understanding a life-cycle approach learning unit b: exploring eco-efficiency exercise: sessel...
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Understanding a life-cycle approachLearning unit B: Exploring eco-efficiencyExercise: Sessel Manufacturing Inc.
DEDICATED TO MAKING A DIFFERENCE
Learning objectives
• Experience cross-disciplinary group discussions on business objectives, operations, product design and environmental performance
• Gain insight into link between business and environmental initiatives
Sessel Manufacturing Inc.
Sessel Manufacturing Inc.
Retail Inc.
EMS – ISO cert.
Our tasks
We have been asked to work together on two tasks:
1. Generate options for improvement, as per our customer and market needs
2. Present the business case for the option to the CEO
To do this, we’ll first brainstorm individually and then form groups
Lawn chair details
Design– in house; all parts metal and plastic
Suppliers– provide component plastic parts (i.e. armrests, feet, tube plugs/caps, etc.)
Production– all metal work production done in house (i.e. cutting, bending, welding, deburr)– all finishing and assembly done in house
Distribution– corrugated paper used for protection during stacking of chairs– stacks wrapped on pallet
Use– customers use seasonally and occasionally– chair exposed to 1) weather and seasonal fluctuations 2) heat 3) ultraviolet light 4) rain
and humidity 5) occasional snow
End of use– lawn chair may go to secondary use/garage sale– ultimately sent to landfill
Brainstorming
Project team work
Discuss ideas from all individuals and choose the top five
For those five, consider whether they:– Will provide marketing value to Sessel or the retailer– Have distinct benefits (design, marketing, production,
purchasing/sourcing, management/strategy)– Are technically and economically feasible, as deemed by
the expertise in your team
Select the best option and outline your case for the CEO– Action Plan: what are the short- and long-term actions?– What are the associated benefits for Sessel, Retail Inc.,
both?
The real story
Distribution of the energy consumption over processes
84%
0,05%
0,15%
1% 1% 1%
6%
7%
Pretretment chemicals Cooling zone
Conveyer Powder coat outer
Powder Coating line Pretretment Zone I
Dryer Powder Dryer
0
500
1000
1500
2000
2500
Painting total
Primary energy MJ
Power Thermal Energy
Energy use during finishing
0
500
1000
1500
2000
2500
3000
3500
4000
New Longlife
(w.c.)
Longlife
(w/o.c.)
Longlife
(Scenario 1)
Longlife
(Szenario
PVC)
Primary energy in MJ /Chair
Remove Paint
Transport to Use
Assembly
Coating
Manufacture Basis
Manufacture Top
Disposal
Transport
Cost comparison between design options
Project Duration: 3 MonthsProject Cost: $37,500
Cost Savings: $6,000 per weekReturn on Invest: 6 weeks
Bonus:future market increase expected due to longer life and consumer satisfaction
Details of the life cycle study
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