Product Design
Product design is the most critical phase in product life cycle assessment. The decisions that are
made during this phase greatly affect materials, quality, cost, processes, related packaging and
logistics, and ultimately how the product will be processed when discarded. During design, one
of the goals is to incorporate a systems view in the product or service design that lowers the
environmental impact. This is the first R. Such an approach reduces waste and energy costs
at the supplier, in the logistics system, and for the end user. For instance, by taking a systems
view, Procter & Gamble developed Tide Coldwater, a detergent that gets clothes clean with
cold water, saving the consumer about three-fourths of the energy used in a typical wash.
Other successful design efforts include:
Boston's Park Plaza Hotel eliminated bars of soap and bottles of shampoo-by installing
pump dispensers in its bathrooms, saving the need for I million. plastic containers
a year.
UPS reduced the amount of materials it needs for its envelopes by developing its reusable
express envelopes, which are made from 100% recycled fiber. These envelopes are designed
to be used twice, and after the second use, the envelope can be recycled.
Coca-Cola's redesigned Dasani bottle reduced the amount of plastic needed and is now
30% lighter than when it was introduced.
Product design teams also look for alternative materials from which to make their products.
Innovating with alternative materials can be expensive, but it may make autos, trucks, and aircraft
more environmentally friendly while improving payload and fuel efficiency. Aircraft and
auto makers, for example, constantly seek lighter materials to use in their products. Lighter
materials translate into better fuel economy, fewer carbon emissions, and reduced operating
cost. For instance:
An excellent place for operations managers to begin the sustainability challenge is with good product
design. Here Tom Malone, CEO, of MicroGreen Polymers, discusses the company's new ulira light cup
with production personnel (above). The cup, which can be recycled over and over and never go to a
landfill, is produced in MicroGreen's Arlington, Washington plant (right).
---Mercedes is building some car exteriors from a banana fiber that is both biodegradable and
lightweight.
---Some Fords have seat upholstery made from recycled plastic soda bottles and old clothing.
---Boeing is using carbon fiber, epoxy composites, and titanium graphite laminate to reduce
weight in its new 787 Dreamliner.
Product designers often must decide between two or more environmentally friendly design
alternatives. Example S1 deals with a design for disassembly cost—benefit analysis. This process
focuses on the second and third Rs: reuse and recycle. The design team analyzes the amount of
revenue that might be reclaimed against the cost of disposing of the product at its end-of-life.