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SUSTAINABLE PRODUCT &
PROCESS DEVELOPMENT
ISQA 511 Dr. Mellie Pullman
Overview
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Design for “…”
Protocols
Herman Miller Case
Tool Demonstration
 EQFD
(QFDE)
Sustainability Product and Process
Protocols and Frameworks
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1970s & 1980s
1990s
2000s
• Pollution Control
• Pollution Prevention
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• Cradle to Cradle
• Life Cycle Analysis
• Biomimicry
Eco-Efficiency
Design for Environment
The Natural Step
Industrial Ecology
Design for…
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Manufacturing and
Assembly
Disassembly
 Recycle
 Reuse
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Logistics
Or Design for
Sustainable Supply
Chain Management
Sustainable Design & Supply Chain
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Aspects of sustainability can pervade all design
activities affecting the product during its life time:
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Social, economic, and environmental aspects of
Raw materials
 Production
 Packaging
 Transportation
 Redistribution
 Disassembly
 Recycling
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Measures (Carbon Footprint, LCA, energy, water, etc.) and
Methods (EQFD)
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Example: Ikea’s Air Hunting Competition
Glimma tea candle
Internal competition to reduce unnecessary air in their product
packaging to lower logistics cost and increase efficiency in
transportation and warehouse
Air= Packaging Space
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How does this effect:
 Transportation
 Vehicles
 Warehouse
 Environment
loads
Design for Environment Flow and
Support Tools
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DfE Project
Development*
Quantitative
design review on
sustainability
(LCA)
Production
Project Concept
Development
(QFDE Tool)
Conceptual
Design
Design Detail
Qualitative design
review on
sustainability
aspects
* Initially, a philosophy or
framework may create guiding
principles such as
C2C or Natural Step
Cradle to Cradle Philosophy
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Biological
Technical
Manufacturing
&
Assembly
plants
soil nutrients
animals
decomposes
Materials
Product
Customer Use
Environmental Quality Function
Deployment
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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)
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EQFD accounts for environmental needs and
characteristics
Why use this tool?
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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,
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Customer & environment needs, engineering metrics,
components, manufacturing process, & production process.
Proven track record of success with new product
development.
Fundamental Design Objectives
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Maximize customer satisfaction (using customer and
other stakeholders)
 What
are the customers needs for the product both
functionally and environmentally?
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Minimize cost of use
Minimize environmental impacts
Sample of Environmental Needs and
Engineering Metrics
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Environmental Needs
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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
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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
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EuP: Energy Using Products
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EU direction requires
EuPs to incorporate lifecycle-based
environmental
considerations into
product development
process
Other criteria that you
should consider?
Green Product Design for Hairdryer
Life Cycle Analysis Scope
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Disposal
at end of
life
Extracting
&
processing
raw
materials
Recycling
Manufacturing
Useful life,
maintenance &
reuse
Packaging
Transportation
&
Distribution
Voice of Customer issues
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Typical Needs (pick 3)
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Dries quickly
Quiet
Comfortable to hold
Less energy consumption
Operates easily
Reliable
Portlable
Needs related to Environment
(pick 3)
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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
Engineering Metrics
Maximum Importance
Customer Importance
Relative Weight
Visual Weight influence
Row #
Customer Needs or Requirements
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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
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0.09
3
Easy to Smash
7
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0.16
5
Easy to sort
8
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0.09
3
Easy to Recycle
Engineering Metrics for producers &
environmental view
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Hair dryer EMs(pick 3)
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Air flow
Air temperature
Weight
Hardness
Physical lifetime
Number of parts
Environmental EMs(pick 3)
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Rate of recyclable
materials
Rate of standardized
components
Number of materials
Amount of energy
consumed
Biodegrability
Toxicity of Materials
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Comfortable to Hold
9
3
Less Energy Consumption
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Easy to Dissesemble
3
1
9
Easy to Smash
1
1
9
Easy to sort
Easy to Recycle
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9
9
9
9
9
rate of recycled materials
amount of energy consumed
physical lifetime
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hardness
Quiet
number of materials
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Number of parts
Air temperature
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Weight
Air Flow
Engineering Metrics
Dries quickly
Customer Needs or Requirements
Looking at your weight-importance
scores
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What is more important measurement?
What should the producer focus on here?
Other Details of Interest
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Are any of these related factors (roof of house)?
 What
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problems or opportunities might this reveal?
Right side of house and basement, competitor’s
situation > strategic insights?