or excess metal that was removed. The waste generated is called chips or swarf; which are basically long, stringy tendrils or shavings. Chips can be extremely sharp, and this creates a disposal problem, as they can cause serious injuries if not handled correctly. Depending on the composition of the material, it can persist in the environment for a long time before degrading. This, combined with the small size of some chips (e.g. those of brass or bronze), allows them to disperse widely by piggy-backing on soft materials and also to penetrate the skin as deep splinters.
Drilling and milling operations also use oxy-fuel cutting torch and etching and masking chemicals. Milling can produce extreme heat due to intense friction. To prevent the heat from spreading and destroying the work-piece, a coolant is used which decreases the friction and temperature and prevents excessive tool wear.
About my company
Harit Disposal Solutions LTD.
My company aims to bring about Smart and efficient Waste Management solutions to the Metalworking industry. The above mentioned companies are pioneers in the metal cutting industry and their products and services consist of Milling, turning, filing, etc.
My company would collaborate with these companies to process the waste generated. The chips and bundles of excess metal can’t be sent to the landfills because they are contaminated by coolants and oils. In landfills, these liquids may seep into nearby soil and destroy the fertility of the ground. These waste materials would be processed in a centrifuge to separate liquid from the waste metal. The liquid can be further processed so that it’s no longer toxic. The metal bundles and chips would be recycled. This recycled metal can be further manufactured to form other products. This recycling would reduce the amount of mining and refining done every day to meet the ever increasing global demand for metal.
We also aspire to come up with newer ideas and technologies in Metalworking industry to reduce the amount of waste produced per job.
Budget
The proposed operation would require extensive resources and funding. The yearly budget stands around USD 10 billion.
Tracked metrics with a CE/PLM and green focus
Management by Objectives with a CE/PLM and green focus
- Eco-friendly: Our services would help eliminate the toxicity of the waste chemicals and coolant liquids. Also, the metal waste won’t have to be dumped in landfills, where it would be hazardous to anyone since the fillings and chips are sharp and small.
- Trustworthy partnership: Our partnership with the suppliers would be based on a mutual trust and respect.
- Research and Development: Additional funding and brain-power would be redirected to research and development department to improve the efficiency of the operation. An efficient operation would drastically reduce the capital spent on recycling and coolant separation and processing.
Key processes with a sustainable green PLM/CE focus
- Centrifugation: Centrifugation is used to separate the coolant liquid and oil which has contaminated the metal waste. The principle of this operation is that denser particles move towards the periphery and lighter materials migrate towards the axis.
- Research and Development: Our company has well established research facilities which continuously work on improving the efficiency of the operation and bringing down the cost and energy expended.
- Quality Assurance: Harit Disposal Solutions LTD strives to make the planet cleaner and greener. A federal or state pollution regulator would have full access to the facilities and their suggestions would be taken into account. This will keep the air, ground and water pollution to a minimum.
- Marketing: Marketing department would be responsible for advertising our services and accomplishments thereby earning us clients and valuable goodwill of the public.
Sustainable Green focus
Harit Disposal Solutions LTD. strives to make the environment cleaner and sustainable. The company takes numerous steps to process harmful chemicals and coolant liquids and recycle waste metal, which would in turn reduce the amount of metal mined around the planet. The below links to maritime videos by Mr. Paul G. Ranky bolsters our inspiration and drives us to exceed our responsibility to the environment. Since the chemicals would be processed to eliminate their toxicity, they will cease to be a threat to the marine life.
Social Networking Articles
Global Clean Energy Investment Is Down, But Solar Is Cheaper & Offshore Wind Is Booming
As per the research conducted by Bloomberg New Energy Finance, global investment in clean energy fell by 18% last year – leaving it far behind the goals stated in the Paris Agreement.
This reduction in investment is partly because Solar energy got a lot cheaper than what it used to be. Therefore, despite reduction in investment, a record of 70 MW of solar capacity was installed around the world. Some nations have begun showing interest in harnessing the power of off-shore winds, such as China, U.S. and Taiwan.
China has pulled back its investment because the clean energy it produced is bottled up. To spread the energy produced, China is building a national power grid to connect rural areas all over the mainland. So, this slowdown in investment is most likely temporary.
Increased concern about global warming and lower clean energy prices will soon give a boost to the investments in near future.
Link to the detailed discussion
P&G vows to eliminate all manufacturing waste within four years
Procter & Gamble Co have committed to bring down all manufacturing waste from more than 100 plants to zero by 2020. The company is planning an investment to recycle or re-use about 650,000 metric tons of waste that at the present goes to landfills. About 56% of its plants have already achieved the goal of zero waste to landfills.
P&G strives to achieve its goal by ensuring that all incoming materials be either converted to finished products, recycled or re-used in some way. As an example, liquid waste from its plant in Ohio is converted to alternative fuel for vehicles. Non-recyclable plastics from plants in India are shredded and pressed into building panels.
Link to the detailed discussion
Wind and Solar Growth Outpace Gas
Per a new survey by U.S. Energy Information Administration, more than half of 24,000 MW of electricity generation capacity added comes from renewable resources. Almost 60% of capacity added came from wind and solar resources and about 3% from hydropower, biomass, landfill gas, etc.
EIA noted that increased capacity doesn’t necessarily assure large share in renewable power generation because the renewable resources like wind and solar are intermittent and not periodic. EIA reported that most renewable generation comes from Western states, which accounted for 63 percent of all U.S. hydroelectric power and 77 percent of all solar generation in 2016. Roughly 72 percent of the nation’s wind power came from the Midwest and the South, notably Texas, while 24 percent came from Western states.
In 2016, natural gas power generation surpassed coal fired generation owing to 17% fall in coal production. Natural gas power generation accounted for 34% of total generation compared to coal’s share of 30%.
Let’s create a cleaner and greener future 
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