Sustainability risk identification in product development

Sustainability-related issues present significant financial, strategic, compliance and operational risks to manufacturers. Many of these risks directly or indirectly result from the way a product is designed and managed across its life cycle. Assessing sustainability risk (S _R) at the product design stage is crucial for the development of products that both minimise sustainability risk exposure and are environmentally sustainable. Managing the costs associated with these risks requires risk management intervention at the design stage before these costs are committed throughout the life cycle (production, use, end-of-life). The goal of the sustainability risk assessment (SRA) methodology is to provide an approach to comparing the financial cost of a ‘sustainable product’ vs. an ‘unsustainable product’, by factoring in the effects of S _R on life-cycle cost. The SRA methodology demonstrates that, in some cases, sustainable products cost less than unsustainable products when sustainability risk is considered in the costing analysis. This paper outlines the first step of the SRA methodology, which is a process for identifying S _R inherent in the product life cycle. Once key risks are identified, the subsequent steps of the SRA assess and prioritise these risks for treatment through changes to product design and materials composition.     

Environmental implications of planned obsolescence and product lifetime: a literature review

The aim of this paper was to explore the implications of planned obsolescence (PO) and the associated product lifetime on the environmental impact of products. To achieve this task, a literature review was performed to assess both the historical context and recent situation of planned obsolescence. A search in scholarly journals was performed to evaluate to what extent product lifetime and PO have been discussed in the recent literature. Based on the findings, selected cases of PO are discussed and trends in the practice of limiting product lifetime are identified. Factors considered to have a significant influence on product lifetime have been identified and discussed. The discussion of case studies made it possible to establish the links between product design, manufacturing and associated impacts of lifetime. The role of the actors along the value chain is also considered to propose a business scheme, where the influences of consumer behaviour and design choices are crucial. Finally, strategies to facilitate the definition of different scenarios are given. These strategies may serve to increase the reliability of environmental assessment throughout a product life cycle.     

A sustainable method for optimizing product design with trade-off between life cycle cost and environmental impact

In today’s competitive market, corporations have learned that taking sustainability issues into account can significantly improve their public image. Modern producers therefore must simultaneously reduce the environmental impact of their products and make economic gains. Therefore, making trade-offs between economic and environmental issues is required to ensure a company’s continuity. In doing so, companies have attached a great deal of importance to the new product design phase. However, optimization at the design stage becomes very complex for a product with a large number of parts, which can have several design alternatives with similar forms and functionality, but different costs and environmental impacts. In the automobile, shipbuilding and aircraft industries, if the conventional complete enumeration method is applied, the time required for selecting the optimal combination of design alternatives with respect to life cycle cost and environmental impact may exceed a human’s natural life span. To overcome this limitation, this paper introduces an optimization method for use as a design aid tool that enables a designer to assess the life cycle cost and environmental impact of his/her design very early in the product development process. To support the developed method, an illustration is provided using a case study on a locally manufactured automobile.     

Decision support for sustainable manufacturing using decision guidance query language

Sustainability has become a very significant research topic as it impacts many different manufacturing industries. Therefore, the technologies for monitoring, analysing, evaluating and optimising the sustainability performance of manufacturing processes and systems are very critical for decision makers on the shop floor. This paper introduces a decision guidance management system that provides actionable recommendations through quantitative analysis of the sustainability measures of manufacturing processes and systems based on life cycle assessment. The system determines decision preferences through dynamically collected data and decision makers' responses, taking into account the prevailing constraints. Optimal decisions can be derived using mathematical and constraint programming. By using decision guidance query language, this methodology allows users to make optimal decisions without an extensive mathematical or operations research background. Knowledge of relational databases is sufficient for a user to formulate the optimisation problem and obtain optimal solutions. The methodology is demonstrated with a machining operation case study, in which a list of sustainability metrics are identified and sustainability modelling methods are proposed. Important sustainable machining performance measures are optimised, resulting in actionable recommendations.     

Life cycle assessment part 1: framework, goal and scope definition, inventory analysis, and applications

Sustainable development requires methods and tools to measure and compare the environmental impacts of human activities for the provision of goods and services (both of which are summarized under the term "products"). Environmental impacts include those from emissions into the environment and through the consumption of resources, as well as other interventions (e.g., land use) associated with providing products that occur when extracting resources, producing materials, manufacturing the products, during consumption/use, and at the products' end-of-life (collection/sorting, reuse, recycling, waste disposal). These emissions and consumptions contribute to a wide range of impacts, such as climate change, stratospheric ozone depletion, tropospheric ozone (smog) creation, eutrophication, acidification, toxicological stress on human health and ecosystems, the depletion of resources, water use, land use, and noise-among others. A clear need, therefore, exists to be proactive and to provide complimentary insights, apart from current regulatory practices, to help reduce such impacts. Practitioners and researchers from many domains come together in life cycle assessment (LCA) to calculate indicators of the aforementioned potential environmental impacts that are linked to products-supporting the identification of opportunities for pollution prevention and reductions in resource consumption while taking the entire product life cycle into consideration. This paper, part 1 in a series of two, introduces the LCA framework and procedure, outlines how to define and model a product's life cycle, and provides an overview of available methods and tools for tabulating and compiling associated emissions and resource consumption data in a life cycle inventory (LCI). It also discusses the application of LCA in industry and policy making. The second paper, by Pennington et al. (Environ. Int. 2003, in press), highlights the key features, summarises available approaches, and outlines the key challenges of assessing the aforementioned inventory data in terms of contributions to environmental impacts (life cycle impact assessment, LCIA).     

Life cycle assessment part 2: current impact assessment practice

Providing our society with goods and services contributes to a wide range of environmental impacts. Waste generation, emissions and the consumption of resources occur at many stages in a product's life cycle-from raw material extraction, energy acquisition, production and manufacturing, use, reuse, recycling, through to ultimate disposal. These all contribute to impacts such as climate change, stratospheric ozone depletion, photooxidant formation (smog), eutrophication, acidification, toxicological stress on human health and ecosystems, the depletion of resources and noise-among others. The need exists to address these product-related contributions more holistically and in an integrated manner, providing complimentary insights to those of regulatory/process-oriented methodologies. A previous article (Part 1, Rebitzer et al., 2004) outlined how to define and model a product's life cycle in current practice, as well as the methods and tools that are available for compiling the associated waste, emissions and resource consumption data into a life cycle inventory. This article highlights how practitioners and researchers from many domains have come together to provide indicators for the different impacts attributable to products in the life cycle impact assessment (LCIA) phase of life cycle assessment (LCA).     

A hybrid approach using AHP–TOPSIS–entropy methods for sustainable ranking of structural materials

Nowadays, many countries are looking towards sustainability as a goal because our world has limited resources and serious environmental impacts. In the construction industry, the process of sustainable selection of structural material is considered one of the keys to achieve more sustainable construction. In this paper, the theories of decision making are utilised to develop an approach for evaluation and ranking the structural materials over their total life based on sustainability criteria using multi-attribute decision-making methods. One of them is Analytical Hierarchy Process which is utilised to build the problem hierarchical structure and assign weights of the predetermined sustainable factors. The other is Technique for Order Preference by Similarity to the Ideal Solution which is utilised to rank the structural materials within both each material life cycle phase and the complete material life cycle phases. The third is the concept of entropy by Shannon to evaluate the weight factor for each phase of material life cycle. The proposed approach presents an objective, systematic and comprehensive method for the sustainable ranking of materials that links between the structural element design and the sustainable selection of materials.     

A Graph Theory approach to measure the performance of sustainability enablers in a manufacturing organization

In a manufacturing organization, the term sustainability deals with the impact of production process and products on the environment and society, laying emphasis on preservation of scarce resources. In this article, the study concentrates on developing a Graph Theory model to measure the performance and inter-relationship between the sustainability enablers in an organization, thereby to quantitatively measure the extent to which ‘sustainable manufacturing’ practices are being followed in the organization. The objective of this study was to identify a set of sustainability enablers and attributes that impact a manufacturing organization. Digraphs were developed for the whole system and sub-systems depicting the inter-relationships and dependencies between various enablers and attributes to interpret the performance of the sustainability enablers in the case organization. Using the best case and worst case values, the level of sustainable manufacturing practices of the organization was found by Comprehensive Assessment Index. Based on the best case values, the relative significance of individual sustainability enablers are found and compared with worst case situations. The impacts of individual enablers on the overall sustainability level of the organization were also studied.     

Potential release scenarios for carbon nanotubes used in composites

The expected widespread use of carbon nanotube (CNT)-composites in consumer products calls for an assessment of the possible release and exposure to workers, consumers and the environment. Release of CNTs may occur at all steps in the life cycle of products, but to date only limited information is available about release of CNTs from actual products and articles. As a starting point for exposure assessment, exploring sources and pathways of release helps to identify relevant applications and situations where the environment and especially humans may encounter releases of CNTs. It is the aim of this review to identify various potential release scenarios for CNTs used in polymers and identify the greatest likelihood of release at the various stages throughout the life-cycle of the product. The available information on release of CNTs from products and articles is reviewed in a first part. In a second part nine relevant release scenarios are described in detail: injection molding, manufacturing, sports equipment, electronics, windmill blades, fuel system components, tires, textiles, incineration, and landfills. Release from products can potentially occur by two pathways; (a) where free CNTs are released directly, or more frequently (b) where the initial release is a particle with CNTs embedded in the matrix, potentially followed by the subsequent release of CNTs from the matrix.The potential for release during manufacturing exists for all scenarios, however, this is also the situation when exposure can be best controlled. For most of the other life cycle stages and their corresponding release scenarios, potential release of CNTs can be considered to be low, but it cannot be excluded totally. Direct release to the environment is also considered to be very low for most scenarios except for the use of CNTs in tires where significant abrasion during use and release into the environment would occur. Also the possible future use of CNTs in textiles could result in consumer exposure. A possibility for significant release also exists during recycling operations when the polymers containing CNTs are handled together with other polymers and mainly occupational users would be exposed.It can be concluded that in general, significant release of CNTs from products and articles is unlikely except in manufacturing and subsequent processing, tires, recycling, and potentially in textiles. However except for high energy machining processes, most likely the resulting exposure for these scenarios will be low and to a non-pristine form of CNTs. Actual exposure studies, which quantify the amount of material released should be conducted to provide further evidence for this conclusion.     

A design for EoL approach and metrics to favour closed-loop scenarios for products

Recently, environmentally conscious design and extended producer responsibility have become key aspects for companies that need to develop products that are sustainable along their whole life cycle. Design for End of Life (EoL) is a strategy that aims to reduce landfill waste through the implementation of closed-loop product life cycles. It is important to consider disassembly and EoL scenario management as early as the design phase. For these reasons, this paper presents an approach to help designers in the evaluation and subsequent improvement in product EoL performance. The method is based on four innovative EoL indices that compare different EoL scenarios for each product component. In this way, the designer can modify the product structure or the liaisons to maximise the reuse and remanufacture of components as well as material recycling. The presented case studies confirm the validity of the approach in helping designers during the redesign phase of goods and products to reduce the quantity of materials and industrial wastes sent to landfill.     

Social metrics in the process industry: background,theory and development work

Sustainable development as the leading global development paradigm and sustainability as a cornerstone of modern industrial development have guided this development work on social metrics in the process industry. This study addresses the development of social metrics in the process industry and for metal production, in particular, at the plant level. The developed social indicators are one part of the overall sustainability index that aims to present a balanced and holistic view of plant-level sustainability performance, encompassing information on all different dimensions. This development work was preceded by the benchmarking and review of existing global reporting frameworks, initiatives and the literature. Current indicators of industrial sustainability mainly satisfy the needs of corporate-level management and capital investors. Therefore, plant-level indicators are critically needed to support and fill potential gaps in corporate-level assessments and management with a special emphasis on plant-level sustainability. The purpose of our development work for social indicators was to operationalise the concept of sustainability and associated performance measurement at the plant level. The development of social indicators was carried out through workshops with industry partners. As a joint effort, eight core social indicators and their associated sub-indicators were developed. We also report the results of our benchmarking and review of existing frameworks, initiatives and the literature. The social part of the overall sustainability index provides the information on both in-plant sustainability performance and the direct and indirect impacts of plant-level operations on the surrounding society including various stakeholders, interest groups and citizens.     

An integrated approach for the benchmarking of production facilities’ environmental performance: data envelopment analysis and life cycle assessment

Environmental impacts have become an important consideration in the manufacturing industry due to increasing public pressure for environment protection and the requirements of recently launched legislations. Data envelopment analysis (DEA) is a widely adopted methodological approach for the benchmarking of the relative efficiency of different production units. Changes in production efficiency may affect environmental impacts. DEA can be used for identifying the most efficient production facility and hence, the environmental impacts generated from the different production lines can then be benchmarked. Life cycle assessment (LCA) is carried out to quantify the full environmental impacts of a product from ‘cradle to grave’. The integration of LCA with DEA, efficiency and environmental impact of different production processes for a certain family of products can be evaluated and benchmarked. The proposed two-stage approach can help to reduce the aggregate environmental impacts of the manufacturing phase and is used to benchmark the environmental performance of several production lines in a manufacturing company.     

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.     

Impact of incorporating customer preference in sustainable remanufacturing of commercial returns

This paper investigates optimum production parameters for a reverse supply chain for manufacturing of primary products and remanufacturing of commercial returns (products returned by customers for refund or exchange). The market for the product consists of two categories, the primary and remanufactured products. The demands for these markets are independent and considered to be random variables following a normal distribution function. The approach presented in this work differs from many previously published works because the acceptability of products varies among customers. The interaction between the designed quality and variable customers’ preferences determines the likelihood of a product being returned. Two major decision variables targeted in this study are the production cycle time and the targeted quality for production of parts used in the product. Through an analytical formulation and numerical examples, a relationship between the total profit of the system and the two decision variables is developed and optimised. The analysis demonstrates that the total profit of the hybrid system could be increased significantly by targeting the optimum targeted (not necessarily the highest) values for quality of parts and the optimum cycle length. And this objective could be accomplished with significant gain with respect to sustainability and waste reduction.     

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.     

Social sustainability performance indicators – experiences from process industry

Sustainable industrial development can be advanced through the development and application of sustainability metrics. This study addressed the application of social sustainability metrics to the measurement of sustainability performance within process industry and to metal production at the plant level in particular. The applied social sustainability indicators are one part of the overall sustainability index which aims at presenting a balanced and holistic view of plant-level sustainability performance. Application of plant-level indicators can support informed decision-making and fill in potential gaps in corporate-level assessments and reporting initiatives with respect to plant-level social sustainability performance. The social part of the overall index provides information on both in-plant sustainability performance and on the direct and in-direct impacts of plant operations on the surrounding society with special emphasis on the supply chain and emerging social due diligence aspects. The results of pilot implementation of social indicators in Ruukki Lappohja plant indicated a very high level of social sustainability performance with minor areas of improvement such as social risk management auditing covering the whole supply chain, suppliers communication on social responsibility requirements to workers and sub-suppliers, signing of the code of conduct by employees and reporting on policies on local community relations, safety in supply chain covering suppliers and contractors and factory health and safety performance in relation to average field of industry performance in this field.     

Sustainability indicators for clean development mechanism projects in Vietnam

The Clean Development Mechanism (CDM) is one of the flexible instruments of the Kyoto Protocol designed to combat climate change so as to bring advantages to developing countries and developed countries alike. Indeed, CDM projects have a two-fold objective: to offset greenhouse gas emissions and to contribute to sustainable development in the host country. However in many cases, the latter objective appears to be marginalized. This is at least partly due to the difficulties surrounding the definition and the measurement of sustainability, in particular in a developing country context. To assess CDM projects’ contribution to sustainable development in the host country, scholars and practitioners need adapted indicator sets. A set of indicators were developed by way of an iterative Delphi approach amongst selected Vietnamese experts. The Delphi approach allowed a systematic collection of the experts’ judgements on the sustainability indicators through a set of sequentially applied questionnaires, interspersed with feedback from earlier responses. This exercise resulted in the selection of a set of 36 indicators, which emphasise economic efficiency, public health and pollution issues. The exercise yielded a locally supported and context-specific set of sustainability indicators that will allow Vietnamese decision-makers to enhance the sustainability of the approved CDM projects. In the future this set should be continually improved through real-life application and further participation from local stakeholders. This study is a first step in a long-term process towards developing an adapted toolkit for sustainability assessment of CDM projects in Vietnam.     

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.     

Performance evaluation of lean sustainable systems using adaptive neuro fuzzy inference system: a case study

The modern manufacturing organisations have been adopting both lean and sustainable manufacturing paradigms to survive in the competitive environment. Lean and sustainable strategies aim at achieving productivity improvement by streamlined processes and waste elimination. The performance of such integrated lean sustainable system has to be assessed to ensure whether the strategic objectives are in line with customer value and to identify improvement opportunities that enable and enhance the competitive advantage of an integrated lean sustainable system. This paper presents the formulation of conceptual performance evaluation model to assess lean sustainable systems. Appropriate performance indicators have been identified and adaptive neuro fuzzy inference system approach is used to evaluate lean sustainability. A case of automotive component manufacturing firm in Indian scenario is exemplified. Based on the evaluation, lean sustainability index was computed and the firm was found to be ‘Averagely Lean Sustainable’. Further improvement actions to enhance the lean sustainable performance were planned and implemented. The developed performance evaluation model is capable of effectively evaluating the lean sustainable performance of manufacturing firms and has more practical relevance.     

Societal implications of nanotechnology: occupational perspectives

Nanotechnology-infused products have begun to enter the market in spite of the fact that many sectors of society are still debating whether or not exposure to such products will result in detrimental side effects. Due to a lack of regulation of nanoproducts, it is difficult to track these products to assess how they interact with humans and the environment. Acknowledging this limitation, several studies are starting to investigate situations where individuals are exposed to nanoparticles in the workplace; it is to be noted that manufacturing of materials is the first stage in the product life cycle where exposure may occur. This paper reviews and discusses the potential societal implications associated with the manufacturing of nanoparticles: health concerns, workers’ perceptions, rights, ethics, and the role of policy and regulation. Scenarios are presented, possible implications are discussed, and recommendations are given for appropriate action. Finding the right solution to the identified implications represents a critical challenge. In summary, it is imperative that all stakeholders including industry, academia, government entities, and the public adopt a proactive attitude to ensure that nanotechnology matures in a sustainable manner.