Sustainability in Product Design and Manufacturing

1
Sustainability in Product Design and Manufacturing
Focus of today is on the design and manufacturing
components of the Company Cycle
2
Discussion Questions for Today

• Principles and Practices of Ecological Design
• What are THREE key ideas/concepts that you
  learned in this reading?
• To what extent does ecological design, as
  described in this article, address economic and
  social aspects of product and service design?
  Can you identify the economic and social benefits
  (and costs) to ecological design?
• EPEAT
• How does EPEAT certification focus on the design
  of electronic products?
• What did you find most interesting about the
  outcomes of the certification program as reported
  by the Green Electronics Council and discussed by
  Jeff Omelchuk?

3
Discussion Questions for Today

• Wal-Marts Sustainability Strategy
• Applying the GIST to electronics initiative
• How was Wal-Marts electronics initiative
  governed (the governance part of GIST)?
• From Wal-Marts perspective, what role did
  innovation play in this initiative?
• Were stakeholders engaged in this initiative?
• And how transparent was Wal-Mart in this
  initiative?

4
Sustainability in Product Design and Manufacturing
Key Concepts for Today

• Eco-Design
• Eco-Effectiveness
• Bio-Mimicry
• Eco-Efficiency
• LEAN Manufacturing
• EHS and EMS
• ISO 14001
• Life Cycle Analysis

Design
Manufacturing
Measure Impact of Design and Manufacturing
5
Sustainability in Product Design and Manufacturing
Eco-Design

• What is Design?
• A discipline that explores the dialogue between
  products, people, and contexts.
• A process that defines a solution to help people
  achieve their goals.
• An artifact produced as the result of solution
  definition.

6
Sustainability in Product Design and Manufacturing
Eco-Design

• What is Industrial Age Design?
• Form follows Function
• Optimize the function, value and appearance of
  products and systems for the mutual benefit of
  both user and manufacturer.
• Mechanistic Engineered.

7
Sustainability in Product Design and Manufacturing
Eco-Design

• What is Eco-Design?
• Form co-determined with Function
• Optimize the function, value and appearance of
  products and systems for the benefit of the
  system and its constituents.
• Whole Systems Socio-Ecologically Engineered

• (Shu-Yang, Freeman and Cote, 2004)

8
Sustainability in Product Design and Manufacturing

• Eco-Effectiveness

Central design principle of eco-effectiveness is
waste equals food (heard this before?) Instead
of using only natural, biodegradable fibers like
cotton for textile production (a
pesticide-intensive agricultural process), why
not use non-toxic synthetic fibers designed for
perpetual recycling into new textile products?
Instead of minimizing the consumption of energy
generated from coal, oil, and nuclear plants, why
not maximize energy availability using solar and
wind sources? From cradle-to-grave to
cradle-to-cradle closed loop systems
9
Sustainability in Product Design and Manufacturing
Eco-Effectiveness

• To assist companies in (re)designing
  eco-effective products, Cradle to Cradle Design
  Protocol assesses materials used in products and
  production processes.
• The four categories are
• Green Little or no risk. This chemical is
  acceptable for use in the desired application.
• Yellow Low to moderate risk. This chemical is
  acceptable for use in the desired application
  until a green alternative is found.
• Orange There is no indication that this is a
  high risk chemical for the desired application,
  but a complete assessment is not possible due to
  lack of information.
• Red High risk. 'Red' chemicals (also sometimes
  referred to as 'X-list' chemicals) should be
  phased out as soon as possible. 'Red' chemicals
  include all known or suspected carcinogens,
  endocrine disruptors, mutagens, reproductive
  toxins, and teratogens. In addition, chemicals
  that do not meet other human health or
  environmental relevance criteria are 'red'
  chemicals.

10
Sustainability in Product Design and Manufacturing
Eco-Effectiveness

• Human Health Criteria
• Carcinogenicity
• Teratogenicity
• Reproductive Toxicity
• Mutagenicity
• Endocrine Disruption
• Acute Toxicity
• Chronic Toxicity
• Irritation of Skin/Mucous Membranes
• Sensitization
• Carrier Function or Other Relevant Data

• Environmental Relevance Criteria
• Algae Toxicity
• Bioaccumulation (log Kow)
• Climatic Relevance/Ozone Depletion Potential
• Content of Halogenated Organic Compounds (AOX)
• Daphnia Toxicity
• Fish Toxicity
• Heavy Metal Content
• Persistence/Biodegradation
• Toxicity to Soil Organisms (Bacteria and Worms)

11
Sustainability in Product Design and Manufacturing
Eco-Effectiveness

• Cradle-to-Cradle
• MBDCs certification
• gDiapers Cradle-to-Cradle Certified

12
Sustainability in Product Design and Manufacturing
Biomimicry

• The conscious emulation of life's genius is a
  survival strategy for the human race, a path to a
  sustainable future. The more our world looks and
  functions like the natural world, the more likely
  we are to endure on this home that is ours, but
  not ours alone.
• Janine Benyus, author of Biomimicry

13
Sustainability in Product Design and Manufacturing
Biomimicry

• Orb Weaver Spider Silk
• The spiders fiber is stronger and more resilient
  than anything on the market today. This new
  renewable material could be used in parachute
  wires, suspension bridge cables, sutures,
  protective clothing, etc.
• Nexias BioSteel

14
Sustainability in Product Design and Manufacturing
Biomimicry

• Blue Mussels
• The blue mussel byssus is the material that
  attaches the mussel to a rock. This sealant
  eventually degrades after its mission is
  finished. This could inspire an alternative to
  plastics, e.g., a time-release coating for
  disposable biobased cups and cutlery which would
  eventually degrade, allowing the degradable
  material underneath to be composted.
• Columbia Forest Products PureBond

15
Sustainability in Product Design and Manufacturing
Biomimicry

• Abalone Shells
• Abalone shells with mother of pearl coating have
  a crystalline coating, which self assembles in
  perfect precision and is more resilient than
  anything produced by humans.
• Mimicking abalone shells could revolutionize and
  inspire biologically safe hard coatings that need
  to be lightweight but fracture resistant.

16
Sustainability in Product Design and Manufacturing
Eco-Efficiency
Product or service value Eco-efficiency
Environmental influence

• Environmental impact is related to business
  factors
• Improving eco-efficiency means increasing product
  value or reducing environmental impact
• Units and measurement methods are suggested

17
Sustainability in Product Design and Manufacturing
Eco-Efficiency

• 1. Reduce Material Intensity of Goods and
  Services
• Johnson Johnson Targeted 25 reduction in
  packaging by 2005
• 2. Reduce Energy Intensity (to produce and
  consume)
• Whirlpool Low energy refrigerators (Energy Star)
• 3. Reduce Toxic Dispersion
• Novartis (Swiss life sciences company) combined
  insecticide with pheromones

18
Sustainability in Product Design and Manufacturing
Eco-Efficiency

• 4. Increase Recyclability
• HP printed circuit boards are refined to recover
  precious metals
• 5. Increase Durability (extending the useful life
  of products)
• Ricoh increase durability of copy machines
  (leased so remain a revenue stream not about
  products but about materials and energy)

19
Sustainability in Product Design and Manufacturing
Eco-Efficiency

• Doing more with less
• Industry interested because eco-efficiency means
  greater economic benefit.
• Companies quickly took up extensive programs
  promoting eco-efficiency.
• Based on Reduce, Reuse, Recycle, and Regulate.

20
Packaging Design Exercise
Sustainability in Product Design and Manufacturing

• Select a product you bought recently.
• Redesign the packaging with the criteria given on
  the next slide.

21
Packaging Design Exercise
Packaging Design Criteria

• FOR ECO-EFFICIENCY
• Reduced Material Intensity
• Reduced Energy Intensity
• Reduced Dispersion of Toxic substances.
• Enhanced recyclability
• Maximized use of renewables
• Extended product life
• Increased service intensity

• STANDARD CRITERIA
• Relevance
• Performance
• Profit/Cost
• Aesthetics

• FOR EFFECTIVENESS
• Waste Food
• Recyclable
• Reusable
• Compostable

22
Sustainability in Product Design and Manufacturing
LEAN Manufacturing

• Origins
• Toyota Production System (TPS) generally
  considered the source of the concepts of Lean
  Manufacturing.
• The Usual Focus
• Set of TPS 'tools' that assist in the
  identification and steady elimination of waste
  (muda), the improvement of quality, and
  production time and cost reduction.
• Muda has an intuitive and practical relation to
  Eco-Efficiency.

23
Sustainability in Product Design and Manufacturing
LEAN Manufacturing

• A second approach to Lean Manufacturing, as
  practiced by Toyota, focuses on improving the
  'flow' or process variation (thereby steadily
  eliminating mura) throughout the system and not
  upon 'waste reduction' per se.
• Maximizes contributions of people and materials
• Common Adaptation - Focus only on mura tools
  approach.
• Only temporary success without focus on BOTH mura
  and unevenness a systems approach.

24
Sustainability in Product Design and Manufacturing
EHS and EMS

• EHS Environmental, Health Safety
• Departments of Organizations
• Derived from Compliance Perspective
• Can be difficult to integrate into lines of
  businessas a business strategy.
• EMS Environmental Management System
• Derived generally from continuous improvement
  standards of ISO 9001.

25
Sustainability in Product Design and Manufacturing
EHS and EMS
Environmental Management Systems Continuous
cycle of planning, implementing, reviewing and
improving the PROCESSES and ACTIONS that an
organization undertakes to meet its business and
environmental goals.

• Major Components
• Policy
• Planning
• Implementation and Operation
• Checking and Corrective Action
• Management Review

26
Sustainability in Product Design and Manufacturing
EHS and EMS

• Environmental Management Systems
• This model leads to continual improvement based
  upon
• Planning, including identifying environmental
  aspects and establishing goals plan
• Implementing, including training and operational
  controls do
• Checking, including monitoring and corrective
  action check and
• Reviewing, including progress reviews and acting
  to make needed changes to the EMS act.

27
Sustainability in Product Design and Manufacturing

• 3M Corporation Video
• Lets watch this video and see what elements of
  sustainability in product design and
  manufacturing are mentioned

28
Sustainability in Product Design and Manufacturing

• Life Cycle Analysis

• Takes a holistic view of and measures
  environmental and social impacts from raw
  material extraction to final use/disposal.

29
Sustainability in Product Design and Manufacturing
Life Cycle Analysis

• Stages of LCA
• Definition of Goals and Scope
• Life Cycle Inventory Analysis measure materials
  and energy used and environmental releases that
  arise along entire continuum of the product or
  process life cycle
• Life Cycle Impact Assessment examine actual and
  potential environmental and human health effects
  associated with use of resources and materials
  and with the environmental releases that result.
• Life Cycle Improvement Assessment systematically
  evaluate and implement opportunities to make
  environmental improvements based on previous
  assessments.

30
Sustainability in Product Design and Manufacturing
Life Cycle Analysis
From the Institute for Lifecycle Environmental
Assessment
31
Sustainability in Product Design and Manufacturing
Life Cycle Analysis
32
Sustainability in Product Design and Manufacturing
33
Sustainability in Product Design and Manufacturing
34
Sustainability in Product Design and Manufacturing
Hypothetical example of LCA impacts of Shoes A
(leather) and B (synthetic)