green manufacturing: the art of sustainability

Green Manufacturing: The Art of Sustainability

Malcolm FoxSustainability Director, NSF International

©NSF International, 2010

NSF International Live Safer™

Leading public health and safety company

NSF‐ISR: world‐class quality, environmental, aerospace, food, and information security systems registrar

NSF Sustainability: Major provider of LEED reviews for US Green Building Council

Sustainability Standards: furniture, green chemistry, building products and materials

3rd Party sustainable product & systems certifications: carpets, furniture, personal care, WaterSense℠, forestry, EMS, greenhouse gas emissions, fisheries, organic food…

Environmental claims verification: eco‐efficiency, DfE, recycled content, energy usage, recyclability, compostability, CleanGredients®…

Manufacturing services: environmental impact assessment, supply chain assessment, sustainability measurement…


Art, Manufacturing & Sustainability…

1. Sustainability and manufacturing in context

2. The future of sustainable manufacturing…the art

3. Sustainable manufacturing in practice…the science

Bob Johnson Wheel Cube


Context…Production Trends

Adapted: Dr. David Dornfeld


Sustainability…

United Nations: “Development that meets the needs of the present without compromising the ability of future generations to meet their own needs”

Complex balance of social, economic, and environmental needs

New economic models of extraction, production, consumption

New models of governance


China 5.7India 1.9

Sustainability Challenges…Climate Change

Climate Change 2007: Synthesis Report, United Nations IPCC


279 transboundary river basins; 45% world’s surface; 40% population

Sustainability Challenges…Water

UNEP Year Book 2010


Externalities…

Worldwide environmental damage costs due to business…off balance sheet externalities

United Nations Principles for Responsible Investing. Trucost, plc.

Automotive industry Beer industry

Company that fails to adapt Company adapts

Externalities internalized…climate change value‐at‐risk

Climate Change – A Business Revolution, The Carbon Trust

Up to 65% loss;

Up to 80% gain


Value‐at‐Risk…Food & Beverage

20 US Large‐cap food & beverage.

$1.1 bn loss EBITDA, regulatory cost of carbon alone.

Analysis emissions data 20 food & beverage companies in the S&P500. NSF/Trucost


Sustainable Manufacturing…

Burden of environmental impacts was a social cost…becoming more and more the manufacturers burden…cost…and opportunity?



The art of sustainable manufacturing…holistic views

Matthew Moore Rotations: Moore Estates


Impact Reduction View…Ricoh Comet

Ricoh Comet Circle Concept

Energy + Materials

Traditional environmental

concepts


Life Cycle View…Extraction/Production/Consumption

EXTRACTION

SINKS

PRODUCTION

CONSUMPTION

Enabling Sustainable Production-Consumption Systems, Lebel & Lorek, Annual Review of Environment and Resources, 2008.

Importance of Design, Supply Chain, End‐of‐Life



The science…

Beuysian School of Art & Sustainability


Sustainability Noise

Carpet giant Mohawk aims to weave sustainability into every fiber of its operations

…closing the loop, and bringing things full circle…

We are nearing the tipping point…

ConAgra Foods to Reduce Packaging, Water, Greenhouse Gas and Solid Waste by 2015

BASF First Chemical Company as Founding Member of The Sustainability Consortium

the triple bottom line

Swiffer Designer Speaks Up Over Greenwashing Criticism

HP Reduces GHG Emissions 10%, Sets New Targets

Ritz-Carlton, St. Regis Join Pilot Food Recycling ProgramWal-Mart, Others Push

‘Sustainable’ Toys Toward $1B Market

Ford Saves $1.2M by Shutting Down PCs

Whole Foods, Starbucks Top Sustainable Retail Design Awards


Value Creation


Value Creation & Sustainability


Lean Manufacturing & Sustainability

Sustainable manufacturing fits well within a lean manufacturing culture: Common culture: continual improvement, employee involvement, operation‐focus, metrics‐driven, supply chain investment, holistic thinking

Strong relationship between manufacturing waste and environmental impacts: defects, waiting, unnecessary processing, over‐production, movement, inventory, complexity

Powerful methods: Kaizen, Six Sigma, TPM, JIT, etc.

Integration with E/Q Management Systems


Sustainability Metrics…What’s Important

Corporate Register, Reporting Awards

3100 “corporate responsibility” reports. Top Three:

•Vodaphone (377 pages!)•Coca Cola (50 pages)•Dell (110 pages)


Sustainability Metrics…You Are Being Watched…

Newsweek Green Rankings

EarthSense

Dow Jones

New Scientist


Sustainability Metrics…Parameters

Vodaphone Corporate Responsibility Report



Vodaphone Corporate Responsibility Report

Siemens Greening Corporate America



Parameters over which you have control, influence

Quantify environmental impacts

Establish tolerances

Eliminate gaps

Demonstrate ROI


Barriers

Lean methods do not usually target sustainability metrics

Environmental personnel are often not well integrated into lean production efforts

The wealth of sustainability information is often not in the hands of lean production practitioners…Stakeholders!!!

Majority of benefits arise from design stage

Regulatory friction; regulatory uncertainty


Summary…

The game: reduce risks & embrace opportunities from economic, social, and environment developments.

Translate opportunities & risks to the manufacturing environment: value and externalities

Metrics, integration, performance

Brandon Ballengee The Spiny Diatom Chaetoceros


Resources…

No shortage of resources: EPA’s Lean to Green, Commerce Dept. Sustainable Business Clearinghouse, NIST, SME, etc

Malcolm Fox, Sustainability Director, NSF International [email protected]

Brandon Ballangee Cleared & Stained Hymenochirus Family Frog