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