Cleaning Africa Through Product Design: a field Study Regarding Plastic Recycling and Sustainable Product Development in Zanzibar
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Cleaning Africa through product design: A field study regarding plastic recycling and sustainable product development in Zanzibar Master of Science Thesis in the Master Degree Programme, Industrial Design Engineering ANNA ENGSTRÖM ELLEN ÖSTERDAHL Department of Product and Production Development Division of Design and Human Factors CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden, 2011 Cleaning Africa through product design: A field study regarding plastic recycling and sustainable product development in Zanzibar ANNA ENGSTRÖM AND ELLEN ÖSTERDAHL © ANNA ENGSTRÖM AND ELLEN ÖSTERDAHL, 2011 Published and distributed by Chalmers University of Technology Department of Product and Production Development SE-412 96 Göteborg Sweden Telephone: +46 (0)31-772 1000 Printed in Sweden by Chalmers Reproservice Göteborg, 2011 ii Abstract This Master’s thesis was carried out at the department The product development phase was carried out at of Product and Production Development at Chalmers Chalmers in Sweden. With respect to the gained University of Technology by Anna Engström and knowledge regarding the local market and its envi- Ellen Österdahl, master students at the programme ronment, and with respects to other important con- Industrial Design Engineering. The project was siderations, such as ergonomics, several demands and performed in cooperation with Zanrec Plastics, a small requirements for the school furniture were defined. Swedish company aiming at introducing a scalable A number of concepts were developed and evalu- plastic recycling system in developing countries, ated against these demands in an iterative process. starting in the island of Zanzibar, just outside the coast The concept that best fulfilled the demands and the of Tanzania in East Africa. requirements from both the user, Zanrec Plastics, and potential investors, was then further developed. The aim of the project was to utilise recycled plastic material as a basis for development of a new product, The final result is a unique set of modular school fur- made partially or fully from recycled plastic. The aim niture, made entirely out of plastic material. The fur- was also to identify needs on the local market that niture have been design to fit primary school children could be fulfilled by this plastic product. The local in East Africa, meaning that the furniture are ergo- market was defined as East Africa with a primary nomically adapted to the children, providing them focus on the island of Zanzibar. The developed prod- with better workspaces than the current furniture. As uct should be a part of Zanrec Plastics’ business con- Zanrec Plastics wishes to educate the local commu- cept, meaning that it should be a sustainable product, nity in terms of sustainability and recycling, these new well adapted to the local society, and that it should be school furniture will work as excellent educational produced locally in Zanzibar. products within an educational environment. The modularity of the furniture makes them easy to trans- In the first phase of the project, a theoretical pre-study port and thus facilitates export to other areas in need. was carried out and then followed by a seven week- The products can be produced locally in Zanzibar and long field study in Zanzibar. General cultural obser- assembled only using a few local tools. The result of vations and several interviews with local people were this Master’s thesis is consequently a sustainable out- performed during the field study, giving the project come that includes both social and environmental sus- group new insights and knowledge regarding the East tainability aspects, as it provides work opportunities in African culture. A number of interesting needs and the local community as well as introduces a life cycle areas for future product development was identified, opportunity for plastic material. and after consulting Zanrec Plastics and supervisors, school furniture was selected as the most interesting Keywords: recycling of plastic, Zanzibar, East Africa, area. The current need for functional school furniture field study, product development for developing coun- in Zanzibar is big, and it is need that most likely can tries, emerging markets, sustainable product develop- be translated to other developing parts of the world. ment, school furniture. iii Preface This report is the final outcome of a Master’s thesis; the final examination for a Master of Science in Industrial Design Engineering at Chalmers University of Technology in Gothenburg, Sweden. It was carried out during 2011 in cooperation with Zanrec Plastics. We would like to thank all of those who have, in one way or the other, contributed to the success of this project. A special thanks to our examiner Örjan Söderberg and supervisor Thomas Nyström at Chalmers for supporting, guiding, and believing in us throughout this process. Also, we would like to express our gratitude towards Fredrik Alfredsson and Erik Gulbrandsen at Zanrec Plastics for all their valuable input and support, both in Sweden as well as in Zanzibar. We would also like to acknowledge the people who helped us during our field study in Zanzibar. A special thanks goes out to Ingvild Andersen, Janni Martensen, Mr Rajab Ameir and Dr Flower E. Msuya. Also, we would like to thank Yvonne Young, coordinator of the Minor Field Study scholarship at Chalmers, and the people at SIDA, Internationella Programkontoret as well as Sveriges Ingenjörer for supporting our project financially. We owe our deepest gratitude to Marcus Hansson, for sharing his valuable rendering skills and time. Last but not least, we would like to thank our families and friends for encouraging us and bearing with us during this journey. Anna Engström and Ellen Österdahl Gothenburg, 2011 v Table of contents 1. Introduction 3 1.1 Background 3 1.1.1 The company 3 1.2 Aim and goal 3 1.2.1 Effect goal 3 1.2.2 Project aim 3 1.2.3 Product aim 4 1.3 Limitations 4 1.4 Project plan 5 1.5 Report outline 5 2. Theory 9 2.1 Zanzibar 9 2.1.1 History and politics 9 2.1.2 Population 9 2.1.3 Religion 10 2.1.4 Etiquette 10 2.1.5 Economy 10 2.1.6 Transportation 10 2.2 Cultural differences 11 2.2.1 Cultural Dimensions according to Hofstede 11 2.3 Product development in developing countries 13 2.4 Plastics 14 2.4.1 What are plastics? 14 2.4.2 Consumer plastics 14 2.5 Recycling of plastics 15 2.5.1 The process of recycling plastics 16 2.5.2 The impact of plastic recycling 17 2.5.3 Solid Waste Management in developing countries 18 2.5.4 Recycling in developing countries 18 2.6 Manufacturing methods 18 2.6.1 Rotation moulding 18 2.6.2 Extrusion 19 2.7 Ergonomics 20 2.7.1 Sitting and writing issues 20 2.7.2 School furniture 20 3. Methods 22 3.1 Research and Design Methodology 22 3.1.1 Introductory methods 22 3.1.2 Data collection 22 3.1.3 Analysis 23 3.1.4 Creativity 23 3.1.5 Visualisation 24 3.1.5 Evaluation 24 vii 4. Field study 29 4.1 Introduction 29 4.2 Implementation 29 4.2.1 Observations 29 4.2.2 Interviews 29 4.3 Result 30 4.3.1 General cultural observations 30 4.3.2 Comparison to Hofstede 34 4.3.3 Plastic and waste management 35 4.3.4 Identified areas of interest for product development 39 4.3.5 Selected focus area 40 4.3.6 Education and schools in Zanzibar 41 4.4 Conclusion of field study 43 4.4.1 Base for product development 43 5. Product development 47 5.1 Definition of product 47 5.1.1 The user and the context 47 5.1.2 Image board 48 5.1.3 Function analysis 48 5.1.4 Specification of demands 48 5.1.5 Designing for the Base of the pyramid 48 5.2 Concept development 50 5.2.1 Idea generation 50 5.2.2 Concept principles 50 5.3 Concept evaluation 53 5.4 Concept selection 53 5.5 Further development 53 5.5.1 Form development 54 5.5.2 Joining and assembly 55 5.5.3 Opening up for co-design 57 6. Final result 61 6.1 PlastikiRafiki furniture 61 6.1.1 Manufacturing and material 61 6.1.2 Assembly 62 6.1.3 Ergonomics and usage 63 6.1.4 Product identity and expression 65 6.1.5 Need in other areas 65 6.2 Evaluation of result 67 6.2.1 Fulfilment of demands 67 6.2.2 Sustainability 67 6.2.4 Ergonomic evaluation 67 viii 7. Discussion 73 7.1 Mission of the thesis 73 7.2 Fulfilling the aim 73 7.2.1 Effect goal 73 7.2.2 Project aim 73 7.2.3 Product aim 73 7.3 Limitations 73 7.4 Project plan 74 7.5 Field Study 74 7.5.1 Preparations 74 7.5.2 Implementation and result 74 7.6 Product Development 75 7.6.1 Product development in developing countries 75 7.6.2 Idea generation 76 7.7 Concept Selection 76 7.8 Final result 76 7.8.1 Manufacturing 76 7.8.2 Assembly 77 7.8.3 Ergonomics and usage 77 7.8.4 Evaluation 77 7.8.5 Social consequences 78 7.9 The project as a whole 78 7.10 Recommendations 78 8. Conclusion 79 9. References 82 Appendix 87 ix Introduction 1. Introduction In this chapter, the background and aim for this Master’s thesis are described. The project time line and limitations are also presented followed by an explanation of the report outline. This Master’s thesis has been performed in coopera- Their work is built around three milestones; a col- tion with Zanrec Plastic, and comprises of two parts; lection system, a processing plant, and an educational firstly a field study, carried out in Tanzania, followed package regarding future sustainable development.