Improvement of agility and sustainability: A case study in an Indian rotary switches manufacturing organisation

Increasing competition has been forcing the modern manufacturing organisations to adopt advanced manufacturing paradigms. Agile Manufacturing (AM) is an advanced manufacturing paradigm that enables an organisation to survive in the competitive business environment. Agility is the performance measure of AM practices. Simultaneously, modern business organisations are forced to evolve environmental friendly products. Sustainability is regarded as an important concept for survival by the modern organisations. In this context, agility and sustainability are regarded as performance measures for contemporary organisations. This paper reports a case study which has been carried out in an Indian rotary switches manufacturing organisation. The candidate product is the knob of rotary switch. Initially Computer Aided Design (CAD) has been used to digitalise the baseline model. Keeping the baseline model as reference, five new knob models have been evolved. Then the sustainability analysis has been carried out to determine the environmental impact of the knob models. The analysis results indicated that the proposed knob models possess minimal environmental impact. The conduct of case study has lead to an inference that there is a significant improvement of agility and sustainability in the design and development of knob of rotary switch.     

Product-service systems in the automotive industry: the case of micro-factory retailing

Solutions to the economic and environmental impacts of the automotive industry have largely focused on technological innovation at the level of products or processes. This paper argues that, in order to achieve sustainability, change processes must be undertaken at the functional and systemic level.The concept of product-service systems (PSS) represents a valuable opportunity to introduce such changes. PSS is predicated on new forms of product ownership, stewardship, design and producer–consumer interaction. The challenge now is to investigate ways in which the PSS concept might be introduced at the empirical level.The paper suggests that the adoption of micro-factory retailing (MFR) ideas offer a means of introducing such a system-level change in the automotive industry. MFR is based on novel approaches to vehicle design that facilitate the economic viability of small-scale localised manufacturing sites. It is argued that such an approach to vehicle production, allows the adoption of a full scale PSS at local levels. Furthermore, via aspects such as the unification of the commerce and manufacturing function, and the proximity of manufacturing and servicing sites to users, the MFR approach may also offer distinct advantages compared with prevailing visions of PSS.     

Proposal for new quantitative eco-design indicators: a first case study

Eco-design is a valuable approach in order to reduce the environmental impact associated with a product system, by introducing environmental considerations early on in its design. Different strategies are possible for the implementation of eco-design, depending on the intended goals as well as the characteristics of the products. The present work proposes a series of eco-design indicators and tests to what extent the application of these simple indicators provides a reliable indication of the reduction of environmental impact, as measured by commonly employed Life Cycle Impact Assessment (LCIA) indicators. The product chosen for the case study was a water source heat pump. Two of the newly-developed indicators were applied and compared to LCIA indicators, focussing on design for disassembly and for recycling. A good and robust correlation was found, providing support to the thesis that these simple eco-design indicators can be used as a proxy to quickly and effectively gauge the environmental improvements introduced in a product system at the design stage.     

Developing sustainable products and services

In light of increasing pressures to adopt a more sustainable approach to product design and manufacture, the requirement to develop sustainable products is one of the key challenges facing industry in the 21st century. Hence, the concept of developing sustainable products as well as services is evolving as a key element of Cleaner Production. Sustainable product development initiatives (mainly through eco-design) have been evolving for some time to support companies develop more sustainable products. Ireland has been running the highly successful Environmentally Superior Products (ESP) initiative that supports industrial companies to incorporate a more sustainable approach to the development of products and/or services. The lessons learned from the ESP and other global Sustainable Product and Service Developments in industry and research, are being used to develop a method for effective sustainable product and/or service development (SPSD) in industry. The method is designed to provide pragmatic guidance to business and industry for developing sustainable products and services as well as incorporating this approach within existing corporate strategy, cleaner production and product development systems. This method is being developed by the authors at the Environmental Policy and Management Group (EPMG), Department of Environmental Science and Technology, Imperial College London, UK in conjunction with industry and practitioners. The method provides a framework for implementing SPSD throughout the entire lifecycle of a product and/or service. It can be used to identify, assess and implement the options for optimum sustainability in the design and development of a product and/or service. This paper describes the key features of this method.     

Environmental aspects when manufacturing products mainly out of metals and/or polymers

The most fundamental aspect in the ISO 14001 standard Environmental management systems—Specification with guidance for use is to find out ways by which an organisation influences environment to a significant degree. This paper examines environmental data from companies manufacturing products mainly from metals and/or polymers. The data were collected in a uniform way by use of special guidelines. Weighting or valuation methods often used in life cycle assessments were used to quantitatively compare and rank environmental aspects. The study results suggest that, in general, the largest environmental impact in the investigated manufacturing sub-sector can be associated with product use and/or disposal phases. This in turn shows a need for more attention on environmental work on the design for environment than what the ISO 14001 standard requires. It is further suggested that weighting or valuation methods can aid in determining the significance of environmental impacts and aspects in the context of ISO 14001.     

浅析绿色制造的战略环境评价

绿色制造的战略环境评价是实现可持续发展的关键技术 ,是协调环境与社会经济发展的重要手段。它要求在绿色制造初期———绿色设计阶段就考虑整个制造过程的环境影响 ,从决策源头上控制环境污染的产生和生态环境的破坏。本文从绿色制造的广义内涵入手 ,分析了绿色制造战略环境评价的理论基础和综合集成特性 ,并提出了战略环境评价的指标体系和综合集成评价方法。     

Service Engineering: a novel engineering discipline for producers to increase value combining service and product

In order to pursue sustainability, commercial activities between the supply and demand sides must be somehow changed. In the context of eco-design, producers must need a much bigger framework than is available in current eco-design techniques. This calls for establishing a new discipline. This paper aims at proposing a novel engineering discipline for producers toward sustainable production and consumption, Service Engineering (SE). For the sake of this, the scheme of SE is first explained. Second, a methodology of modeling and designing services, and a computer-aided design tool called Service Explorer, are presented. Third, they are proved to be effective through two applications. In SE, positive and negative changes of consumers are modelled as value and cost, respectively. In addition, the model to describe a target consumer is provided for grounding the identified value. A design methodology including the identification of value with realization structures is also provided. Furthermore, SE allows designing services in parallel with products. In the application to service redesign of an existing hotel in Italy, it was demonstrated that the presented methods and tools facilitate designers adding new value like the view of outside through a window in energy-saving structure. It was also proven to deal with both products and services through generating a solution called “cash-back per non-wash” system for washing towels. The other smaller-scaled application to design of renting home appliances revealed that they support to determine a property of an adopted physical product like the size of a TV set depending on target customers’ properties effectively.     

Collaborative activity with business partners for improvement of product environmental performance using LCA

Collaborative activities with business partners have potential to improve environmental performance of product and life cycle assessment (LCA) is an essential technique to implement eco-design of product and production process. However, collection of LCA data from supply chain is a major issue for LCA practitioners. We propose a Supply Chain Collaboration Model (SCCM), which is a framework for collecting producer-specific LCA data from business partners and for promoting improvement activity of product environmental performance. We demonstrate the practicability of the SCCM using three case studies. In each case study, two or three partner companies organized a product improvement project and carried out process analysis techniques such as LCA and material flow cost accounting (MFCA). As a result, improvement activities from the economical standpoint could provide an incentive for business partners to collect LCA data, and thus the SCCM is an effective framework for eco-design.     

An integrated approach to achieving campus sustainability: assessment of the current campus environmental management practices

Universities can nowadays be regarded as ‘small cities’ due to their large size, population, and the various complex activities taking place in campuses, which have some serious direct and indirect impacts on the environment. The environmental pollution and degradation caused by universities in form of energy and material consumption via activities and operations in teaching and research, provision of support services and in residential areas could be considerably reduced by an effective choice of organizational and technical measures. Although many environmental protection measures can be seen at some universities, but a more systematic and sustainable approach to reducing the negative impacts of those activities and making the campuses more sustainable, is generally lacking. Therefore, this paper proposes a framework of a more suitable approach to achieving campus sustainability that could remedy the limitations of the current environmental management practices in universities and ensures more sustainability through the integration of three strategies, namely: university Environmental Management System (EMS); public participation and social responsibility; and promoting sustainability in teaching and research.     

Accelerating preliminary eco-innovation design for products that integrates case-based reasoning and TRIZ method

While the innovativeness and market potential of a new product is normally emphasized, its environmental impact is often neglected. Despite their ability to help designers reduce the environmental impact of products throughout their life cycle, many eco-design methods focus on the redesign of existing products, necessitating a more innovative design capacity. This work describes a novel model to accelerate the preliminary eco-innovation product design by integrating the advantages of case-based reasoning and the TRIZ method. Previous cases from a database support a novel design to satisfy functional performances under the CBR framework. The innovative principles and evolution patterns of the TRIZ method can enhance the design level of new products to achieve eco-innovation. Four eco-innovation concepts for a PC mouse demonstrate the effectiveness of the proposed model.     

Eco-design in innovation driven companies: perception, predictions and the main drivers of integration. The Spanish example

This study attempts to contribute to the scarce knowledge on how eco-design, and to broad extent sustainability, is connected to innovation driven companies. In particular, this cross sectional research verifies i) perception and knowledge of eco-design of the professionals from innovation driven companies in Spain, ii) specific eco-design strategies towards sustainability that innovation driven companies are integrating in their strategic plans and their application in the supply chain and iii) the companies’ future predictions on innovation and eco-design linkage. The methodology of this paper is based on a survey, developed defining measurable proxies for both eco-design and innovation approaches and conducted on 10,000 multidisciplinary professionals from Spanish innovation driven companies. The study shows that sustainability is a cardinal driver for innovation and that responses have specificities regarding company size, activity or respondent position. Innovation and eco-design strategies for the future aim to use materials with a lower environmental impact and to develop new concepts.     

Transitioning to sustainable production – part II: evaluation of sustainable machining technologies

This paper presents a case-study that highlights the importance of sustainable machining technologies in achieving sustainable development objectives. A technology evaluation was undertaken to understand the likely impacts of the use of technology on sustainability performance measures. The evaluation is more than an experimental method for supporting the design of technology and an instrument for supporting decision-making. It is also a tool for supporting technology policy and for encouraging its adoption and application in industry. More specifically, a sustainability evaluation of cryogenic and high pressure jet-assisted machining in comparison to conventional machining is examined. Sustainability performance measures refer to environmental impact, energy consumption, safety, personal health, waste management, and cost. The case-study refers to the machining of high-temperature Ni-alloy (Inconel 718). It is shown that tooling costs represent the major contribution to the overall production cost, which contradicts previous analyses, and that sustainable machining alternatives offer a cost-effective route to improving economic, environmental, and social performance in comparison to conventional machining.     

Environmental management accounting in Lithuania: exploratory study of current practices,opportunities and strategic intents

There is a growing consensus among the Lithuanian policy makers, practitioners and industrialists that environmental policy must move from a reactive stance to a more proactive, sustainable development approach. As a result, many companies are increasingly interested in the application of economic incentives at least as supplements or reinforcements of environmental standards.The Institute of Environmental Engineering (EU Centre of Excellence in Sustainable Industrial Development (APINI – SID)) in 1992–2003 has been involved in introduction and implementation of preventive environmental strategy in industry in Lithuania and in other countries. In Lithuania, these efforts resulted in the implementation of more than 200 cleaner production innovations in more than 150 Lithuanian companies. It should be stressed that effective plant maintenance is becoming a higher priority to plant managers. It is important to ensure cost-savings, at all levels, that include maximizing productivity and implementing energy-saving approaches. Effective and efficient maintenance are not just desirable, but fundamental to profitable business operations. Therefore, central to the environmental view of sustainable development is the concept that economic and social systems are sub-systems of the global environment.APINI's experience shows that decision-makers at the company level often fail to recognize the economic values of natural resources as assets as well as the business and financial value of good environmental performance. Therefore, there is a need to upgrade the business decision-making process by including information on material flows and related costs to account for efforts of sustainable development [Staniskis JK, Stasiskiene Z. Promotion of cleaner production investments: international experience. Journal of Cleaner Production 2002;11(6):619–28. ISSN: 0959-6526, Elsevier Science]. Decisions are increasingly affected by environmental costs. Application of environmental management accounting (EMA), which integrates two of the main principles of sustainable development – environment and economics, can help to significantly improve corporate decision-making.EMA is becoming increasingly important not only for environmental management decisions and development of environmental management systems (EMS), but also for all types of routine management activities, such as product and process design, cost allocation and control, capital budgeting, purchasing, product pricing and performance evaluation.Companies, which use EMA as a part of integrated management system, are provided with accurate and comprehensive information for the measurement and reporting of environmental performance.This paper investigates the current state of EMA practices in Lithuanian SMEs that have already been or are being implementing EMS and which have implemented CP innovations. In this case, EMA is analysed as an innovative assessment and evaluation method of EMS and CP innovation's environmental impacts and economic benefits. It should be stressed, that there are obvious differences in case studies from different industries. However, review of the results shows that there are many similarities in what improvements can be suggested for environmentally concerned companies both in terms of environmentally sound operation and for reporting of environmental management accounting information.     

Re-considering product design: a practical “road-map” for integration of sustainability issues

The proliferation of sustainability assessment principles, strategies, actions, and tools has created confusion about pathways forward for companies. It is unclear how existing approaches are complementary or distinct. How does a company assess current products and materials? How could designers create more sustainable products? What criteria, principles, approaches, and tools should be applied? Why? Is there a practical “road map” to guide product designers and product development managers in integrating sustainability issues into their decision-making processes?This article builds on previous frameworks for understanding the interconnections between various assessment principles, strategies, actions, and tools related to industrial ecology, human and labor rights, and corporate social responsibility [Waage S, Geiser K, Irwin F, Weissman A, Bertolucci M, Fisk P, et al. Fitting together the building blocks for sustainability: a revised model for integrating ecological, social, and financial factors into business decision-making. Journal of Cleaner Production 2005;13(12):1117–206; Robèrt K-H, Schmidt-Bleek B, Aloisi de Larderel J, Basile G, Jansen JL, Kuehr R, et al. Strategic sustainable development—selection, design and synergies of applied tools. Journal of Cleaner Production 2002;10(3):197–214; Robèrt K-H. Tools and concepts for sustainable development, how do they relate to a framework for sustainable development, and to each other? Journal of Cleaner Production 2000;8(3):243–54]. Expanding on past work, this piece suggests a “road map” for application by product designers and product development managers. A four-phase process is offered for integrating systems and sustainability perspectives into product design, manufacturing, and delivery decisions.     

Combining eco-design and user benefits from human-powered energy systems,a win–win situation

This paper presents the use of the human body to power electronic products, two product design cases applying human-powered energy systems and the relation with eco-design. The paper illustrated how the use of an alternative energy system (i.e. human-powered energy systems) offers new viewpoints to the design engineer and brings about environmental improvements. ‘Green marketing’ experiences from Philips teach us that environmental benefits should be backed-up by additional user benefits in order to be effective in the market. Human-powered energy systems offer these possibilities.     

Diversity of eco-innovations: Reflections from selected case studies

An analytical framework is developed in this paper in order to explore the diversity of eco-innovations according to several key dimensions (design, user, product service and governance). The framework is used to analyse a set of case studies of eco-innnovation processes. The diversity of the analysed eco-innovations appears to be considerable; each of them involves different kinds of combinations of elements pertaining to those dimensions. Albeit the design dimension is decisive to determine the environmental impacts of the innovation, all dimensions can play a significant role in the management of eco-innovation. Our findings suggest that the capacity of eco-innovations to provide new business opportunities and contribute to the transformation towards a sustainable society depends on the interplay of those dimensions and the engagement of key stakeholders in the innovation process.     

Ecodesign methods focused on remanufacturing

Understanding the product's ‘end-of-life’ is important to reduce the environmental impact of the products' final disposal. When the initial stages of product development consider end-of-life aspects, which can be established by ecodesign (a proactive approach of environmental management that aims to reduce the total environmental impact of products), it becomes easier to close the loop of materials. The ‘end-of-life’ ecodesign methods generally include more than one ‘end-of-life’ strategy. Since product complexity varies substantially, some components, systems or sub-systems are easier to be recycled, reused or remanufactured than others. Remanufacture is an effective way to maintain products in a closed-loop, reducing both environmental impacts and costs of the manufacturing processes. This paper presents some ecodesign methods focused on the integration of different ‘end-of-life’ strategies, with special attention to remanufacturing, given its increasing importance in the international scenario to reduce the life cycle impacts of products.     

Development of an eco-ideation tool to identify stepwise greenhouse gas emissions reduction options for consumer goods

Pressure on consumer goods manufacturers to develop new products with significantly less environmental impact is growing, through increased consumer awareness of environmental issues and governments setting ambitious emissions reductions targets. A strategic response to this pressure is to prepare a portfolio of innovative product ideas to meet a range of future emissions reductions targets. However, although extensive work exists on ideation (the generation of novel product ideas) and eco-design (design for reduced environmental impact), eco-ideation (generation of ideas that particularly aim to reduce environmental impacts) has had little attention. The challenge of eco-ideation is to release the creativity of a broad range of employees, only few of whom may be familiar with the drivers of environmental impact.This paper proposes a novel tool to facilitate the generation of radical product and process ideas giving step-change reductions in greenhouse gas emissions. The features of products and processes that drive greenhouse gas emissions across the product life cycle were characterized with a set of indicators. A simple visual tool was created to show these indicators on a sliding scale between best and worst imaginable performance. A leading question associated with each slider was designed to stimulate lower impact ideas. The tool was iteratively refined and simplified through structured testing with individuals from across a range of roles and differing knowledge of environmental impacts. The final eco-ideation tool used 14 scales, with leading questions for each scale developed to stimulate idea generation.The tool’s effectiveness was evaluated through use in a series of 15 individual workshops and compared with the outcomes of an equal number of conventional 12-person group-brainstorming sessions. The comparison suggests that using the simple tool generally leads to a wider range of more radical ideas than emerge from group brainstorming.     

A method for sustainable product development based on a modular system of guiding questions

In this paper, we present a method for sustainable product development (MSPD) with the aim of integrating social and ecological aspects of sustainability with a strategic business perspective in product development. The method applies backcasting from basic principles for sustainability, which allows a strategic approach, and it includes a modular system of guiding questions that are derived by considering these principles and the product life cycle. Initial testing in Swedish companies indicates that the suggested MSPD promotes a ‘bird's eye’ perspective and encourages and aids development of products that support society's transformation towards sustainability. Furthermore, it is concluded that the modular system provides flexibility and user-friendliness.