Archives—May 2013

Sustainable development of the manufacturing industry: casting and forging

This is a guest blog post from Minglei Guan, one of my students in the “Sustainability Science, Policy and Assessment” course this spring:

Sustainability is an important development goal for humanity in modern society. Manufacturing is a central feature of many economic development pathways, and in this sense casting and forging are therefore a necessary focus for sustainable development strategies. Casting (pouring hot metal into a mold) and forging (pressing metal into a certain shape) are two ways that all metal tools and products are made.

The economic issues for the casting and forging manufacturing industry can be summarized as low profit margins with high cost of capital, and market volatility. Low profit margins are common for small manufacturers when they lack an ability to improve their production processes, training and equipment. This issue can result in bankruptcy for small manufacturers, which then negatively impacts society through the loss of jobs. Economic support from government and industrial organizations can help alleviate this issue. For the second issue, the high cost of capital, is mainly driven by the cost of raw materials, labor, and energy. For the casting and forging manufacturing industry, the cost of materials is the most important. Efforts such as waste reduction and improved production methods are good ways to solve the issue, using approaches such as production life cycle improvement and TNS zero waste strategy.  Finally, the market volatility needs to be dependent upon local market requirements.

The casing and forging industries also have a large impact on the environmental dimension of sustainable development. High energy usage, materials resources waste and environmental damage are common to the casting and forging manufacturing industry.  High energy usage and materials resources waste are both resource issues; production life cycle improvement and TNS zero waste approaches can also be used to solve them. Emissions are also a serious problem for the industry. New technologies such as the “CRIMSON” model can be used to reduce emissions from the sand casting process. However, typically either new laws or environmental decrees are needed to limit greenhouse gas and smoke emissions or to filter them before they are released.

Finally, from social dimension, the industry has significant social impacts such as those related to labor costs and environmental damage as it impacts human health. To solve social, environmental and economic issues for the casting and forging manufacturing industry, one needs to considered relationships among these three views. Balanced development for society, the environment and the economy can push the manufacturing industry towards sustainability.