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SUSTAINABLE PRODUCT & PROCESS DEVELOPMENT

ISQA 511 Dr. Mellie Pullman

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Overview

Design for “…” Protocols Herman Miller

Case Tool

Demonstration EQFD (QFDE)

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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

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Design for…

Manufacturing and Assembly

Disassembly Recycle Reuse

Logistics Or Design for

Sustainable Supply Chain Management

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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)

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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 CompetitionGlimma tea candle

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Air= Packaging Space

How does this effect: Transportation loads Vehicles Warehouse Environment

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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

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Cradle to Cradle Philosophy

Biological

plants

animals

decomposes

soil nutrients

Technical

Manufacturing &Assembly

Product

Customer Use

Materials

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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

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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.

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Fundamental Design Objectives 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

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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

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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

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Life Cycle Analysis ScopeExtracti

ng & processing raw

materials

Manufacturing

Packaging

Transportation &

Distribution

Useful life, maintenance & reuse

Recycling

Disposal at end of life

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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

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Row #

Visual Weight

influence

Relativ

e Weigh

t

Custome

r Importance

Maximum Importanc

e

 

Engineering

Metrics

 

Customer Needs or Requirements

 

 1 ||||||| 0.16 5 5 Dries quickly

 2 |||||| 0.13 4   Quiet

 3 |||||| 0.13 4   Comfortable to Hold

 4 |||| 0.09 3   Less Energy Consumption

 5 ||||||| 0.16 5   Easy to Dissesemble

  6 |||| 0.09 3   Easy to Smash

  7 ||||||| 0.16 5   Easy to sort

  8 |||| 0.09 3   Easy to Recycle

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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)

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Engineering Metric

s

Air Flow

Air temperature

Weight

Number of

parts

number of

material

s

hardness

physical lifetime

amount of

energy

consume

d

rate of

recycled material

s

Customer Needs or Requirements

 

Dries quickly 9 9           9  

Quiet 9             9  

Comfortable to Hold     9       3    

Less Energy Consumption 9 9           9  

Easy to Dissesemble 3   1 9 9        

Easy to Smash 1   1 9   9      

Easy to sort                  

Easy to Recycle                  

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Looking at your weight-importance scores

What is more important measurement? What should the producer focus on here?

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Other Details of Interest

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?