A Total Product System Concept - a case study of the smart (tm) automobile

Increasing demand from consumers plus EU legislation has raised awareness within the automotive production sector of the urgent need to reduce the environmental impacts from the three main stages in vehicle life – car manufacture, car use and end-of life vehicle processing. The paper reviews how the originator and manufacturer of the smart automobile has worked directly with its main system partners to address environmental issues in these three stages while optimizing performance across the parameters of commercial viability. This required the creation of strategic relationships within the supply chain. Overall, this innovative approach is viewed in the context of a total product system. The smart car highlights the following critical areas: use of modularity in product design and production facility layout; emphasis on partner participation from product creation to after-sales; and the use of highly customised build-to-order product system to 'green' the entire supply chain. In particular, the case study compares the process characteristics empoyed at the smart car factory, called 'smartville', with more traditional approaches to vehicle manufacture. It exmaines these issues in a preliminary attempt to establish the actual or potential reduction of environmental impact in the three stages of vehicle life, including the role of main suppliers in this process

An investigation into standards in sustainable design and manufacture

This paper reports upon the application of standards to reduce the negative environmental impacts of manufacturing through product lifecycle planning and closed loop production. By eliminating waste and retaining the energy embodied within materials and components, manufacturing can become more sustainable from both ecological and financial perspectives. Energy consumption and the associated carbon pollution can thus be minimised. Environmental Management System implementation is also considered

Sustainable product development strategies: Business planning and performance implications

Copyright © 2012 by Institution of Mechanical Engineers. This is the author's accepted manuscript. The final published article is available from the link below.Manufacturing firms are under many financial and competitive pressures which focus attention on the performance of their manufacturing processes. In this paper the opportunities for improving the environmental impact of products within the constraints of existing manufacturing infrastructure are examined. Approaches which support sustainability in two aspects are proposed, firstly, the provision of products to the users in ways which extend the product life and secondly, manufacturing approaches which reduce resource usage. This paper outlines three different sustainable development strategies for different product types and describes the cost implications for manufacturers across the life-cycle. The performance measures affected by these strategies are examined drawing on product development case studies from a number of high technology sectors to highlight the different approaches taken. The results are intended to aid manufacturers during the earliest stages of business planning to consider alternative product development approaches which are more sustainable

Sustainable development strategies for product provision and manufacturing approaches

Manufacturing firms are under many pressures both financially and competitive which focus attention on the performance of their manufacturing processes. In this paper the opportunities for improving the environmental impact of products within the constraints of existing manufacturing infrastructure are examined. Approaches which support sustainability in two aspects are proposed, firstly, the provision of products to the users in ways which extend the product life and secondly, manufacturing approaches which reduce resource usage. The provision and manufacture of products in ways that are truly sustainable are inhibited by three issues: firstly, decisions are predominantly made solely from the perspective of the “vendor” (and do not consider the wider perspective); secondly, that generally the scope of business planning is still rooted in production/manufacturing costs (and not consumption costs) and thirdly, the current performance measures (e.g. KPIs) mainly focus on profitability. The rationale for this conference paper is the argument that there is a need to raise the awareness during the earliest stages of business planning that there may be alternative approaches which are more sustainable. The concepts presented here will underpin further research into performance measures which encompass sustainability and resulting business planning implications

Can procurement affect design performance?

There is an emerging view in the construction industry that better performance or better value for money can be achieved by integrating teamwork for planning, design and construction of building projects. There are though, two opposing perspectives regarding how changes in traditional design practices should occur. Advocates of sustainable construction in North America posit that it is a matter of evolving processes, moving from a sequential to an iterative approach to design, whereas the British government supports the view that a change in how projects are procured is required to transform the context that dictates relationships among the members of the team. The objective of the research is to study the influence of procurement on the performance of integrated design teams. It analyses, through case studies representing these two perspectives, the influence of procurement on the performance of integrated teams. The research is conclusive in that it is the context created by contractual relationship, and not the process set up for conducting integrated design, that most influence team efficiency. It demonstrates that traditional procurement processes reinforce socio-cognitive barriers that hinder team efficiency. It also illustrates how new procurement modes can transform the dynamics of relationships between the client and the members of the supply chain, and have a positive impact on team performance

Integration of end-of-life options as a design criterion in methods and tools for ecodesign

Ecodesigning a product consists (amongst other things) in assessing what its environmental impacts will be throughout its life (that is to say from its design phase to its end of life), in order to limit them. Some tools and methods exist to (eco)design a product, just like methods that assess its environmental impacts (more often, a posteriori). But it is now well accepted that these are the early design decisions that will initiate the greatest consequences on the product’s end-of-life options and their impacts. Thus, the present work aims at analysing traditional design tools, so as to integrate end-of-life possibilities in the form of recommendations for the design step. This proposal will be illustrated by means of a wind turbine design.EcoSD networ

Product life cycle information management in the electronics supply chain

Information availability and data transparency are key requirements from manufacturers when supporting products throughout the life cycle, for example when implementing product service systems. The application of embedded wireless technologies into printed circuit boards (PCBs) can help bridging current knowledge gaps and to minimise both technical and financial risk through reduced product downtime, improved quality of tracking and enhanced end-of-life decision making. The application of embedded RFID into PCBs for life cycle monitoring of electronic products to support Product Service Systems is discussed in this paper

Investigation into current industrial practices relating to product lifecycle management in a multi-national manufacturing company

Product Lifecycle Management (PLM) systems have gained growing acceptance for managing all information relating to products throughout their full lifecycle, from idea conceptualisation through operations to servicing and disposal. This paper, through an in-depth exploratory study into a leading power generation manufacturing organisation, presents current PLM issues experienced by manufacturing companies, exploring three separate topics: 1) PLM, 2) Knowledge Management and Lessons Learnt and 3) Product Servicing and Maintenance. Following a review of published literature, results of the investigation are presented, analysing the responses of 17 employees interviewed. With respect to Product Development, it was found that information traceability is time consuming and change management requests take too long to complete. Results relating to knowledge management indicate that the Company operates a ‘who you know’ culture, but do aim to capture lessons learned on the manufacturing shop floor and assembly lines. Therefore, a prototype design is proposed to integrate the capturing of lessons learnt within the existing PLM system

The Changing Landscape of Energy Management in Manufacturing

The production and use of energy accounts for around 60% of global greenhouse gas (GHG) emissions, providing an intrinsic link between cause and effect. Considering that the manufacturing industry is responsible for roughly one-third of the global energy demand enforces the need to ensure that the manufacturing sector continually strives to reduce its reliance on energy and thus minimise GHG released into the atmosphere. Consequently, efficient management of energy consumption is of paramount importance for modern manufacturing businesses due to well-documented negative impacts regarding energy generation from fossil fuels and rapidly rising worldwide energy costs. This has resulted in a proliferation of research in this area which has considered improvements in energy consuming activities at the enterprise, facility, cell, machine and turret levels. However, there is now a need to go beyond incremental energy efficiency improvements and take more radical approaches to reduce energy consumption. It is argued that the largest energy reduction improvements can be achieved through better design of production systems or by adopting new business strategies that reduce the reliance of manufacturing businesses on resource consumption. This chapter initially provides a review of research in energy management (EM) at various manufacturing focus levels. The inappropriateness of current methods to cater for transformative and radical energy reduction approaches is discussed. In particular, limitations are found at the business strategy level since no technique exists to consider the input of these high level decisions on energy consumption. The main part of the chapter identifies areas of further opportunity in energy management research, and describes a method to facilitate further reductions in energy use and GHG production in manufacturing at the business strategy level

The influence of a collaborative procurement approach using integrated design in construction on project team performance

Purpose – The purpose of the paper is to study the influence of procurement on the performance of integrated design teams. Design/methodology/approach – The research paradigm is based on Russian socio-constructivist approach to activity theory. Activity theory, as opposed to natural or social science, is a design science approach that focuses on the context aspect of project. A triangulation of qualitative research methods is used to investigate the dynamic of integrated teams in two different procurement contexts. Findings – The paper is conclusive regarding the influence of procurement on team efficiency. It demonstrates that traditional procurement processes reinforce socio-cognitive barriers that hinder team efficiency. It also illustrates how new procurement modes can transform the dynamic of relationships between the client and the members of the supply chain, and have a positive impact on teamperformance. Practical implications – The paper demonstrates first that problems with integrated design team efficiency are related to context and not process – they are not technical but socio-cognitive; second that fragmented transactional contracting increases socio-cognitive barriers that hinder integrated design team performance; third that new forms of relational contracting may help to mitigate socio-cognitive barriers and improve integrated design team performance, fourth that changing the context through procurement does not address the problem of obsolete design practices. Originality/value – The paper brings together theories of production in lean construction and social learning as a rival approach to traditional project management theory for demonstrating the importance of context on team performance