sustainable product design lecture-idbm

Sustainable Product Development | IDBM | Helsinki | 291008

Sustainable Product Development

IDBM | Helsinki | 29102008

In today’s matinee, tragic comedy in three acts

1. What is sustainability2. How to design it3. Why it’s important

Prelude:

A GOOD IDEA...

Material use

twice the normal

manufacturing

difficult and expensive

design makes the bottle

hard to use and reuse

because of design, the bottle

cannot be recycled

Act One:

We’re running on an enormous

ecological deficit:

By a moderate business-as-usual scenario, by 2050

we spend twice as muchas the Earth can produce.

...but, unfortunately,

right now, we’re running on 140% capacity

PEOPLE

PLANET

PROFIT

SUSTAINABILITY

PEOPLE

PLANET

PROFIT

SUSTAINABILITY

Equitable

Viable

Bearable

Ecological modernization:

Our problems have to be solved by developing existing society further.

Act Two:

Question:

Are people going to change their habits?

Worldwide,

2% buy green for the sake of green

To recap,

1. Price2. Quality3. Ease of use4. Availability5. Eco-friendliness

Traditional thinking says

eco = expensive.

Traditional thinking says

eco = expensive.

ECO ECOE c o n o m i c a l l y v i a b l e

Eco l og i ca l l y f r i end l y

No matter what you are doing,

materials, energy, transportcost money

maximizing eco-efficiency= minimizing expenses

...with one big if:

it must be designed from the start.

PEOPLE

PLANET

PROFIT

SUSTAINABILITY

DESIGN

ENGINEERING

BUSINESS

Two basic strategies:

1) Design for longevity2) Design for disposal(if the product is necessary at all)

Design for longevity•Timeless, classical design

•Long lifespan

•Durability

•Designed for ease of repair and maintenance

•Designed for modularity

•Possibilities for reuse

•Possibility to upgrade with latest technology

Design for disposal•Fashionable design

•Designed for takeback

•Designed for recycling

•Designed for eco-friendly disposal

Design for longevity Design for disposal

•Timeless, classical design

•Long lifespan

•Durability

•Designed for ease of repair and maintenance

•Designed for modularity

•Possibilities for reuse

•Possibility to upgrade with latest technology

•Fashionable design

•Designed for takeback

•Designed for recycling

•Designed for eco-friendly disposal

Vastuullinen & Poikkitieteellinen Tuotekehitys | IDBMPro | Lahti | 161008-17102008

The LiDS Wheel

6. Optimized lifetime

5. Lowimpact use

4. Efficient distribution

3. Optimized manufacturing

2. Lowimpact materials

1. Innovation

7. Optimized End-of-life

•Also known as Eco-design Strategy wheel

•Generative ideation tool, subjective

When to use

•when there is little hard data available

•as a tool to stimulate ideation

•for evaluating the relative impact of two different products

SOURCE: Modified from the Lids Wheel, HanBrezet, et al, Promise Manual, Delft Universityof Technology /Okala Design Guiden 2007

LiDS Wheel

Vastuullinen & Poikkitieteellinen Tuotekehitys | IDBMPro | Lahti | 161008-17102008

Comprehensive method to assess all impacts over all lifecycle.

Qualitative Matrix LCA

Based on technical expertise to evaluate impacts through out the Lifecycle.

Pharos

Based on health pollution, resource use, social and community indices

Total Beauty

Five-topic method based on subjective judgement.

Environmental Impact Assessment Methods

EcologicalFootprint

Not yet fullydeveloped

QualitativeMatrix LCA

Depends on the knowledge

of users

LiDSwheel

MBDCDeficient global

Warning,Missing lifecycle

phases

Life CycleAssessment

TotalBeauty

PharosNot yet fullydeveloped

Subjective(guessing, with often

unrepeatable results)

Objective(physical measurement,

With repeatable results)

Comprehensive(Complete impact types

and all lifecycle phases)

Incomplete(few impact types

And/or missing lifecycle phases)

SOURCE: Okala Design Guide 2007 / IDSA

Trouble with LCAs

• Life cycle analysis is time-consuming• Collecting data for the entire life cycle

can be difficult

Single number LCA rides to rescue

Eco-99 takes into account:•Health effects•Ecosystem effects•Resource depletion

Including•Materials usage•Production processes•Energy generation•Disposal & recycling

...and gives a single number

What “light” LCA is good for

• Benchmarking • Evaluating concepts• Testing assumptions• Comparing products, firms

and industries

DO NOT USE FOR• Marketing claims• Greenwashing• Any public claims

For initial stages of design & development:

Light LCA: Eco-99 Manual

• Developed for designers• From Netherlands• Based on European averages• Gives one indicator value(Single-score LCA)• In “Points” = 1/1000 of average European

consumer’s yearly environmental footprint• FREELY DOWNLOADABLE, www.pre.nl

Using LCA

1. Establish the purpose of the calculation: product, product component, comparing two different products...

2. Define the life cycle: draw a diagram3. Quantify materials and processes; make assumptions where needed4. Fill in the data5. Interpret the results; MAKE A STRESS TEST!

Example: Life cycle of a coffee maker

Coffee beans Paper Polystyrene Aluminium Steel Glass

Assembly &transport

Packaging

Devicedisposal

Coffeedisposal

Filterdisposal

Packagedisposal

Electricity

Transport & processing

FiltersInjectionmolding

ExtrusionPress

formingBlowing

Systems view: Coffee maker

Purpose: • Make coffee and keep it hot

System includes• All products and processes that are

needed to produce coffee in a home during the lifetime of the device.

Assumptions:• Lifetime 5 years• 5 cups of coffee twice a day • Kept warm for 30 minutes

Fill in the form...

Estimate energy use for glass blowing

Fill in the form...

Find indicator value for 4 megajoules of electricity

Fill in the form...

What has thebiggest impact?

Fill in the form...

What has thebiggest impact? Electricity

13 875 mPts

Total mfg.536 mPts

If you get stuck:

• Check whether the missing value has significant impact

• Use similar indicators• Analyze from e.g. electricity

usage• Get help

Complex products

Analyze in parts, add up the results

Complex products

Uncertainties arise from• correctness of the model:

assumptions, attitudes, values

• data uncertainties: absolute and relative uncertainties

Uncertainties and how to deal with them

Products, materials,manufacturing processes• Similar = relative error,

doesn’t hurt (by much)

• Different = results uncertain!

Rule of thumb: • Similar processes: 10-50%

difference in results

• Different processes: at least 100% difference required!

Uncertainties and how to deal with them

Difference matters!

Electricity13 875 mPts

Total mfg.536 mPts

Esimerkki: MacBook Pro chassis

Esimerkki: MacBook Pro-kotelo

1. Rajataan tehtävä pelkän kotelon vertailuun

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät

• Oletetaan 6061-alumiini, josta neitseellistä materiaalia 70%

• Menetelminä lastuava työstö vs. prässääminen

• Lastut kierrätetään

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät4. Lasketaan materiaalit ja menetelmät, tehdään oletukset

• 1,133 kg alumiinia, josta poistetaan 1 kg, vs. 0,25 kg alumiinilevyä

• Oletus: 30 % kierrätettyä = valmistuksen ympäristövaikutus (780 * 0,7 + 60 * 0,3) = 564 mPts/kg

• Lastuavan työstön ympäristövaikutus 800 mPts/dm3 poistettua materiaalia

• Alumiinin tilavuus 2,7 kg/dm3 joten lastutaan 1 kg / 2,7 kg/dm3 = 0,37 dm3

1. Prässäämisen ympäristövaikutus 23 mPts/kg muokattua materiaalia2. Oletetaan että lastuista kierrätetään 95 %, vaikutus -720 mPts/kg

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät4. Lasketaan materiaalit ja menetelmät, tehdään oletukset5. Tehdään laskelmat: lastuava työstö

• Alumiinin valmistus: 564 mPts/kg * 1,133 kg = 639 mPts

• Työstö: 0,37 dm3 * 800 mPts/dm3 = 296 mPts

• Lastujen kierrätys: (95 %): 1 kg * 0,95 * -720 mPts/kg = - 684 mPts1. Yhteensä 639 mPts + 266 mPts - 684 mPts = 257 mPts

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät4. Lasketaan materiaalit ja menetelmät, tehdään oletukset5. Tehdään laskelmat: prässääminen

• Alumiinin valmistus: 564 mPts/kg * 0,25 kg = 141 mPts

• Prässääminen: 23 mPts/kg * 0,25 kg = 6 mPts

• Yhteensä 147 mPts

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät4. Lasketaan materiaalit ja menetelmät, tehdään oletukset5. Tehdään laskelmat6. Vertaillaan:

• Lastuava työstö 257 mPts

• Prässääminen 147 mPts

• Eroa 57 %

1. Rajataan tehtävä pelkän kotelon vertailuun2. Määritetään elinkaari: pelkkä tuotanto3. Materiaalit ja menetelmät4. Lasketaan materiaalit ja menetelmät, tehdään oletukset5. Tehdään laskelmat6. Vertaillaan7. Tarkastetaan oletukset

• Onko tulos realistinen?

• Mitä puuttuu?

• Mitä vaikutuksia oletusten muuttamisella on?

• Onko ero riittävän suuri?

Act Three:

By 2025,

75% reduction

By 2050,

93% reduction

However,

There’s some good news

namely,

everything needs to be redesigned.

75% reduction means

2 x endurance2 x less inputs

Question:

What you get when you have:

a) new technologies

b) new user needs

c) new markets

d) new business plans

If you have:

a) new technologiesb) new user needsc) new marketsd) new business plans...?

...what you get is

new opportunities toget cleanly rich(as opposed to filthy rich)

What qualities are important in consumer goods?

Innovativeness

Environmentally friendly

Quality design

0% 20% 40% 60% 80%

In addition,

There’s also some new sources of inspiration

...like

biomimicry

Insecta, (c) Shao Yung Yeh 2008

Other hot ideas:

Breaking the cost barrierConstraint-based designCradle to Cradle

sustainable product design lecture-idbm

sustainable

life cycle

eco expensive

tehdn laskelmat

mritetn elinkaari

pelkk tuotanto

macbook pro

business plans

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