Design for Environment as a Tool for the Development of a Sustainable Supply Chain Maurizio Bevilacqua • Filippo Emanuele Ciarapica Giancarlo Giacchetta Design for Environment as a Tool for the Development of a Sustainable Supply Chain 123 Prof. Maurizio Bevilacqua Prof. Giancarlo Giacchetta Dipartimento di Ingegneria Industriale Dipartimento di Ingegneria Industriale e Scienze Matematiche e Scienze Matematiche Università Politecnica delle Marche Università Politecnica delle Marche Via Brecce Bianche Via Brecce Bianche Ancona Ancona Italy Italy e-mail: [email protected] e-mail: [email protected] Prof. Filippo Emanuele Ciarapica Facoltà di Scienze e Tecnologie Libera Università di Bolzano Piazza Università 5 Bolzano Itlay e-mail: fi[email protected] ISBN 978-1-4471-2460-3 e-ISBN 978-1-4471-2461-0 DOI 10.1007/978-1-4471-2461-0 Springer London Dordrecht Heidelberg New York British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Control Number: 2011943354 Ó Springer-Verlag London Limited 2012 Dell is a registered trademark of Dell Inc in the United States and other countries 1999- 2011 Hiatchi Group Ó Hitachi, Ltd. 1994, 2011. All rights reserved Reference to the MET matrix is covered by the Creative Commons Attribution-ShareAlike 3.0 Unported license Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licenses issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers. The use of registered names, trademarks, etc., in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com) Preface This book was born from the idea that Design for Environment (DfE) methodol- ogies could be used as a tool for the development of a more sustainable supply chain. This idea led the authors of this text to focus their research toward the development of new procedures and techniques that allowed the designers to integrate DfE methods and Environmental Supply Chain Management. In the past decade, Environmental Design (‘Eco Design’ or ‘Design for Envi- ronment’) has become one of the most significant agendas for many manufacturing companies. Yet, there is a wide variety in their approaches, strategies and in their levels of execution. The initial reaction of many companies in the late 1980s to the challenge posed by environmental concern and the need to move toward sus- tainability was often a relatively superficial change to their products and their approaches to marketing communications. With the emergence of the enviro- preneuring paradigm, and the acceptance of the business logic, which underpins the need to consider eco-performance, more substantive changes could be expected. The development of innovative methodologies in Environmental Management fields and the application of these in several case studies allowed the authors to publish several papers in international journals and proceedings. These case studies have been used in this book in order to better explain the theoretical topics. The integration of case studies and basic concepts such as Design for Environ- mental, Supply Chain Management and Life Cycle Assessment could be useful in order to make these topics understandable for large numbers of readers. This text is directed to several professional figures such as industrial designers, production process owners, heads of technical/marketing/sales departments, mechanical/managing/production engineers and to everyone involved in environ- mental issues. The aim is to provide to all of these professional figures some guidelines to develop, within their area of interest, Design for Environmental (DfE) programs with the objective of redesigning the entire supply chain. Moreover the aims of this book are to set target specifications for the product and its life cycle, and to establish eco-design concepts. v vi Preface In this text the Design for Environmental concepts have been enlarged. In fact we want to evaluate not only the way in which the product design phase could influence environmental performances of a supply chain but also how re-designing the supply chain could provide a decrease of environmental impact. While much early environmental new product development (ENPD) work employed a design- for-environment approach, which emphasized the reduction of the post-use environmental burden, more recently, there has been an increased emphasis on the ‘‘embodied’’ environmental burdens of the materials used. Suppliers have an important role in determining all aspects of product quality including eco- performance. ENPD requires a detailed understanding of the socio-environmental impacts of the whole supply chain, down to the simplest ingredient, which may previously have been perceived as standardized and unlikely to pose quality problems. Contents 1 Introduction ........................................ 1 1.1 Objectives and Outlines of this Book . 7 References . 9 2 Integration of Design for Environmental Concepts in Product Life Cycle ......................................... 11 2.1 Environmental Aspects in Product Life Cycle . 12 2.1.1 LCA and Product Development . 16 2.2 Design for Environmental Concepts . 20 2.2.1 Integration of LCA Technique and Design for Environmental Methods . 27 References . 30 3 LCA Process in the Eco-Design Process.................... 33 3.1 Life Cycle Assessment . 33 3.1.1 Goal Definition and Scoping . 35 3.1.2 Life Cycle Inventory. 36 3.1.3 Life Cycle Impact Assessment . 44 3.1.4 Life Cycle Interpretation . 52 3.2 Case Study: LCA as a Tool in ‘‘Design for Environmental’’: A Comparative Study Between Domestic Refrigerators. 52 References . 60 4 Sustainable Product Assessment Tools..................... 61 4.1 Matrix Assessment Tools. 61 4.2 Checklists . 62 4.3 Spiderweb Diagrams . 63 4.4 Parametric Assessment . 66 4.5 Summing up the Engineering Perspective . 68 References . 72 vii viii Contents 5 Case Study: The Domestic Cooker Hood ‘‘F77’’ ............. 75 5.1 Structure of the Analysis . 75 5.1.1 Functional Units. 75 5.1.2 System Boundaries . 75 5.2 Life Cycle Inventory. 76 5.2.1 Production–Use–End of Life . 76 5.3 Data: Sources and Assumptions . 78 5.4 Life Cycle Impact Assessment (LCIA) . 78 5.5 Results and Discussion . 80 5.6 Manufacturing . 82 5.7 End of Life . 89 5.8 Impact Improvement with LED Light . 90 5.9 Use of Electro-Galvanized Stainless Steel . 92 5.10 Modification of Distribution Modality. 92 References . 95 6 Designers’ Utilization of DfE and Requirements ............. 97 6.1 Integration of Environmental Management System and Design for Environmental . 98 6.2 Design for Environmental and Product Life Cycle Cost . 104 6.2.1 Related Research Works . 106 References . 109 7 Case Study: Development of a Sustainable Product Life cycle in Manufacturing Firms ....................... 113 7.1 Research Approach. 114 7.2 Procedure Development. 115 7.3 Approach and Parameters Used in the LCA Study . 117 7.3.1 Product-Specific Requirements (PSR) . 117 7.3.2 LCI: Life Cycle Inventory . 120 7.3.3 LCIA: Life Cycle Impact Assessment . 121 7.4 Application Example. 121 7.4.1 Environmental Break Even Point . 127 7.4.2 Economic/Environmental Break Even Point. 129 7.5 Discussion and Conclusions . 130 Reference . 132 8 Design a Sustainable Supply Chain ....................... 133 8.1 Environmental Pressures and Supply Chain Response . 137 8.1.1 Regulations . 137 8.1.2 Consumers and Ethical Responsibility. 145 8.1.3 Resources . 148 8.2 The Supply Chain Response . 149 Contents ix 8.3 The Costs of a Sustainable Supply Chain . 156 References . 165 9 Environmental Aspects in Strategic Decisions ............... 169 9.1 Sustainable Logistic Network. 173 9.2 Suppliers Management and Selection . 183 9.3 Environmental Material Management . 190 9.3.1 A Revised Economic Order Quantity: Improving the Inventory Management Model . 195 9.4 Closed-Loop Supply Chains and Reverse Logistics. 206 References . 215 10 Case Study: A Carbon Footprint Analysis in Textile Supply Chain ....................................... 219 10.1 Carbon Footprints in the Supply Chain . 220 10.2 Materials and Methods . 220 10.2.1 Related Research Works . 221 10.3 Case Study . 224 10.3.1 System Boundaries . 224 10.3.2 Functional Unit . 224 10.3.3 LCIA . 226 10.4 The Production Process . 227 10.4.1 Impact Calculated by IPCC 2007 . 227 10.5 Uncertainty Assessment IPCC 2007 . 228 10.5.1 Life Cycle Interpretation . 229 10.6 Sensitivity Analysis . 231 10.6.1 Transport. 231 10.6.2 The Combination of Road Rail Transportation . 232 10.6.3 Suppliers Selection . 233 10.6.4 A Change in Consumer Behaviour . 234 10.7 Discussion and Conclusions . 234 10.8 Appendix. 238 References . 238 11 Optimizing Sustainability in Products and Services ........... 241 11.1 Sustainability in Products and Services . 241 11.2 Three-Dimensional Concurrent Engineering (3DCE) to Integrate New Product Development (NPD) and Environmentally Responsible Manufacturing (ERM). 254 References . 262 12 DfE Procedures in the Development of a More Sustainable Supply Chain ....................................... 265 12.1 Introduction . 265 x Contents 12.2 Barriers in Implementation of DfE in the Supply Chain Management. 273 12.3 DfE and Supply Chain Stakeholders . 275 References . 280 13 Methods for Weighting DfE Choices in the Development of a More Sustainable Supply Chain .....................