SUSTAINABLE PRODUCT & PROCESS DEVELOPMENT ISQA 511 Dr. Mellie Pullman 1

Overview  Design for “…”  Protocols  Herman Miller Case  Tool Demonstration  EQFD (QFDE) 2

Sustainability Product and Process Protocols and Frameworks 1970s & 1980s Pollution Control Pollution Prevention 1990s Eco-Efficiency Design for Environment The Natural Step Industrial Ecology 2000s Cradle to Cradle Life Cycle Analysis Biomimicry 3

Design for…  Manufacturing and Assembly  Disassembly  Recycle  Reuse  Logistics  Or Design for Sustainable Supply Chain Management 4

Sustainable Design & Supply Chain  Aspects of sustainability can pervade all design activities affecting the product during its life time:  Social, economic, and environmental aspects of Raw materials Production Packaging Transportation Redistribution Disassembly Recycling  Measures (Carbon Footprint, LCA, energy, water, etc.) and Methods (EQFD) 5

Internal competition to reduce unnecessary air in their product packaging to lower logistics cost and increase efficiency in transportation and warehouse Example: Ikea’s Air Hunting Competition Glimma tea candle 6

Air= Packaging Space  How does this effect:  Transportation loads  Vehicles  Warehouse  Environment 7

Design for Environment Flow and Support Tools DfE Project Development* Project Concept Development (QFDE Tool) Conceptual Design Qualitative design review on sustainability aspects Design Detail Quantitative design review on sustainability (LCA) Production * Initially, a philosophy or framework may create guiding principles such as C2C or Natural Step 8

Cradle to Cradle Philosophy Biological plantsanimalsdecomposessoil nutrients Technical Manufacturing & Assembly ProductCustomer UseMaterials 9

Environmental Quality Function Deployment  Quality Function Deployment is a product development tool that comes out of Japan (House of Quality)  Typically used to optimally meet customer needs  Converts their needs (CN) to measurable engineering characteristics/metrics (EC/EMs)  Targets are then set for EC/EMs  Second stage translates the EC/EMs to specific components parts and design features. (third and forth stage sets up manufacturing process and production process)  EQFD accounts for environmental needs and characteristics 10

Why use this tool?  Team approach: pulls designers, marketing, engineers, and process development people together to look at the impact of their decisions on the final product,  Systematic: considers environmental impact of design choices & alternatives in an orderly way,  Sequential development: customer & environmental needs are considered up front and trickle through system,  Customer & environment needs, engineering metrics, components, manufacturing process, & production process.  Proven track record of success with new product development. 11

Fundamental Design Objectives 12  Maximize customer satisfaction (using customer and other stakeholders)  What are the customers needs for the product both functionally and environmentally?  Minimize cost of use  Minimize environmental impacts

Sample of Environmental Needs and Engineering Metrics Environmental Needs  Less material usage  Less energy & water consumption  Easy to transport and store  Easy to process and assemble  High durability  Easy to reuse  Easy to disassemble & sort  Easy to maintain  Easy to compact  Safe to incinerate  Easy to dispose of or safe to landfill  Harmless to biosphere  Safe emissions Environmental Engineering Metrics  Weight  Volume  Number of parts  Variety of materials  Likelihood of getting dirty or oxidizing  Hardness  Physical lifetime  Energy consumption  Rate of recycled material  Sensory impact (noise, visual, etc.)  Emissions mass (air, water, soil)  Biodegradability  Material Toxicity 13

Class Demonstration of EQFD  EU direction requires EuPs to incorporate life- cycle-based environmental considerations into product development process  Other criteria that you should consider? EuP: Energy Using Products Green Product Design for Hairdryer 14

Life Cycle Analysis Scope Extracting & processing raw materials Manufacturing Packaging Transportation & Distribution Useful life, maintenance & reuse Recycling Disposal at end of life 15

Voice of Customer issues  Dries quickly  Quiet  Comfortable to hold  Less energy consumption  Operates easily  Reliable  Portlable  Easy to disassemble  Easy to smash  Easy to sort  Easy to recycle  Safe to incinerate  Safe to landfill Typical Needs (pick 3) Needs related to Environment (pick 3) Rate the importance of each on a scale of 1-5 for your 6 items 16

17 Row # Visual Weight influence Relative Weight Customer Importance Maximum Importance Engineering Metrics Customer Needs or Requirements 1 ||||||| Dries quickly 2 |||||| Quiet 3 |||||| Comfortable to Hold 4 |||| Less Energy Consumption 5 ||||||| Easy to Dissesemble 6 |||| Easy to Smash 7 ||||||| Easy to sort 8 |||| Easy to Recycle

Engineering Metrics for producers & environmental view  Air flow  Air temperature  Weight  Hardness  Physical lifetime  Number of parts  Rate of recyclable materials  Rate of standardized components  Number of materials  Amount of energy consumed  Biodegrability  Toxicity of Materials Hair dryer EMs(pick 3)Environmental EMs(pick 3) 18

19 Engineering Metrics Air Flow Air temperature Weight Number of parts number of materials hardness physical lifetime amount of energy consumed rate of recycled materials Customer Needs or Requirements Dries quickly 99 9 Quiet 9 9 Comfortable to Hold 9 3 Less Energy Consumption 99 9 Easy to Dissesemble Easy to Smash Easy to sort Easy to Recycle

Looking at your weight-importance scores  What is more important measurement?  What should the producer focus on here? 20

Other Details of Interest 21  Are any of these related factors (roof of house)?  What problems or opportunities might this reveal?  Right side of house and basement, competitor’s situation > strategic insights?