C1: Engineering Approaches Sustainable Manufacturing

At the Forefront: Manufacturing and Product Design Why? Energy usage, oil usage, depletes natural resources, generates by-product waste, hazardous material, genetic engineering. Beyond quality control ISO 9000 We all like new products and ones that make our life better or more convenient. Are we willing to change in terms of expectations?

Innovation is the Key Benefits of Designing for the Environment: Reduce strains on natural environment Longevity of raw materials Reduce waste to landfill

Sustainable Engineering Design for the Environment Innovation designed for the environment Sustainable Manufacturing Lean manufacturing with environmental stewardship Reduces water, energy, waste through design – usage – end of life No longer will design for recyclability but reusability

Strategies Product Design: Redesigning with the Whole Life Cycle in Mind: The Evolution of Product Design & Composition at Levi Strauss & Co. | Sustainable Brands Design for Environment: reduce environmental impacts of a product in production and end use. Less material Less energy Different product altogether Less/eliminate chemicals Durability and longevity

Designing for disassembly Designing for end of life Easily disassembled or reused

Benefits to Manufacturers Improve efficiency, not just quality control Save energy Improve product reliability Reduce hazardous waste material Eliminate waste to zero waste Lose customers if not sustainable Avoid bad press Shut out of entire markets Pressure from customers, NGO’s

Grey/Black List, No Not “A” List Grey list: countries phasing out chemicals Black list: chemicals not permitted at all Carcinogen – cancer Teratogen –birth defects Endocrine disruptor – mimics hormones Mutagen – mutates genetic code Bioaccumlative toxin – remains in body tissue Sony Playstation banned in EU due to cadmium (RoHS)

RoHS European Union’s Restriction of Hazardous Substances Directive or RoHS Effective on July 1, 2006 Restricts the use of certain materials Lead Mercury Cadmium hexavalent chromium bromine-containing flame retardants: PBB (polybrominated biphenyls) PBDE (polybrominated diphenyl ethers) -- in electrical and electronic products.

Zero Waste The quality movement created Zero Defect Thus, Zero Waste Drives innovation and efficiency It does not mean zero by-products You find markets for your unused material “Zero Waste to Landfill” for solid waste Also focus on emissions/energy/air pollution waste reduction You paid for it, don’t waste it. Sell it.

Zero Waste Strategy

Biomimicry Example Startup Calera: mimics coral to extract CO2 from industrial emissions and bubbles through sea water to manufacture cement Biomimicry Janine Benyus: 2009 speech Ask Nature - the Biomimicry Design Portal