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33.6.2 EXAMPLE 2
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This study involved the use of an automated photoresist dispensing system (Briones, 2006). Photoresist is one of the most expensive chemicals used in the semiconductormanufacturing process. Typical costs range from $53 to $106 per liter ($200 $400 per gallon). Photoresist waste is not one of the larger waste streams, but the cost of the chemicals motivated this facility to install an automated dispensing system. Prior to
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ELECTRONICS, SEMICONDUCTORS, AND OTHER ELECTRICAL EQUIPMENT
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automation, the 1-gallon bottles storing the photoresist chemicals were visually monitored and replaced by the operators. Typically, operators replaced used bottles containing approximately 5 cm (2 in) of photoresist in the bottom to prevent the system from running dry. Eventually the waste from each bottle was mixed and disposed of off-site. The time and labor required for monitoring, the high cost of new chemical, and the disposal costs involved with the waste made these activities of concern. An automated system was installed to provide maximum usage of photoresist from the supply bottles and continuous operation with minimal operator assistance. The automated system reduced photoresist waste by 50 percent.
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A California semiconductor manufacturer studied approaches to reduce solvent wastes (Briones, 2006). The conclusions indicated that solvent segregation, solvent substitution, direct solvent reuse, distillation, and evaporation could accomplish a 70 percent solvent reduction. Segregation of chlorinated solvents from nonchlorinated solvents was recommended to facilitate waste reduction by increasing recyclability. Minimizing water mixing, separating chlorinated from nonchlorinated solvent wastes, separating aliphatic from aromatic solvent wastes, and separating Freon from methylene chloride facilitated recycling.
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33.7 Additional Information
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1 www.dtsc.ca.gov/PollutionPrevention/P2_Semiconductor-Ind-Conf.cfm. 2 Cui, Jirang and Forssberg, Eric, Mechanical Recycling of Waste Electric and
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Electronic Equipment: A Review, Journal of Hazardous Materials B 99, 2003, pp 243-263.
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34.1 Industry Overview
NAICS code: all 33300s
INDUSTRY SNAPSHOT
28,306 machinery manufacturing operations in the United States 1,172,889 employees $252.5 billion in annual sales 3.0 tons of solid waste generation per employee Major waste streams: paper, plastic, wood, and metals
Industries in the machinery manufacturing subsector create end products that apply mechanical force, for example, the application of gears and levers, to perform work. Some important processes for the manufacture of machinery like forging, stamping, bending, forming, and machining are used to shape individual pieces of metal. Processes, such as welding and assembling are used to join separate parts together. Although these processes are similar to those used in metal-fabricating establishments, machinery manufacturing is different because it typically employs multiple metal-forming processes in manufacturing the various parts of the machine. Moreover, complex assembly operations are an inherent part of the production process. In general, design considerations are very important in machinery production. Establishments specialize in making machinery designed for particular applications. Thus, design is considered to be part of the production process for the purpose of
INDUSTRIAL AND COMMERCIAL MACHINERY INCLUDING AUTOMOTIVE MANUFACTURING
implementing the North American Industry Classi cation System (NAICS). The NAICS structure re ects this by de ning industries and industry groups that make machinery for different applications. A broad distinction exists between machinery that is generally used in a variety of industrial applications (i.e., general-purpose machinery) and machinery that is designed to be used in a particular industry (i.e., specialpurpose machinery). Three industry groups consist of special-purpose machinery agricultural, construction, and mining-machinery manufacturing; industrial-machinery manufacturing; and commercial- and service industry machinery manufacturing. The other industry groups make general-purpose machinery: ventilation, heating, airconditioning, and commercial refrigeration equipment manufacturing; metalworkingmachinery manufacturing; engine, turbine, and power transmission equipment manufacturing; and other general-purpose machinery manufacturing. The global automotive industry is a highly diversi ed sector that comprises manufacturers, suppliers, dealers, retailers, original equipment manufacturers, aftermarket parts manufacturers, automotive engineers, motor mechanics, auto electricians, spray painters or body repairers, fuel producers, environmental and transport safety groups, and trade unions. The United States, Japan, China, Germany, and South Korea are the top ve automobile-manufacturing nations throughout the world. The United States is the world s largest producer and consumer of motor vehicles and automobiles accounting for 6.6 million direct and spin-off jobs and represents nearly 10 percent of the $10 trillion U.S. economy. The automobile is one of the most important industries in the world, which provides employment to 25 million people in the world. The automobile and automotive-parts manufacturers constitute a major chunk of the automotive industry throughout the world. The automotive-manufacturing sector consists of automobile and light-truck manufacturers, motor vehicle body manufacturers, and motor vehicle parts and supplies manufacturers. This sector is engaged in manufacturing of automotive and light-duty motor vehicles, motor vehicle bodies, chassis, cabs, trucks, automobile and utility trailers, buses, military vehicles, and motor vehicle gasoline engines. The worldwide automobile industry is largely dominated by ve leading automobile-manufacturing corporations, namely, Toyota, General Motors, Ford Motor Company, Volkswagen AG, and Daimler Chrysler. These corporations have their presence in almost every country and they continue to invest into production facilities in emerging markets, namely, Latin America, Middle East, Eastern Europe, China, Malaysia, and other markets in Southeast Asia with the main aim of reducing their production costs. The automotive industry occupies a leading position in the global economy, accounting for 9.5 percent of world merchandise trade and 12.9 percent of world export of manufacturers. This industry manufactures self-powered vehicles, including passenger cars, motorcycles, buses, trucks, farm equipment, other commercial vehicles, and automotive components and parts. The United States is the major revenue source for the global automotive industry with a market share of $432.1 billion, occupying 37.2 percent of the world s marketplace. In the year 2006, America sold around 16.5 million vehicles. The automobile
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