Preliminary Product Development Approach for Discarded …
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9 Macro-phase III—Sustainable and Cyclical Production
Design
After the definition of the material reuse and new product design in the previous
phases, Macro-Phase III develops the manufacturing project of the new product
having as premises: (i) the zero (or minimum) generation of waste within the production line, and (ii) the connection of all supply chain, from production to the end of the
product life cycle and its respective return (Reverse Logistics). This Macro-Phase
was divided into two steps to facilitate the application of the approach.
9.1 Step 01—Zero Waste Manufacturing
The manufacturing design of the approach was based on the P–V Analysis of (FUSCO
2003) to outline the layout of its production line with the premise of reuse of discarded
materials/products for manufacturing new products with waste zero. The online
production layout was adopted with minor adjustments so that the waste of materials
is zero along the production chain of the proposed U-TURN approach. The most
important adjustment is the creation of “collection points”. Collections Point are
large volume containers that must be located at a determined site on the physical
arrangement of the production line, preferentially at the end of each phase or step.
Alternatively, they can be allocated at a fixed spacing, such as every 20 m, ensuring
that no scrap is properly discarded for its reuse.
The distance between one point and another, if it is not possible to place after each
productive step, will be fixed, but the spacing will be different for each production
process, because the more extensive the line, the greater the spacing may be, and the
opposite being true.
For the effective approach’s functioning, a person responsible for collecting materials from all these points must be designated. The material can be collected through
a pallet style cart (platform) with tires. The period of between collections will
depend greatly on the productive volume of each line but should be scheduled before
the complete filling of the containers, ensuring that no scrap is disregarded. The
collected materials/product will be sent to the first productive Macro-Phase, making
the production waste into the raw material or disposing of it in the correct locations.
Thus, it is expected that 100% of the productive scrap returns to the process, ensuring
that no residue is discarded along the line.
9.2 Step 02—Integrated Supply Chain
The second premise proposed by the U-TURN approach is to systematically connect
all stages of the production chain of a product manufactured from waste disposal.
303
9 Macro-phase III—Sustainable and Cyclical Production
Design
After the definition of the material reuse and new product design in the previous
phases, Macro-Phase III develops the manufacturing project of the new product
having as premises: (i) the zero (or minimum) generation of waste within the production line, and (ii) the connection of all supply chain, from production to the end of the
product life cycle and its respective return (Reverse Logistics). This Macro-Phase
was divided into two steps to facilitate the application of the approach.
9.1 Step 01—Zero Waste Manufacturing
The manufacturing design of the approach was based on the P–V Analysis of (FUSCO
2003) to outline the layout of its production line with the premise of reuse of discarded
materials/products for manufacturing new products with waste zero. The online
production layout was adopted with minor adjustments so that the waste of materials
is zero along the production chain of the proposed U-TURN approach. The most
important adjustment is the creation of “collection points”. Collections Point are
large volume containers that must be located at a determined site on the physical
arrangement of the production line, preferentially at the end of each phase or step.
Alternatively, they can be allocated at a fixed spacing, such as every 20 m, ensuring
that no scrap is properly discarded for its reuse.
The distance between one point and another, if it is not possible to place after each
productive step, will be fixed, but the spacing will be different for each production
process, because the more extensive the line, the greater the spacing may be, and the
opposite being true.
For the effective approach’s functioning, a person responsible for collecting materials from all these points must be designated. The material can be collected through
a pallet style cart (platform) with tires. The period of between collections will
depend greatly on the productive volume of each line but should be scheduled before
the complete filling of the containers, ensuring that no scrap is disregarded. The
collected materials/product will be sent to the first productive Macro-Phase, making
the production waste into the raw material or disposing of it in the correct locations.
Thus, it is expected that 100% of the productive scrap returns to the process, ensuring
that no residue is discarded along the line.
9.2 Step 02—Integrated Supply Chain
The second premise proposed by the U-TURN approach is to systematically connect
all stages of the production chain of a product manufactured from waste disposal.