SUSTAINABLE PRODUCT & PROCESS DEVELOPMENT ISQA 511 Dr. Mellie Pullman

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

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

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

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) and Methods (EQFD)

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

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

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

The Natural Step Approach How does the how the step or material conforms to each of the system conditions:  eliminate our contribution to the progressive buildup of substances extracted from the Earth's crust (for example, heavy metals and fossil fuels)  eliminate our contribution to the progressive buildup of chemicals and compounds produced by society (for example, dioxins, PCBs, and DDT )  eliminate our contribution to the progressive physical degradation and destruction of nature and natural processes (for example, over harvesting forests and paving over critical wildlife habitat)  eliminate our contribution to conditions that undermine people’s capacity to meet their basic human needs (for example, unsafe working conditions and not enough pay to live on).

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

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

Example QFD (Climbing Harness) * Pullman, Moore & Wardell JPIM 2002

Tutorial on

EQFD: CNs and EMs (left wall & ceiling) Column # Direction of Improvement ▼▲▼▼◇▼ Row # Weight Chart Relative Weight Customer Importance Maximum Relationship Engineering Metrics concentration of chemical biodegradable content energy consumption to handle water consumption to clean pollution/toxic quantity of chemical Customer Needs or Requirements 1 ||||||| 15%69Little or NO PPE ▽●○○●● 2 ||||||| 15%29Less Time ●○●●○▽ 3 ||||||| 15%59Easy to apply and wash ●▽●●▽▽ 4 ||||| 10%49Low Cost ▽●▽▽▽▽ 5 ||||| 10%29Low environmental impact ▽●▽▽▽○ 6 |||||||||| 20%79 No Impact on surface being treated ▽●○▽○▽ 7 |||||||||||| 25%89Removes Moss completely ●○●●○● Relationships Positive ● Neutral ○ Negative ▽ Direction of Improvement Maximize ▲ Target ◇ Minimize ▼

Roof: EM Correlations + + − + + − + + − − Column # Direction of Improvement ▼▲▼▼◇▼ Engineering Metrics concentration of chemical biodegradable content energy consumption to handle water consumption to clean pollution/toxic quantity of chemical Customer Needs or Requirements Little or NO PPE ▽●○○●● Less Time ●○●●○▽ Easy to apply and wash ●▽●●▽▽ Low Cost ▽●▽▽▽▽ Low environmental impact ▽●▽▽▽○ No Impact on surface being treated ▽●○▽○▽ Removes Moss completely ●○●●○● Correlations Positive + Negative − No Correlation

Complete EDFD With Competitors Evaluation + + − + + − + + − − Column # Direction of Improvement ▼▲▼▼◇▼ Row # Weight Chart Relative Weight Customer Importance Engineering Metrics concentration of chemical biodegradable content energy consumption to handle water consumption to clean pollution/toxic quantity of chemical Our Product Competitor #1: Product Name Row # Customer Needs or Requirements 1 ||||||| 15%6 Little or NO PPE ▽●○○●● ||||||| 15%2 Less Time ●○●●○▽ ||||||| 15%5 Easy to apply and wash ●▽●●▽▽ ||||| 10%4 Low Cost ▽●▽▽▽▽ ||||| 10%2 Low environmental impact ▽●▽▽▽○ |||||||||| 20%7 No Impact on surface being treated ▽●○▽○▽ |||||||||||| 25%8 Removes Moss completely ●○●●○● Target 1% 50% 100 kw 100 gal 5 5 gal Our Product1%8% Competitor #1: Product Name 2%0%

Customer Needs Roof Moss Remover Product Row # Weight Chart Relative Weight Customer Importance Customer Needs 1 ||||||| 15%6Little or NO PPE 2 ||||||| 15%2Less Time 3 ||||||| 15%5Easy to apply and wash 4 ||||| 10%4Low Cost 5 ||||| 10%2 Low environmental impact 6 |||||||||| 20%7 No Impact on surface being treated 7 |||||||||||| 25%8 Removes Moss completely

Engineering Metrics Roof Moss Removal Product Column # Direction of Improvement ▼▲▼▼◇▼ Engineering Metrics concentration of chemical biodegradable content energy consumption to handle water consumption to clean pollution/toxic quantity of chemical

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

Class Demonstration of EQFD  EU direction requires EuPs to incorporate life-cycle-based environmental considerations into product development process EuP: Energy Using Products Green Product Design for Mobile Phones

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

Voice of Customer issues  Cheap/quality  Lightness  Additional services & accessories  Operates safely  Operates easily  Repairable/updateable  Reliable  Aesthetic appearance  Durable  Safe Emission  Less material usage  Renewable/reusable  Resource use efficient  Harmless to living environment  Safe Disposal  More recycled Material usage  Easy to disassemble 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

Go to Template, put down your 6 and give rating of importance (1-5) where 5 is very; 1 is low.

Engineering Metrics for producers & environmental view  Development Time  Tooling cost  Energy cost  Physical lifetime  Weight  Volume  Number of parts  Number of types of material  Energy Resource (battery types and renewables)  Rate of recyclable materials  Rate of standardized components  Mass of air pollution  Mass of water pollution  Mass of soil pollutant  Mass of valuable materials  Toxicity of Materials Mobile phone EMs(pick 3)Environmental EMs(pick 3)

Go to Template, put down your 6 and looking at the CNs and EM, provide relationships between the two, then calculate the weighted importance of each EM

Looking at your weight-importance scores  What is more important, environmental EMs or phone Ems?  What should the producer focus on here?  Are any of these related factors (roof of house)?  Right side of house and basement, competitor’s situation > strategic insights?