SUSTAINABILITY IN PRODUCT DESIGN AND MANUFACTURING

Cavtat, 20 April 2009.

53. EOQ Congress

Katarina Gaži – PavelićPodravka d.d., Koprivnica, Croatia

[email protected]

SUSTAINABILITY IN PRODUCT

DESIGN AND MANUFACTURING

53rd EOQ CONGRESS

NEW SOCIETY FOR THE BRAVE OF HEART AND MIND


53. EOQ Congress

Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

Overview

• Introduction

• Production and consumption

• The sustainable alternative

• Conclusion

Introduction

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53. EOQ Congress


The Ant Design Example

• Safely and effectively handle their own material wastes and those of other species

• Grow and harvest their own food while nurturing the ecosystem of which they are a part

• Construct houses, farms, dumps, cemeteries, living quarters, and food-storage facilities from materials that can be truly recycled

• Create disinfectants and medicines that are healthy, safe, and biodegradable .

• Maintain soil health for the entire planet.


53. EOQ Congress


Looking Ahead 100 years

How are we going to:

• stabilize the climate by reducing GHG emissions globally by more than 60%?

• meet basic needs for food, water, shelter, and energy of 9 billion people?

• reduce proportion of the world’s population living in dire poverty? ($2/day, 3 billion)

• achieve a low carbon economy? – from “take-make-waste” production cycle to “cradle-

to-cradle”?

• achieve a more peaceful, secure world?

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Green Revolution

“We need to deal with not only the way the

world produces food but the way it is

distributed, sold and consumed, and we

need a revolution that can boost yields by

working with rather than against nature.” *

*Achim Steiner, UN Under-Secretary-General and UNEP Executive Director

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53. EOQ Congress


Feeding the world

The the entire projected population

growth could be fed by a more

efficient production.

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Food crises

• More than the half of the food produced today is

either lost, wasted or discarded as a result of

inefficiency in the human-managed food chain.

• Food prices may increase by 30-50 % within

decades. *

* “The Environmental Food crises: Environment's role in averting future food crises” report

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Production and consumption

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53. EOQ Congress


Current Production System

At each step in the production process:

• waste is generated

• significant quantities of fossil fuels are consumed (also in transporting raw materials and partially finished products).

• large quantities of water are consumed and contaminated

Current production demands that we:

• have to keep “going back to the well” to extract more and more raw material.

• have to keep finding new places to dump regular solid waste and the hazardous wastes generated by many production practices.

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53. EOQ Congress

Naziv prezentacije Katarina Gaži - Pavelić

Cradle To Grave Design

MakeTake

Landfill,

incineration

Raw materials

extraction and

synthesis

Manufacturing and

production, packaging,

distribution, selling, use

Waste


53. EOQ Congress


Production and Consumption

• Concepts of production and consuption have

been disconnected for a long time

• Produce what can be used and reused

• Industry should mimic biology, where one

species' excrement is another's food

• Zero waste is the new (and somewhat utopian)

concept

The sustainable alternative

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What is the Alternative?

• Industrial Ecology

Designing an industrial system that operates like a

natural system.

• Product as Service

Products are not sold, their service is leased to the

customer/consumer.

• Cradle-to-Cradle/Design for Disassembly / Take-

Back Programs

Designing products that can be easily disassembled

after their useful life and most of the useful material

can be reused for new products.14


53. EOQ Congress


Key Concepts for Today

The Life-cycle Concept

• Biological and the

technical nutrients

• Not cradle to grave, but

Cradle to Cradle

• Today

– We get rid of waste by

making it someone else

problem


53. EOQ Congress


Sustainability in Product Design and

Manufacturing

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Manufacturing

• Eco design

• Eco-Effectiveness

• Bio-Mimicry

Life Cycle Analysis

Impact of Design and

ManufacturingDesign

• Eco-Efficiency

• Lean

Manufacturing

• EH&S and EMS

– ISO 14001


53. EOQ Congress


Basic C2C Concept

• Eco-efficiency: being less bad

The strategy for "sustainability" of minimizing

harm to natural systems by reducing the amount

of waste and pollution generated by human

activities.

• Eco-effectiveness: being good

C2C strategy for designing human industry that

is safe, profitable, and regenerative, producing

economic, ecological, and social value.


53. EOQ Congress


LCA

• “Gate-to-gate” or “cradle-to-gate” = not true LCA

• “Cradle to grave” = traditional LCA

• “Cradle to cradle” = current/evolving LCA

Practical LCA

Full LCA Not LCA

Conclusion

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New Design

• Design life cycles instead of products

• Design services instead of products

• Use a minimum of material

• Increase product life time

• Make the product recyclable

• Use recycled materials

• Natural materials may not be better

• Estimate the actual energy consumption

• Replace toxic and hazardous materials

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Positive Outcomes

• Products are perceived differently by both customers and businesses: focus is on the service, not the product itself

• Durability is the new mantra

• Designing for disassembly and reuse (modular design)

• Manufacturers adopt a more cyclic way of thinking about their production process.


53. EOQ Congress


Positive Outcomes cont.

• Employment shift from extraction/disposal

industries to service, collection and re-processing

industries.

• Buildings (like trees) produce more energy than

they consume and purify their own waste water

• Transportation that improves the quality of life

while delivering goods and services

• A world of abundance, not one of limits, pollution,

and waste.

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Katarina Gaži – PavelićPodravka d.d., Koprivnica, Croatia

[email protected]

HVALA NA PAŽNJI!

THANK YOU!

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SUSTAINABILITY IN PRODUCT DESIGN AND

MANUFACTURING

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SUSTAINABILITY IN PRODUCT DESIGN AND MANUFACTURING