Southampton (United Kingdom), 5th-8th July 2010 Southampton, 5th-8th July 2010 Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention

Southampton (United Kingdom), 5th-8th July 2010 WP5. Zero Waste Entrepreneurship: Production Model Project month #15/60 Task 5.1 month #9/18 Project month #15/60 Task 5.1 month #9/18

Southampton (United Kingdom), 5th-8th July 2010 Activities done Production models Definition of production models Existing production models and chronological evolution Elements in ZeroWIN Technologies (production, transport, use, end of life) Methods and strategies on waste prevention (pollution control and prevention, recycling and waste minimisation, eco-design, eco- efficiency... industrial ecology... ZeroWIN) Analysis and improvement tools (LCA, LCC, SLCA...) Zero waste thinking at the production models Identification of the zero waste concepts within production models Status of WP5 - Task 5.1 1/1

Southampton (United Kingdom), 5th-8th July 2010 Definitions of production model Information which describes the production processes, resources and strategies of a company The detailed manufacturing capability of a company and its current manufacturing status Supports the formulation of new and better production strategies Facilitates the development of factory models Becomes a source of information for real time production control applications A production model involves not only the manufacturing of goods and services, but also the design, management, supply and sale, that includes: Technology Management skills Machinery (and associates skills) Production organization Work organization Human resource management practices (HRM) Industrial relationship (IR) practices

Southampton (United Kingdom), 5th-8th July 2010 Production models and chronological evolution 1/2 The evolution of production models Completely custom - craftsman (pre-1800) English system (1800s): introduction of general purpose machines that could be used for a variety of products. American system (1850s): emphasized precision and inter-changeability. And changed from a "best fit" to a "greatest clearance without loss of functionality" focus. Scientific management (1900s): pre-specified worker motions and moved the control totally into the hands of management. Process improvement (Statistical Process Control) (1950s): the identical procedure will produce different results on the same machine at different times. It emphasized outliers rather that mean performance. Numerical control (1970s): combining the versatility of general purpose machines with the precision and control of special-purpose machines. Computer integrated manufacturing (1980s) Logistics/Supply-chain management (1990s)

Southampton (United Kingdom), 5th-8th July 2010 Production models and chronological evolution 2/2 Craft or Guild system English system of manufacturing American System of manufacturing Soviet collectivism in manufacturing Mass production Just in Time manufacturing Lean manufacturing World class manufacturing Flexible manufacturing Mass customization Agile manufacturing Rapid manufacturing

Southampton (United Kingdom), 5th-8th July 2010 Elements in ZeroWIN 1/2 LCA Industrial Symbiosis Industrial Eco-Parks RFID Product Stewardship Supply Chain Management Carbon footprinting WP2: Innovative Technologies WP3: Waste Prevention Methods and Strategies WP4: System Tools - Analysis & Improvement WP1: Vision on Zero Waste Entrepreneurship

Southampton (United Kingdom), 5th-8th July 2010 Transport and Distribution Use Production End of Life Elements in ZeroWIN 2/2 MATERIAL SUPPLIER Materials COMPONENT SUPPLIER Components WASTE COLLECTOR DISMANTLER Parts REFURBISHER Spares RECYCLER Materials, Fuels WASTE MANAGER Products WP6: Development of Pilot Applications in Industrial Networks: Case Studies MANUFACTURER Products MANUFACTURER Components CONSUMER RETAILER SUB CONTRACTOR LCA Indicators -1 Industrial Ecology Zero Waste Eco-design Industrial Symbiosis Industrial Eco-Parks RFID Product Stewardship Supply Chain Management Indicators -2 Energy Waste Water Carbon footprinting Research Development Innovation WP2: Innovative Technologies WP3: Waste Prevention Methods and Strategies WP4: System Tools - Analysis & Improvement Extraction SUPPLIER Raw Materials By-products Waste

Southampton (United Kingdom), 5th-8th July 2010 “Prevention practices” Process design Input substitution Plant improvement Good housekeeping Re-use and recycling “Resource productivity” Resource efficiency Energy use and greenhouse gas emissions Water use and impacts Control of minor elements and toxics By-product creation Elements in ZeroWIN Technologies & Waste prevention methods and strategies

Southampton (United Kingdom), 5th-8th July 2010 Still today industry follows very conventional production model Its major goal is, in most cases, the shareholder value (especially for enterprises listed in various stock exchanges) and therefore very short-term oriented and product oriented Private entrepreneurs tend to think more long-term but also they only concentrate on the sustainability of their individual company. Also in this model the bigger picture is totally missing The ZeroWIN production model has not to concentrate on individual companies but look on the industrial networks in total, consider both economic and environmental values and think in products and by-products Focus on resource-use optimization and waste prevention Framework for the application of new technologies, methodologies and strategies Use system tools for monitoring and improve To be validated in real industrial networks and case studies Zero waste thinking in production models

Southampton (United Kingdom), 5th-8th July 2010 Objectives of zero waste thinking in production models The aim is to expand the already existing models of production to integrate the vision of the ZeroWIN (zero waste and sustainable industry) Zero waste of resources (maximising efficiency): materials, energy, people… Zero emissions and waste: air, water, soil Zero waste in activities: administration, production… Zero waste in product life: manufacturing, transport, use, end of life Zero use of toxics: processes and products Contribution to meet at least two of the three aims of the ZeroWIN 30% reduction of greenhouse gas emissions (energy) 70% overall re-use and recycling of waste (materials) 75% reduction of fresh water use (utilities)

Southampton (United Kingdom), 5th-8th July 2010 WCM (World Class Manufacturing) production model WCM applies to all areas of production and aims to optimise results through Continuous improvement of processes and product quality Control and gradual reduction of production costs Flexibility to respond to market requirements Involvement and motivation of employees WCM seeks the client satisfaction and the success is based on the participation of employees The essence of World Class Manufacturing is the number ‘ZERO’ ZERO accidents (safety) ZERO machine breakdowns (production) ZERO defects in products ZERO customer claims ZERO waste disposal (environment)

Southampton (United Kingdom), 5th-8th July 2010 WCM (World Class Manufacturing) scheme

Southampton (United Kingdom), 5th-8th July 2010 GENERAL PRINCIPLES PRINCIPLE OF DESIGN PRINCIPLES OF OPERATIONS PRINCIPLES OF HUMAN RESOURCE 1. Work together with clients, organize by client/ product families (what they buy/ use) 2. Capture and apply competitive information and the best practical application related to the client 3. Be dedicated to the continuous and expeditious improvement in quality, response time, flexibility and value 4. Employees engaged in frontline change and strategic planning 5. Leave only best components/ operations/ suppliers 6. Reduce flow time, distance, and start /change times along customers chain 7. Operate closely with the rate of use or client demand 8. Expand on human resources: cross- training, job rotation and career and improvements in quality & safety 9. Expand the range of rewards, recognition & remuneration, to promote employee contributions PRINCIPLES FOR IMPROVING THE QUALITY AND PROCESSES PRINCIPLES OF INFORMATION OPERATIONS AND CONTROL PRINCIPLE OF CAPACITY PRINCIPLES OF PRODUCTION AND MARKETING 10. Reduce continually changes and drawbacks 11. Teams in the front line have the record and process information in the workplace 12. Check the radical causes of cost and performance, to reduce transactions and reporting presentation, simplifying external communications 13 Align performance measures with the universal client wishes: quality, speed, flexibility & value (QSFV) (measurements) 14. Improve the equipment and human work present before considering a new equipment and automation 15. Ensure that equipment and working facilities are simple, flexible, mobile, low cost and readily available in parallel, one for each product family or clients 16. Promote, market and sell the growing capacity and competence of the organization (the results of the other fifteen principles) WCM (World Class Manufacturing) principles

Southampton (United Kingdom), 5th-8th July 2010 General principles Principle of design 5. Leave only best components/ operations / suppliers (Life Cycle perspective) WCM (World Class Manufacturing) principles with strategic environmental aspects 1/3 Eco-design Environmental strategy & policy 1. Work together with clients. organize by client/ product families (what they buy/ use) 2. Capture and apply competitive information, best practical application & environmental performance related to the client 3. Be dedicated to the continuous and expeditious improvement in environment, quality, response time, flexibility and value 4. Employees engaged in frontline change and strategic planning Environmental requirements of the client Product/ process demands: - Environmental performance of competitors - Environmental legislation evolution - Market demands - Environmental policy: product/ process goals Continuous survey of the foreseen evolution of product demands General environmental awareness Design for sustainability: - Evaluation of impacts through the life cycle - Verify less impacting providers, processes and components. specific procedures (indicators, methodologies, etc.) ZeroWIN

Southampton (United Kingdom), 5th-8th July 2010 Principles of human resource WCM (World Class Manufacturing) principles with strategic environmental aspects 2/3 Principles of operations 6. Reduce flow time, distance, and start/ change times along customers chain 7. Operate closely with the rate of use or client demand Principles for improving the quality and processes Pollution prevention Clean production Energy efficiency… Optimize transport logistics: distances, packaging… Optimize storage needs: - Land use for storage - Spill/emission risks in storage - Products out of specification 8. Expand on human resources: cross- training, job rotation and career and improvements in quality & safety 9. Expand the range of rewards, recognition & remuneration, to promote employee contributions Training in environmental aspects Articulate systems for facilitating the contribution of employees to zero waste: - Inputs for eco-design - Inputs for process improvement - Inputs for good housekeeping - Inputs for reducing rejects… 10. Reduce continually changes and drawbacks (technical and environmental) 11. Teams in the front line have the record and process information in the workplace. Process optimization: - Identify improvement potentials regarding energy use, material & water consumption, consumption of hazardous substances, emissions -identify technology changes Environmental process performance data gathering ZeroWIN

Southampton (United Kingdom), 5th-8th July 2010 Principles of information operations and control Principle of capacity Principles of production and marketing 14. Improve the equipment and human work present before considering a new equipment and automation. 15. Ensure that equipment and working facilities are simple, flexible, mobile, low cost and readily available in parallel, one for each product family or clients. 16. Promote, market and sell the growing capacity and competence of the organization (the results of the other fifteen principles). Environment al claims: -ISO EMAS -Eco-labels -EPD -Self claims... LCA LCC SLCA... WCM (World Class Manufacturing) principles with strategic environmental aspects 3/3 12. Check the radical causes of cost and performance, to reduce transactions and reporting presentation, simplifying external communications. 13 Align performance measures with the universal client wishes: quality, speed, flexibility & value (QSFV). (measurements) Methodologies for data evaluation Indicators Adapt environmental measurement systems to the standards of the client (carbon footprint, etc.) Communication of environmental performance: Consistent Green Marketing of: -Product: environmental claims, comparative assessment, Inclusion in BAT... - Process: Carbon footprint, declarations in energy reduction... ZeroWIN

Southampton (United Kingdom), 5th-8th July 2010 WCM (World Class Manufacturing) scheme + ZeroWIN

Southampton (United Kingdom), 5th-8th July 2010 Open discussion Zero waste thinking at the production models Test with WCM (World Class Manufacturing) Selection of a production model for ZeroWIN Project Group electronics Group building and construction Integrating the ZeroWIN vision in a production model Contributions from partners Contributions from stakeholders at Vision Conference Activities to do Expertise based inputs (GAIKER, SAT, BIOIS, CEIFA, PE, UCCA, others) First ZeroWIN production models (project month #18/60 Oct. 2010) Tuned ZeroWIN production models (project month #21/60 Jan. 2011) … Deliverable 5.1 “ZeroWIN Production Model Developed” (due on project month #24/60, Apr. 2010) Status of WP5 - Task 5.1 2/2

Southampton (United Kingdom), 5th-8th July 2010 Thank you !!! Sixto Arnaiz GAIKER Technological Centre Parque Tecnológico, Zamudio (Spain) Telephone: Fax: Internet:

Southampton (United Kingdom), 5th-8th July 2010 Others OTHERS NOT USED

Southampton (United Kingdom), 5th-8th July 2010 WP5. Zero Waste Entrepreneurship: Production Model

Southampton (United Kingdom), 5th-8th July 2010 WP5. Zero Waste Entrepreneurship: Production Model

Southampton (United Kingdom), 5th-8th July 2010 Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention Prevention practices Resource productivity Resource efficiency Energy use and GHG emissions Water use and impacts Control minor elements and toxics By-product creation Process design Input substitution Plant improvement Good housekeeping Re-use and recycling

Southampton (United Kingdom), 5th-8th July 2010 WP6: Development of Pilot Applications in industrial networks Case Studies - CS1: prototype of a D4R laptop - CS2: prototype of a D4R photovoltaic system - CS3: regional reuse network for ICT products - CS4: new buildings in Portugal - CS5: new buildings in UK - CS6: revitalization of the Deutsche Bank headquarter in Frankfurt - CS7: demolition of End-of-Life buildings in Portugal - CS8: demolition of End-of-Life buildings in UK - CS9: case study in the automotive sector

Southampton (United Kingdom), 5th-8th July 2010 WORLD CLASS MANUFACTURING - 7 Keys The 7 keys to WCM success, in no particular order, are: Reduce Lead Times (reducir tiempos de entrega?) Cut Operations Costs Speed Time-to-Market Exceed Customer Expectations Streamline Outsourcing Processes (concentrar subcontratacion?) Manage Global Operations Improve Business Performance Visibility

Southampton (United Kingdom), 5th-8th July 2010 WORLD CLASS MANUFACTURING - 4 strategies The 4 basic strategies: Total Quality Management (TQM) = zero defects Employee involvement Benchmarking TQM tools Just in time (JIT) = zero inventories Improve quality and productivity Total Productive Maintenance (TPM) = zero failures Participation of all employees Continuous improvement process (CIP) = zero obsolescence Latest advances in technology and production systems

Southampton (United Kingdom), 5th-8th July 2010 WORLD CLASS MANUFACTURING - 10 pillars The 10 pillars: Safety/hygiene and working environment Cost deployment Focussed improvement Autonomous activity Professional maintenance Quality control Early products/equipment management People development Environment Customer service

Southampton (United Kingdom), 5th-8th July 2010 PRODUCT Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention LCA Tool : Env. Impacts MATERIAL SUPPLIER: materials COMPONENT SUPPLIER: assembly RETAILER: Logistics and distribution CONSUMER Post-consumer waste Outsourcing Services MANUFACTURER RECYCLINGREUSERECOVERY CONSUMER EHAVIOUR Zero Waste Thinking (at the Production Model) LCC Tool : Cost WP2: Innovative technologies WP3: Waste prevention methods and strategies Indicators -1 Indicators -2 Waste Water Energy Prevention Downstream Design Supplier Relationships Symbiosis Recommendations RFID Protocol WASTE WP4: System tools – Analysis & Improvement REVERSE LOGISTICS Upstream

Southampton (United Kingdom), 5th-8th July 2010 Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention MATERIAL SUPPLIER: materials Internal (stocks and balances) Material Waste (phased out, out of specifications, broken, losses, rejections, scraps...) Energy per product unit Water per product unit External and bibliography (LCA) Materials Indicators Origin Quantity per product unit Energy content Toxic substances content Biodegradability Recyclability Associated process (extraction, refining) Renewable Indicators -1 Indicators -2 Waste Water Energy MATERIAL SUPPLIER: materials Internal (accounts) Raw materials to scraps and/or waste Waste management cost By-product revenue External (LCC) Material costs Transport costs ? Costs ??????

Southampton (United Kingdom), 5th-8th July 2010 Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention MATERIAL SUPPLIER: materials Internal (stocks and balances) Material Waste (phased out, out of specifications, broken, losses, rejections, scraps...) Packages (pallets, big-bags...) Internal logistics (storage, internal movements...) External and bibliography (LCA) Materials Indicators Quantity per product unit Energy content Toxic substances content Biodegradability Recyclability Associated process (extraction, refining) Renewable Indicators -1 Indicators -2 Waste Water Energy COMPONENT SUPPLIER: components assembly RETAILER: Logistics and distribution MANUFACTURING CASE STUDY Outsourcing Services Internal (stocks and balances) Rejects and scraps Energy per product unit Water per product unit Utilities (water, air, energy, steam...) Consumables: filters, spares External and bibliography (LCA) Origin Transportation mean Packaging External and bibliography (LCA) Waste management Cleaning and maintenance Security Computer Material Energy Catering Auditing

Southampton (United Kingdom), 5th-8th July 2010 Task 5.1 Development of innovative and structured production model for resource-use optimization and waste prevention MATERIAL SUPPLIER: materials COMPONENT SUPPLIER: components assembly RETAILER: Logistics and distribution MANUFACTURING CASE STUDY Outsourcing Services Internal (accounts) Raw materials to scraps and/or waste Waste management cost By-product revenue External Material Transport Energy Costs External Waste management Cleaning and maintenance Security Computer Material Energy Catering Auditing Internal Rejects and scraps Energy per product unit Water per product unit Utilities (water, air, energy, steam...) Equipment depreciation Consumables: filters, spares Personnel (life insurance, health, safety, salary, overheads...) Pollution control (water, air, soil...) External Transport Packaging