Presentation at the 53rd EOQ Congress, Dubrovnik

1. 53. EOQ Congress
Cavtat, 20 April 2009.
SUSTAINABILITY IN PRODUCT
DESIGN AND MANUFACTURING
53rd EOQ CONGRESS
NEW SOCIETY FOR THE BRAVE OF HEART AND MIND
Katarina Gaži – Pavelić
Podravka d.d., Koprivnica, Croatia
katarina.gazi@podravka.hr

2. 53. EOQ Congress
Cavtat, 20 April 2009.
Overview
• Introduction
• Production and consumption
• The sustainable alternative
• Conclusion
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

3. Introduction
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4. 53. EOQ Congress
Cavtat, 20 April 2009.
The Ant Design Example
• Safely and effectively handle their own material
wastes and those of other species
• Grow and harvest their own food while nurturing
the ecosystem of which they are a part
• Construct houses, farms, dumps, cemeteries,
living quarters, and food-storage facilities from
materials that can be truly recycled
• Create disinfectants and medicines that are
healthy, safe, and biodegradable .
• Maintain soil health for the entire planet.
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

5. 53. EOQ Congress
Cavtat, 20 April 2009.
Looking Ahead 100 years
How are we going to:
• stabilize the climate by reducing GHG emissions
globally by more than 60%?
• meet basic needs for food, water, shelter, and
energy of 9 billion people?
• reduce proportion of the world’s population living
in dire poverty? ($2/day, 3 billion)
• achieve a low carbon economy?
– from “take-make-waste” production cycle to “cradle-
to-cradle”?
• achieve a more peaceful, secure world?
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6. 53. EOQ Congress
Cavtat, 20 April 2009.
Green Revolution
“We need to deal with not only the way the
world produces food but the way it is
distributed, sold and consumed, and we
need a revolution that can boost yields by
working with rather than against nature.” *
*Achim Steiner, UN Under-Secretary-General and UNEP Executive Director
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7. 53. EOQ Congress
Cavtat, 20 April 2009.
Feeding the world
The the entire projected population
growth could be fed by a more
efficient production.
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8. 53. EOQ Congress
Cavtat, 20 April 2009.
Food crises
• More than the half of the food produced today is
either lost, wasted or discarded as a result of
inefficiency in the human-managed food chain.
• Food prices may increase by 30-50 % within
decades. *
* “The Environmental Food crises: Environment's role in averting future food crises” report
8 Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

9. Production and consumption
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10. 53. EOQ Congress
Cavtat, 20 April 2009.
Current Production System
At each step in the production process:
• waste is generated
• significant quantities of fossil fuels are consumed
(also in transporting raw materials and partially
finished products).
• large quantities of water are consumed and
contaminated
Current production demands that we:
• have to keep “going back to the well” to extract
more and more raw material.
• have to keep finding new places to dump regular
solid waste and the hazardous wastes generated
by many production practices.
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11. 53. EOQ Congress
Cavtat, 20 April 2009.
Cradle To Grave Design
Take Make Waste
Raw materials Manufacturing and Landfill,
extraction and production, packaging, incineration
synthesis distribution, selling, use
Naziv prezentacije Katarina Gaži - Pavelić

12. 53. EOQ Congress
Cavtat, 20 April 2009.
Production and Consumption
• Concepts of production and consuption have
been disconnected for a long time
• Produce what can be used and reused
• Industry should mimic biology, where one
species' excrement is another's food
• Zero waste is the new (and somewhat utopian)
concept
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

13. The sustainable alternative
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14. 53. EOQ Congress
Cavtat, 20 April 2009.
What is the Alternative?
• Industrial Ecology
Designing an industrial system that operates like a
natural system.
• Product as Service
Products are not sold, their service is leased to the
customer/consumer.
• Cradle-to-Cradle/Design for Disassembly / Take-
Back Programs
Designing products that can be easily disassembled
after their useful life and most of the useful material
can be reused for new products.
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15. 53. EOQ Congress
Cavtat, 20 April 2009.
Key Concepts for Today
The Life-cycle Concept
• Biological and the
technical nutrients
• Not cradle to grave, but
Cradle to Cradle
• Today
– We get rid of waste by
making it someone else
problem
Naziv prezentacije Katarina Gaži - Pavelić

16. 53. EOQ Congress
Cavtat, 20 April 2009.
Sustainability in Product Design and
Manufacturing
Manufacturing Impact of Design and
Design Manufacturing
• Eco design • Eco-Efficiency Life Cycle Analysis
• Eco-Effectiveness • Lean
Manufacturing
• Bio-Mimicry
• EH&S and EMS
– ISO 14001
16 Naziv prezentacije Katarina Gaži - Pavelić

17. 53. EOQ Congress
Cavtat, 20 April 2009.
Basic C2C Concept
• Eco-efficiency: being less bad
The strategy for "sustainability" of minimizing
harm to natural systems by reducing the amount
of waste and pollution generated by human
activities.
• Eco-effectiveness: being good
C2C strategy for designing human industry that
is safe, profitable, and regenerative, producing
economic, ecological, and social value.
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

18. 53. EOQ Congress
Cavtat, 20 April 2009.
LCA
Full LCA Not LCA
Practical LCA
• “Gate-to-gate” or “cradle-to-gate” = not true LCA
• “Cradle to grave” = traditional LCA
• “Cradle to cradle” = current/evolving LCA
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

19. Conclusion
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20. New Design
• Design life cycles instead of products
• Design services instead of products
• Use a minimum of material
• Increase product life time
• Make the product recyclable
• Use recycled materials
• Natural materials may not be better
• Estimate the actual energy consumption
• Replace toxic and hazardous materials
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21. 53. EOQ Congress
Cavtat, 20 April 2009.
Positive Outcomes
• Products are perceived differently by both
customers and businesses: focus is on the
service, not the product itself
• Durability is the new mantra
• Designing for disassembly and reuse (modular
design)
• Manufacturers adopt a more cyclic way of thinking
about their production process.
Sustainability in Product Design and Manufacturing Katarina Gaži - Pavelić

22. 53. EOQ Congress
Cavtat, 20 April 2009.
Positive Outcomes cont.
• Employment shift from extraction/disposal
industries to service, collection and re-processing
industries.
• Buildings (like trees) produce more energy than
they consume and purify their own waste water
• Transportation that improves the quality of life
while delivering goods and services
• A world of abundance, not one of limits, pollution,
and waste.
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23. HVALA NA PAŽNJI!
THANK YOU!
SUSTAINABILITY IN PRODUCT DESIGN AND
MANUFACTURING
Katarina Gaži – Pavelić
Podravka d.d., Koprivnica, Croatia
katarina.gazi@podravka.hr
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