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Sustainable Product & process development

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. Design for…. Manufacturing and Assembly Disassembly Recycle

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Sustainable Product & process development

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  1. Sustainable Product & process development ISQA 511 Dr. Mellie Pullman

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

  3. Sustainability Product and Process Protocols and Frameworks

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

  5. 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)

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

  7. Air= Packaging Space • How does this effect: • Transportation loads • Vehicles • Warehouse • Environment

  8. Design for Environment Flow and Support Tools * Initially, a philosophy or framework may create guiding principles such as C2C or Natural Step

  9. Cradle to Cradle Philosophy Biological Technical

  10. 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

  11. 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.

  12. 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

  13. Sample of Environmental Needs and Engineering Metrics Environmental Needs 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 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

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

  15. Life Cycle Analysis Scope

  16. Voice of Customer issues Typical Needs (pick 3) Needs related to Environment (pick 3) • 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 Rate the importance of each on a scale of 1-5 for your 6 items

  17. Engineering Metrics for producers & environmental view Hair dryer EMs(pick 3) Environmental EMs(pick 3) • 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

  18. Looking at your weight-importance scores • What is more important measurement? • What should the producer focus on here?

  19. 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?

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