Design for environment as a tool for the development of a sustainable supply chain

In this work, design for environment (DfE) methodologies have been used as a tool for the development of a more sustainable supply chain. In particular by combining life‐cycle assessment (LCA) techniques and by using the quality function deployment (QFD) multi‐criteria matrices, an ‘environmental compromise’ can be reached. In this work, the QFD matrices have been developed in a new way using an iterative process that involves the whole supply chain starting from the product life‐cycle, taking into consideration the machines that make the product and their components. This methodology is compatible with the requirements of the various stakeholders, suppliers, manufacturers and clients, involved in the supply chain. To assess the validity of the proposed approach a specific supply chain was studied concerning packaging systems for liquid food substances (beverage cartons). Firstly all the stages which are most critical from the environmental point of view in the supply chain of packaging systems were identified and assessed. The starting point for the analysis of environmental aspects and impacts which characterise the supply chain was LCA, which proved to be useful for the identification and the environmental assessment of the various stages in a packaging system. Through the use of ‘iterative QFD’ it is possible to arrive at a definition of the engineering characteristics of all the machinery which is involved in the supply chain. In particular in this work the authors have tried to identify the critical points in the design of those machines which either make the beverage cartons or are involved in the filling process.     

Life cycle sustainability assessments (LCSA) of four disposal scenarios for used polyethylene terephthalate (PET) bottles in Mauritius

Improper disposal of post-consumer Polythylene Terephthalate (PET) bottles constitutes an eyesore to the environmental landscape and gives rise to numerous environmental and health-related nuisances. These problems impact negatively on the flourishing tourism industry in Mauritius. The present study was therefore undertaken to determine a sustainable disposal method among four selected disposal alternatives of post-consumer PET bottles in Mauritius. The disposal scenarios investigated were: 100 % landfilling (scenario 1); 75 % incineration with energy recovery and 25 % landfilling (scenario 2); 40 % flake production (partial recycling) and 60 % landfilling (scenario 3); and 75 % flake production and 25 % landfilling (scenario 4). Environmental impacts of the disposal alternatives were determined using ISO standardized life cycle assessment (LCA) and the SimaPro 7.1 software. Cost-effectiveness was determined using Life cycle costing (LCC) as described by the recent Code of Practice on LCC. An excel-based model was constructed to calculate the various costs. Social impacts were evaluated using Social Life Cycle Assessment (S-LCA) based on the UNEP/SETAC Guidelines for Social Life Cycle Assessment. For this purpose, a new and simple social life cycle impact assessment method was developed for aggregating inventory results. Finally, Life Cycle Sustainability Assessment (LCSA) was conducted to conclude the sustainable disposal route of post-consumer PET bottles in Mauritius. The methodology proposed to work out LCSA was to combine the three assessment tools: LCA, LCC and S-LCA using the Analytical Hierarchy Process. The results indicated that scenario 4 was the sustainable disposal method of post-consumer PET bottles. Scenario 1 was found to be the worst scenario.     

An economic-environmental analysis of selected barrier-coating materials used in packaging food products: a Swedish case study

The purpose of a barrier coating in food packaging is primarily to increase the shelf life of the foodstuff contained within the packaging, preserve its colour, odour, taste and quality, and thereby reduce food wastage (both at retail outlets and households). While most publications hitherto have compared packaging and barrier-coating materials on the basis of their environmental impacts alone, this paper adopts a more holistic approach by factoring in the economic aspect as well. Four barrier material alternatives—starch, polyethylene, EVOH + kaolin and latex + kaolin are analysed. Two well-defined end-of-life handling scenarios, relevant to Sweden, are: one in which everything except starch is recycled, with starch being composted, and the other in which everything is incinerated. Among the several environmental impact categories which can be analysed, this paper considers only global warming. Two approaches are tested to combine the economic and environmental aspects—normalisation, weighting and aggregating on the one hand, and using the carbon tax to internalise the externality caused by GHG emissions on the other. For the set of weighting factors obtained thanks to a survey conducted by the authors (40.6% for environmental and 59.4% for economic), starch emerges as the most sustainable alternative, followed by polyethylene for both the end-of-life handling scenarios. This tallies with the result obtained by using the carbon tax for internalisation of the externality. The case study, methodology and results presented in this paper, will hopefully be a springboard for more detailed studies of this nature, under the umbrella of sustainability.     

The environmental potential of reuse: an application to used books

Reuse is generally considered to have environmental benefits, but it has not yet been widely adopted in environmental policy or strategy. In this paper, a simple model of second-hand markets is explored with a case study of used books that illustrates the behavior of the model and shows that such a model is consistent with the data. Three questions of the dynamics of reuse are addressed: (1) If it becomes easier to buy and sell used goods (via Internet markets or other means), by how much will sales of used goods increase? (2) When sales of used goods increase, by how much will sales of new goods decrease? (3) When is reuse better than recycling? Expanding from the case study, the model is used to examine how reuse affects the consumption of new goods, and the relative merits of reuse versus recycling. When the used goods market is small, the ratio of the price of used and new goods, an observable quantity, is approximately equal to the fractional decrease in sales of new goods that will result from increased sales of used goods. A formulation of the environmental impact of reuse and recycling is developed that includes the market impact of reuse. Illustrating this formulation for books with a simplified analysis, reuse of books through sales in a second-hand market is estimated to save more than twice as much energy, with considerable uncertainty, than making books from recycled paper. The formulation provides a basis for identifying products and markets for which reuse can be an effective environmental strategy.     

Integration of DFE and DFMA for the sustainable development of an automotive component

The recent developments in manufacturing organizations recognize sustainability as an important value addition for survival in the competitive scenario. The design engineers are in search of approaches for creating environmental conscious products. The purpose of this paper is to report a research carried out for ensuring sustainable product design by the integration of Design for Environment (DFE) and Design for Manufacture and Assembly (DFMA) methodologies. In this context, this paper reports a case study carried out in an automotive component. The candidate product is the charge alternator pulley. The existing pulley has been created using Computer Aided Design. Then sustainability analysis was conducted on the existing component for determining environmental impact. This is followed by the engineering analysis of the component using ANSYS. Then conceptual design changes were developed in the proposed product using DFMA concept. Then the environmental impact has been evaluated in terms of carbon footprint, energy consumption and air/water impacts on proposed product. It has been found that the optimized pulley design possesses minimal environmental impact. The result of the case study indicated that the integration of DFE and DFMA concept could initiate new developments in sustainable designs with minimal impact to the environment and it also reduces the product cost.     

Environmental and economic benefit of recycling model of packaging waste: a case study on aluminum

Abstract

In order to achieve sustainable utilization of natural resources, save energy and protect environment and ecosystem, it is important for a region or a nation to develop and implement a viable waste recycling model from both theoretical and practical point of view. Some packaging recycling models operated in developed countries are introduced in this article. Aluminium can recovery and recycling is emphasized. Cost effective, economic and environmental benefit of different models are compared and analyzed. The result shows that all recycling models have their characteristics due to the initial purpose of recovery and the situation of the implementing country. However, all the models contribute to the reduction of municipal solid waste disposal and resources conservation.     

Selection of green product design scheme based on multi-attribute decision-making method

The function, cost and environmental performance are the primary decision-making factors for scheme selection in green design. For the comprehensive and accurate decision-making in selecting green product design scheme, a quantitative analysis method of multi-attribute decision-making (MADM) is presented. With analysing the multi-attribute of scheme selection, the MADM model is established, which takes environmental impact of materials, disassembly performance, recycling performance, energy efficiency, noise, pollutants to environmental and functional values. Fuzzy technique for order performance by similarity to ideal solution method is applied to solve this model for the feasible solutions. Finally, a case study is given to validate the application of this methodology as a useful design guideline for scheme selection in green design.     

Environmental and economic benefit of recycling model of packaging waste:a case study on aluminum

In order to achieve sustainable utilization of natural resources, save energy and protect environment and ecosystem, it is important for a region or a nation to develop and implement a viable waste recycling model from both theoretical and practical point of view. Some packaging recycling models operated in developed countries are introduced in this article. Aluminium can recovery and recycling is emphasized. Cost effective, economic and environmental benefit of different models are compared and analyzed. The result shows that all recycling models have their characteristics due to the initial purpose of recovery and the situation of the implementing country. However, all the models contribute to the reduction of municipal solid waste disposal and resources conservation.     

Fibre reinforced polymers in the sports industry – Life Cycle Engineering methodology applied to a snowboard using anisotropic layer design

Technological development has had huge impacts in sports performance throughout the years, fostering the development of specific materials and manufacturing processes for sports-related products. Within this context, a new technology for snowboards was developed taking advantage of the internal coupling effects of Fibre Reinforced Plastics (FRP) using an anisotropic layer design. This work deals with the technical, economic and environmental evaluation of a snowboard made of three alternative materials, namely carbon, glass and flax fibre reinforced plastics. It shows how a life cycle analysis can support the design and development of products by applying a Life Cycle Engineering methodology to the design process of a snowboard using an innovative technology. In this case, both the material choice and the fiber placement angles have a significant impact on the stiffness of the resulting FRP and thus in the three dimensions of analysis - cost, environmental and technical. The natural fiber is the most sustainable option environmentally, the glass fiber is the best one economically and the carbon fibre is the best in terms of technical performance. Therefore, the importance attributed to each dimension of analysis is pondered and traded-off to allow an aggregated analysis of the alternatives and a well-informed decision-making.     

Integration & assessment of recycling into c-Si photovoltaic module’s life cycle

Photovoltaic (PV) energy generation devices have experienced a vigorous growth in production over the last decade in all major industrialised countries. In this research paper, the assessment of recycling and subsequent production of new crystalline silicon (c-Si) PV modules taking advantage of the recovered Si in terms of industrial symbiosis is being examined. With the aid of life cycle analysis method, the potential payback is thoroughly examined through a scenario application in the second useful phase of the PV module. Furthermore, key environmental performance indicators have been implemented in order to evaluate power and resource demands.     

The Role of Organizational Perception,Perceived Consumer Effectiveness and Self-efficacy in Recycling Advocacy Advertising Effectiveness

Previous academic research into how consumers evaluate advocacy advertising identified many possible paths involving potentially reflexive effects on how people perceive an advocacy advertising sponsor, the advocated issue and themselves. This paper has examined one possible scenario within this complicated phenomenon: that of advertising advocating a specific environmental consumer action, recycling. In the specific context of this study, structural equation modelling demonstrated clear causal relationships among consumer perceptions of the recycling advertisements’ sponsoring organization, consumer self-efficacy and perceived consumer effectiveness of complying with the advocated issue (recycling behaviour). These factors were shown to impact specific advocacy advertising goals (termed message effectiveness in this study) such as behavioural intention toward the advocated recycling issue and perceived changes in how consumers evaluate the sponsoring organization.     

CAD and DFM: enablers of sustainable product design

Sustainability has been regarded as an important concept for survival in the contemporary scenario. Modern design engineers are in need of approaches for creating sustainable products. In this context, this paper reports a case study carried out in an Indian modular switches manufacturing organisation. The existing handle of the switch has been modelled using computer-aided design (CAD). Then, the sustainability analysis has been carried out for determining the environmental impact. This is followed by the redesign of the handle using design for manufacturability (DFM) principles. The sustainability has been measured in terms of carbon footprint, energy consumption and air–water impacts. It has been found that the redesigned handle possesses minimal environmental impact. It could be inferred from the results of the case study that CAD and DFM could lead to the development of sustainable product design with minimal impact on the environment.     

Construction of an optimum system design method considering product lifecycle

This paper proposes an optimum system design method that especially considers product lifecycles and aims to help designers make effective decisions during the product design phase. By considering and estimating all lifecycle factors of cost and environmental impact in addition to the product performance, this method facilitates development of optimum design solutions that incorporate requirements pertaining to the product's entire lifecycle. Furthermore, quantitative estimation of lifecycle factors enables the numerical expression of optimum solutions, rather than depending primarily on experiment and designer intuition. To demonstrate the effectiveness of the proposed method, this paper develops an optimum system design method for a milling machine as an example of a machine product designed for long term use. The lifecycle cost and the lifecycle environmental impact are generally expressed as the summation of each value during manufacturing phase, usage phase, disposal phase and recycling phase. In this example model, Eco-indicator 99 is used to evaluate environmental impact. In the proposed lifecycle design optimisation method, the relationships among the product performance, the lifecycle cost and the lifecycle environmental impact are evaluated as a multi-objective optimisation problem. Analysis of the obtained Pareto optimum solution sets subsequently enables designers to pursue breakthrough product design solutions.     

Implementation of a software platform to support an eco-design methodology within a manufacturing firm

The paper aims to explore the implementation of an eco-design methodology and the related software platform (G.EN.ESI – Green ENgineering dESIgn) within technical departments of a manufacturing firm. The G.EN.ESI eco-design methodology is based on the life cycle thinking concept and the software platform is conceived as a set of inter-operable software tools able to efficiently exchange data among them and with the traditional design systems (i.e. CAD, PDM and PLM). A multinational company, designing and producing household appliances, adopted the proposed methodology and related software platform for redesigning two cooker hood models with the aim to improve their environmental performances. Design and engineering departments evaluated the methodology and platform impact on the product development process, as well as the platform inter-operability with traditional design tools. The results indicate that methodology and software platform satisfy the requirements of the enterprise in terms of: (i) degree of expertise and training requirement on this subject, (ii) low impact in a consolidated design process and, (ii) good level of inter-operability among heterogeneous tools. However, the testing results highlight the necessity of a further platform optimisations in terms of software integration (single workbench made by integrated software tools with the same graphical user interface).     

Accounting for carbon stocks in models of land-use change: an application to Southern Yucatan

To assess the impact of land-use change on carbon stocks, we apply a new methodology, linking ecological and economic modeling, to southern Yucatan, Mexico. A spatial econometric multinomial logit model of ten land-cover classes is estimated (four primary forest categories, three secondary growth categories, an invasive species, and two agricultural land-cover categories), using satellite data on land cover, linked with census socioeconomic data and other biophysical spatial data from 2000. The analysis is novel in that it is the first attempt to link detailed satellite data on land use, with on-the-ground estimates of carbon stocks in a spatial econometric model of land use. The estimated multinomial logit model is then used with two scenarios of future economic growth (“low growth” and “high growth” changes in population, agricultural land use, market access, and education levels) in the region to predict land-cover changes resulting from the economic growth. The per hectare carbon (C) stocks in each land-cover class are derived from previously published estimates of biomass from field sampling across the study region. We consider aboveground-only, aboveground plus soil, transient and non-transient pools of carbon. These estimates are scaled up to the total area in each class according to the predictions of the model baseline and the two development scenarios. Subsequently, the changes in carbon stocks resulting from the predicted land-cover changes are calculated. Under the low growth scenario, carbon stocks declined by 5%; under the high growth scenario, losses were 12%. Including soil C, the proportional losses were lower, but the absolute amount lost was more than double (to 6 Tg C under the low and almost 15 Tg C under the high-growth scenario). This methodology could be further developed for applications in global change policy, such as payments for environmental services (PES) or reduction in emissions from deforestation and degradation (REDD).     

Ecological and economical assessment of end‐of‐life waste recycling in the electrical and electronic recovery sector

Technological innovation and shorter product life cycles of electrical and electronic equipment coupled with their rapidly growing applications have resulted in the generation of an enormous amount of waste from electrical and electronic equipment (WEEE). To address the potential environmental problems that could stem from improper end‐of‐life management of WEEE, many countries have drafted national legislation to improve the reuse, remanufacture and material recycling from WEEE, and to reduce the amount of such waste going to landfills. With the introduction of such legislation comes an increased need for the recovery operators to evaluate the recycling costs and environmental benefits of reclaimed products and materials in order to select the most appropriate end‐of‐life options for individual products in WEEE. This paper presents a systematic methodology for ecological and economical assessment to provide a holistic understanding of the impacts associated with different end‐of‐life options for such waste. This assessment, in addition to providing decision‐support for the selection of the best possible end‐of‐life option for a particular product in WEEE, could also generate vital information to support the design and material selection processes during the initial product development activities. The assertion made is that the detailed considerations of the ecological and economical impacts associated with different end‐of‐life options will significantly improve the recovery and recycling of WEEE.     

Life cycle assessment of second generation (2G) and third generation (3G) mobile phone networks

The environmental performance of presently operated GSM and UMTS networks was analysed concentrating on the environmental effects of the End-of-Life (EOL) phase using the Life Cycle Assessment (LCA) method. The study was performed based on comprehensive life cycle inventory and life cycle modelling. The environmental effects were quantified using the IMPACT2002+ method. Based on technological forecasts, the environmental effects of forthcoming mobile telephone networks were approximated. The results indicate that a parallel operation of GSM and UMTS networks is environmentally detrimental and the transition phase should be kept as short as possible. The use phase (i.e. the operation) of the radio network components account for a large fraction of the total environmental impact. In particular, there is a need to lower the energy consumption of those network components. Seen in relation to each other, UMTS networks provide an environmentally more efficient mobile communication technology than GSM networks. In assessing the EOL phase, recycling the electronic scrap of mobile phone networks was shown to have clear environmental benefits. Under the present conditions, material recycling could help lower the environmental impact of the production phase by up to 50%.     

Sustainable design of sprocket using CAD and Design Optimisation

The contemporary manufacturing organisations recognise sustainability as a vital concept for survival in the competitive scenario. The modern design engineers are in need of approaches for creating environmentally friendlier products. In this context, this project reports a case study carried out in an Indian sprocket manufacturing organisation. The existing sprocket has been created using Computer Aided Design (CAD). Then, the sustainability analysis has been performed for determining the environmental impact. This is followed by the optimisation of sprocket design using Design Optimisation. The environmental impact has been measured in terms of carbon footprint, energy consumption and air/water impacts. It has been found that the optimised sprocket design possess minimal environmental impact. The results of the case study indicated that CAD and Design Optimisation could lead to the development of sustainable design with minimal impact to the environment.     

Economic and environmental value stream map (E2VSM) simulation for multi-product manufacturing systems

Value stream mapping (VSM) is a well-accepted tool within lean manufacturing concept which is often used for analysing and designing the flow of materials and information required to manufacture a product. However, the analysis is static and single product oriented, which fails to cope with either the variation of production plan or a multi-product environment. In addition, the environmental impact of a manufacturing system is highly associated with the dynamic consumption of energy and resources. Despite the recent integration of VSM with simulation or environmental studies (in the domain of energy efficiency), still neglected is the dynamic assessment of all the resources involved in a multi-product production environment. This paper presents a methodology for modelling multi-product manufacturing systems with dynamic material, energy and information flows with the aim to generate economic and environmental value stream maps (E²VSM). The proposed methodology is validated with an industrial case.     

Sustainable product design using CAD: a case study in an Indian rotary switches manufacturing organisation

Sustainability is gaining importance in contemporary manufacturing organisations. Modern design engineers need approaches for creating environmentally friendly products. In this context, this paper reports a case study carried out in an Indian rotary switches manufacturing organisation. A component of the rotary switch has been modelled using computer-aided design. Then, the sustainability analysis has been carried out for determining the environmental impact. The environmental impact has been measured in terms of carbon footprint, energy consumption and air/water impacts. The handle design has been modified to minimise the environmental impact. The results of this case study indicate that appropriate modifications in design could lead to the development of sustainable design with minimal environmental impact.