1. No category

Product/Service-System Development
towards Innovative and Sustainable
Engineering Solutions
Tim C. McAloone
Disposition
• Service design* and its sustainability potential
• Sustainable design
• Sustainable product/service design
• All of the above from a teaching perspective
* product/service-system design
2
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Service design
Sustainable design
Service design
Sustainable design
3
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Service design
Service design
4
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Why is service engineering so important to
study?
Information/
organisation
Material
Products
Services
11%
30%
9%
50%
[Karmarkar, 2007]
5
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Why is service engineering so important to
study?
13:1
49:1
[Shaheen & Cohen, 2010]
6
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Motivation for PSS
Why be concerned about product and service?
100%
Personal
computers
Locomotives
Ships
annual cost of use:
$6,259
annual operation
costs: $29 bio.
annual operation
costs: ???
decomissioning
network administration
yard operations,
railway administration,
etc.
network equipment
c
80%
r
train operations
40%
aux. motor
e
non-productive
operations by enduser (downtime, file
management etc.)
v
i
cargo-related
systems
s
60%
unforseen
breakdowns
e
network technical
support
infrastructure
Most products are not traditionally designed for service:
•
•
•
•
•
•
Design for Maintenance
Design for Upgrade
Design for (Remote) Monitoring
Design for Reuse
Design for Replacement
Design for Longevity
main motor
administration
fuel
desktop hardware
0%
total expenditure:
5 x product costs
7
freight car services
technical support
product
20%
Illustrative sketch only
locomotive services
locomotives
total expenditure:
21 x product costs
DTU Mechanical Engineering, Technical University of Denmark
Ship
total expenditure:
?? x product costs
[after Wise & Baumgartner, HBR, 1999]
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Presentation title
Total Cost of Ownership
Click to edit Master
for a Ship
title style
[Balstrup Jørgensen and Palm Johannessen, 2013]
8
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Service design
Service design
9
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Sustainable design
Sustainable design
10
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Why is sustainability so important to study?
Meet Allan and Bodil
• Climate change
• Resource depletion
• Over population
• Climate induced pandemics
• Inequity
• Climate refugees
[CIRCA, after University of Augsburg]
11
DTU Mechanical Engineering, Technical University of Denmark
[US EPA]
[US Census Bureau and UN population estimates]
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
“Technology just keeps getting better on its own”
[W. Young, IBM, 1996]
Specific electrical consumption
by household appliances
Private consumption and electricity use in
households
Stock of electrical appliances in
households
”… and it surely needs to!”
“Sustainability is like an undergraduate
party. At 1 am everybody says ‘I’m really
drunk! I had better stop drinking and go
home…’ Same thing happens at 2am,
3am, etc…”
[Energy statistics: Danish Energy Agency, 2011]
12
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Challenges on the path to sustainability
•
13
A product’s use is not defined by the designer, but does the
designer have a responsibility for how products are used?
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Two problems of material product ownership (1)
• Product usage
• The emerging pattern of environmental load vs. responsibility
or ELV
or packaging
or…
Traditional producer responsibility
+ WEEE
Here’s where the action is!
14
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Two problems of material product ownership (2)
• Consumerism
15
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Factor X
(1/2)
• In 2050 we will need 8.5 planets to absorb the amount of
C02 produced.
• In 2050 it will take 3.5 planets to sustain the amount of
cement currently used.
• In 2050 3.5 planets will be needed in order to meet our
current levels of wood consumption.
• In 2050 3.5 planets will be required to meet our current
steel consumption levels.
[demi, 2001]
16
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Factor X
(2/2)
Ehrlich and Ehrlich [1990]:
•
To maintain environmental impacts at their current level, the desired size of
impact reduction over the next forty years (where the world population is set
to double) lies between Factor 4 and a Factor 20.
•
In order to achieve Factor 20 reductions in impact, a radical reconceptualisation of both demand and supply is necessary.
17
DTU Mechanical Engineering, Technical University of Denmark
Design for Environment...
18
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
DISPOSAL
MAINTENANCE
USE
INSTALLATION
SALES
TRANSPORT
ASSEMBLY
MANUFACTURE
RAW MATERIALS
...permeates all phases of the life cycle
14/05/2014
Seven key criteria for sustainable design
Raw
materials
Manufacture
Assembly
Transport
Sales
Installation
Use
Maintenance
Disposal
Durability
Sufficiency
Efficiency
Equity
Systems thinking
Scale
Appropriateness
[Datshefski , after demi project]
19
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Raw
materials
Manufacture
Assembly
Transport
Sales
Installation
Use
Maintenance
Disposal
Please Chair from Steelcase
Fewer parts & changed materials
15% less transport weight (& volume)
Better recyclability
Durability
Efficiency
[see: www.steelcase.com]
20
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Raw
materials
Manufacture
Assembly
Transport
Sales
Installation
Use
Maintenance
Disposal
ReElight: Battery-free bicycle
lamps
Inductive safety lamps for cycles
Eliminates all need for batteries
Extra safety elements added
Durability
Efficiency
Systems thinking
[see: www.reelight.com]
21
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Raw
materials
Manufacture
Assembly
Transport
Sales
Installation
Use
Maintenance
Disposal
’A-Pump’ from Grundfos
Low-energy circulation pump for
housing complexes
Durability
Efficiency
Systems thinking
[see: www.grundfos.com]
22
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Ecodesign methodology
Danish EPA Campaign
Step 1
Use context
Step 2
Overview
Step 3
Eco‐profile
Step 4
Actor‐network
Step 5
Quantifying
Step 6
Conceptualisation
Step 7
Eco‐strategy
23
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Main output: A guide for product development
Guides printed/distributed: 6.000 (4.500 DK + 1.500 UK)
Downloaded: 3.000+
Available electronically
Link on www.ecodesign.dtu.dk
Free of charge
No copyright
24
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Product Life Thinking workshop
Steelcase USA, Sept. ’09
25
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Twelve months after this…
…they still couldn’t do it (on their own)
26
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
...so how to help with ecodesign
implementation?
•
•
•
•
Questionnaire with 34 questions
Sent out to 500+ “DfE practitioners”
Response: 80 companies
Just over half of respondents
from DK
Denmark – 42
USA – 10
Sweden – 8
UK – 7
France – 5
Croatia – 2
Finland – 2
Portugal – 2
Slovenia - 2
• Company demographics:
27
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Largest drivers
• What do you think were the main drivers for your company to start
taking environmental initiatives? (Maximum 3 answers to be selected)
Top 3:
• Legislation
• Customer demands
• Proactive drivers
28
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Largest barriers
• When you started your environmental initiatives, what were the four
most difficult barriers to overcome? (Maximum 4 answers to be selected)
Paraphrasing the survey:
• Lack of allocation of
resources in company
• Difficulty finding relevant
data
• Need for training/
competency lift
• No systematic approach to
ecodesign in the company
product development
model
29
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Ecodesign practices
Collection of ecodesign best practices
62
448
112
Process: comprises all tasks required to bring a product from concept to product including all activities
from raw material to finished goods. This is both formal processes and day-to-day work practices.
People: recruiting, selecting and training engineers, leadership style, organizational structure and learning
patterns. This area also covers the organizational culture
Technical: all tools and technologies needed to bring a product into being. It also entails the “soft” tools
that support the effort of the people involved in the development process.
[Pigosso, 2012]
30
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Promising answer to these problems:
Ecodesign Maturity Model (EcoM2), Daniela Pigosso
Coloplast
Embraer S/A
Grundfos
LEGO Group
Natura
Philips
Healthcare
Tecumseh
[Pigosso, 2012]
31
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
But what about that thing called Factor X?
Lighting Fixtures
F2.44
• Increasing amounts of Factor X
examples
Microwave ovens
• However, “X” is still low
F1.27
• X=10 or X=20 seems impossible
through product design alone
Automatic washing machines
F2.00
[Mitsubishi, 2006]
32
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Service design
Sustainable design
Service design
Sustainable design
33
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Vertical integration of sustainability strategy in
the organisation
34
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Sustainability as a driver for
innovation of whole systems
35
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Environmental improvements through PSS
[Shaheen & Cohen, 2010]
36
DTU Mechanical Engineering, Technical University of Denmark
Integrated product/service design
Sustainable design
...from an engineering education perspective
Service design
Sustainable design
37
DTU Mechanical Engineering, Technical University of Denmark
This is ecodesign!
38
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Educating engineers in product life
thinking and sustainable design
Learning vs. teaching ecodesign
• First task: Eco-game
• Second task: Write an article
about one of the aspects of the
course...
39
DTU Mechanical Engineering, Technical University of Denmark
Teaching Sustainable PSS to engineers
Eco + PSS teaching at DTU
Tasks on PSS course 2013:
• Light and lighting control
• Soft drink vending machines
• Organic waste sorting
• Inter-campus transportation: Lyngby-Ballerup
• Commuting to and from DTU Lyngby campus
• Optimisation of paper consumption
• Coffee rituals, technologies and consumption at DTU
• Hand-tools in DTU’s Estates department
40
DTU Mechanical Engineering, Technical University of Denmark
Product Life Galleries from 2013
41
DTU Mechanical Engineering, Technical University of Denmark
PSS final results from the students
42
DTU Mechanical Engineering, Technical University of Denmark
Reflection & conclusion
43
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Integrated product and service development
PRODUCT DEVELOPMENT
MANUFACTURE
PRODUCT
MARKET
DELIVERY
DESIGN
MARKET
SERVICE DEVELOPMENT
44
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
New perspectives with integrated PSS
development
45
•
Customer activities are part of the value
creation process
•
Company takes upon responsibility in the
value chain and new roles are defined
•
Knowledge and competencies aimed at
customer’s activities
•
Creating new relationships and different
networks of stakeholders
•
Great opportunities for Factor X improvements
through PSS
DTU Mechanical Engineering, Technical University of Denmark
CUSTOMER
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Integrated product/service design
Sustainable design
...it’s not a choice of whether,
it’s a choice of how
Service design
Sustainable design
46
DTU Mechanical Engineering, Technical University of Denmark
IDA Design Symposium: Sustainable by Design: TMcA
14/05/2014
Thank you for listening!
© Technical University of Denmark, Department of Mechanical Engineering, Section of Engineering Design and Product Development
Tim McAloone, Professor, PhD
Technical University of Denmark (DTU),
Department of Mechanical Engineering
Section for Engineering Design and Product Development
Building 426, Produktionstorvet, 2800 Lyngby,
Denmark
Telephone (+45) 4525 6270
Email [email protected]
Homepage www.kp.mek.dtu.dk
© Technical University of Denmark, Department of Mechanical Engineering, Section of Engineering Design and Product Development