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Research paper : A rationalization guideline for the utilization of energy and resources considering total manufacturing processes (H. Kita et al.)−207 Synthesiology - English edition Vol.1 No.3 (2009) [1][2][3][4][5][6][7][8][9][10][11][12]K. Karakida: Ekuserugi no Kiso (Fundamentals of Exergy), Ohmsha (2005) (in Japanese).M. Shukuya, R. Nishikawa, I. Takahashi, M. Saito, H. Asada and K. Izawa: Ekuserugi to kankyo no riron, nagare junkan no dezain towa nanika(Theory of Exergy and Environment – Designing Flow and Cycle), Hokuto Shuppan (2004) (in Japanese).Z. Rant: Exergie, Ein neues Wort fur Technische Arbeits-fahigkeit, Forsch. Ing.-Wes 22, 36-37 (1956).Japan Industrial Standard: General rules for effective energy evaluation method, Japan Industrial Standard Z 9204 (1991) (in Japanese).T. Morihana, I. Takahashi and M. Shukuya: Calculation of exergy consumption in concrete production and operation, Collection of Academic Lectures of the Architectural Institute of Japan D-2, Environmental Engineering II, 495-496 (1997) (in Japanese).J. Yagi, J. Muramatsu and H. Nogami: Chikyukankyo kara seitetsu gijutsu o kangaeru ekuserugi gainen niyoru enerugi yuko riyo, CO2 haishitsu ryo no hyoka (Thinking about iron-making technology in terms of earth environment – efficient energy use by exergy concept, evaluation of CO2 emission), Kinzoku, June ed., 23-32 (1993) (in Japanese).I. Takahashi and M. Shukuya: Consideration of calculation method of exergy-entropy process accompanying chemical change, Collection of Academic Lectures of the Architectural Institute of Japan, 465-466 (1996) (in Japanese).Z. Rant: Zur Bestimmung der spezifischen Exergie von Bnennstoffen, Allg. Warmetech., 10, 9, S172 (1961).J. Szargut und T. Styrylska: Brennst.-Warme-Kraft, 16, 12, 589-596 (1964).T. Nobuawa: Nenryo oyobi nensho (Fuel and Combustion), 43, 11, 49-79 (1976) (in Japanese).H. Kita, H. Hyuga, N. Kondo and I. Takahashi: Exergy analysis in ceramics manufacture process, J. Ceram. Soc. Jpn., 115, No.12, 987-992 (2007) (in Japanese).H. Kita, H. Hyuga, N. Kondo and T. Ohji: Exergy consumption through the life cycle of ceramic parts, Intl. J. App. Ceram. Tech. (in print).Received original manuscript June 11, 2008Revisions received July 9, 2008Accepted July 9, 2008References(53)−of silicon nitride ceramics. Dispatched to Fine Ceramics Research Association in 1999, returned in 2004. Joined High-Temperature Member Process Research Group of Advanced Manufacturing Research Institute, AIST in 2005. Works on application of silicon nitride ceramics. In this paper, worked on data gathering and rationalization of ceramics process.Naoki KondoJoined Government Industrial Research Institute Nagoya, Agency of Industrial Science and Technology in April 1993. Obtained doctorate (Engineering) in January 2000. Dispatched to Ministry of Economy, Trade and Industry from April 2007 to March 2008. Worked on structural ceramics such as superplasticity, high-strength, high-temperature, and low-cost ceramics. In this paper, worked on data collection and rationalization of metal process.Discussion with Reviewers1 Importance of linkage between technology and indexQuestion & comment (Norimitsu Murayama)Figure 2 shows the importance of evaluation index in synthesiological approach to research, and it is the heart of message of this paper. Between technological development and new evaluation index, what is made in “manufacture”? Also, isn’t the arrow from index to technological development “measure”? On contrary, isn’t the arrow from new evaluation index to technological development “advancement”?Answer (Hideki Kita)The object “manufactured” is product or process obtained in the process of technological development. Evaluation index and technological development are joined with double-headed arrow to indicate that improvement and progress take place by mutually reflecting their results. Index becomes “advanced” and the technological development improves in “competitiveness” as result of action of turning the cycle of “concept,” “development,” and “evaluation,” and these were placed outside the triangle.2 Manufacturing efficiencyQuestion & comment (Norimitsu Murayama)Assuming, for example, a sintering process with 100 % alumina, exergy is zero because alumina is a reference material and the exergy fixed in the sintered compact is zero. Therefore, even if there the total exergy input is varied, “manufacturing efficiency” will always be zero, and the differences in process will not be expressed. Rather than using the expression “manufacturing efficiency,” I think it is more appropriate to use the term, for example, “fix ratio of exergy in components.” Also, I think overall performance of the manufacture process can be expressed accurately by showing the values of both “fix ratio of exergy in components” and total exergy input.Answer (Hideki Kita)Exergy is a concept that originated in thermodynamics and applied to matter. In applying exergy to matter, as exemplified by the point that exergies for powder and ingot that have different bonding condition are same, as far as I can understand, systematization is insufficient from physical perspective in addressing surface and interface energy. It is one issue as a manufacturing index, and I mentioned this point in Section 5 of the text.3 Performance evaluation of manufacture process taking in consideration the durability of componentsAuthorsHideki KitaCompleted program at Graduate School, Tokyo Institute of Technology. After working at company, joined AIST in April 2004. Worked on research and production management for engine friction, ceramics material, process, DPF (diesel particulate filter), and others. After joining AIST, works on new formation process and environmental impact assessment based on thermodynamics. In this paper, worked on overall concept and analysis.Hideki HyugaCompleted program in Process Engineering, Graduate School of Engineering, Osaka University. Joined Isuzu Ceramics Research Institute, Co. Ltd. (currently Isuzu Advanced Engineering Center Ltd.). Worked on development

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