What is Sustainable Manufacturing?

Sustainable manufacturing is a critical framework integrating product design and manufacturing planning with production planning control to improve efficiency and decrease environmental pollution. 

A growing number of companies now understand the environmental benefits of green manufacturing, and sustainability will soon be at the forefront of economic growth and global competitiveness. These sustainability manufacturing companies follow principles that inform their sustainable manufacturing strategies and processes. 

Come along as we delve into the definition, principles, and processes of sustainable manufacturing. We will discuss processes like waste reduction to improve efficiency. We will also examine sustainability reports from 4 brands with some of the best sustainability manufacturing practices.

TABLE OF CONTENTS:

What is sustainable manufacturing?

Sustainable manufacturing, also known as green manufacturing, creates products, goods, and services through eco-friendly processes to minimize negative environmental impacts while conserving energy and natural resources. It also ensures the safety of the employees, community, and surrounding environment.

Sustainable manufacturing covers the four stages of a product's lifecycle: pre-manufacturing, manufacturing, use, and post-use. The product, production process, and manufacturing system should reduce waste and energy consumption and provide operational safety to prevent workplace hazards. 

Most of the manufacturing industry does not have sustainable manufacturing practices and economically sound processes that protect the environment from their manufacturing processes. The manufacturing sector in the United States of America contributes 17% of the country's greenhouse gas emissions and is projected to reach 26% by 2030. 

Sustainable manufacturing covers two bottom lines: people and the planet. It advocates for the production of sustainable products via eco-friendly manufacturing processes. We don't have to harm biodiversity and their ecosystems to exist. 

Principles of Sustainable Manufacturing

The principles of sustainable manufacturing, built on the principles of the UN's sustainable development goals, are based on the fact and awareness that we are a part of the ecosystem, and our actions shouldn't compromise the ability of future generations to satisfy their needs.

These principles serve as guidelines for the manufacturing sector, promoting the People's well-being, preserving the planet's natural resources and raw materials, eliminating poverty and enabling Prosperity, and promoting Peace and Partnership across various industries, nations, and communities.

The five p's of eco-friendly manufacturing are the following: 

• People 
• Planet
• Prosperity
• Peace 
• Partnership 

People

The manufacturing industry exists to produce for consumers. The sector also provides jobs for people, making them employees at various levels. Manufacturing processes should also cater to the well-being of the people. 

However, current manufacturing procedures disregard the people for whom it produces. For example, manufacturing corporations underpay and overwork their employees across various supply chain stages. 

These factories do not apply human and labor rights laws in all their dealings. It is one of the core reasons many in America's manufacturing industry moved outside America: to take advantage of the cheap and desperate workforce. 

There's also the undeniable impact of the industry on the people. People must deal with water, air, and sound pollution, improper waste management, and exposure to terrible, hazardous conditions. 

The manufacturing industry needs to prioritize the well-being of the people. It should create a sustainable product design that causes as little harm to the people as possible in all its lifecycle stages. Employees in all stages should be treated fairly, fostering a society with equal dignity. 

Planet

Protecting the planet is one of the guiding principles of green manufacturing. Since the start of industrialization, manufacturing has damaged the earth in various ways. The planet's destruction starts from acquiring raw materials like fossil fuels, minerals, and other organic matter. 

The industry releases tons of greenhouse gas emissions and facilitates deforestation, which destroys wildlife ecosystems. It also causes air, soil, and water pollution from oil spills, chemical spills, and improper waste management, posing health dangers to plants, animals, and humans. 

It is only ideal that we protect and live in balance with the planet that provides for our needs. We shouldn't cause irreparable damage just to further capitalistic gains. The manufacturing industry can produce quality products without ruining the environment with its production processes. 

Prosperity

Next on our list of sustainable manufacturing principles is prosperity. Prosperity emphasizes the possibility of a prosperous economy and industry. However, prosperity does not come at the expense of the environment. Companies can make their profits ethically. They measure their success by environmental and social impact, not just financial performance. 

Peace

Peace among competing manufacturers is compulsory, as it fosters a better working environment for employees, inclusivity, and community. There will be no room for violence if every member of society is gainfully employed and rightfully compensated. 

Also, there will be no uprisings from society if the manufacturing industry doesn't contribute to environmental degradation. There have been protests and uprisings from communities affected by unsustainable manufacturing operations. The companies involved tend to use force to deter them, which might lead to more violence. 

Partnership

Partnerships with other sectors and organizations that engage and promote sustainable manufacturing practices are the backbone of sustainability. We need every hand on deck to ensure that every aspect of the manufacturing industry is sustainable, down to its grassroots. 

It requires the participation of all stakeholders, shareholders, government, and non-profit organizations to hold each other accountable for implementing sustainable manufacturing practices. 

Sustainable Manufacturing Practices and Processes

1. Sustainable Product Design

The backbone of sustainable manufacturing practices is sustainable product design. Sustainable product design means designing a product in the most environmentally friendly way. Manufacturers should consider design choices and processes that minimize negative environmental impacts. 

Sustainability efforts are made throughout the product's lifecycle to ensure that it causes zero to minimal harm to the environment. A product must be sustainable from the raw material sourcing stage through the production and assembly phase to the post-consumer phase. How the raw material is sourced is vital in determining whether a product will be sustainable. 

Products often mined or extracted from beneath the earth damage the environment. For example, the extraction of fossil fuels causes oil spills, which irreparably damage the environment and its inhabitants. Manufacturers must ensure their products are biodegradable, reusable, or easily recycled. 

2. Renewable energy consumption

Using renewable energy sources is a crucial aspect of implementing sustainable manufacturing practices. The industry employs many energy-intensive processes and types of machinery, which burn through quickly. 

Furthermore, it is essential to note that a more significant percentage of the industry's preferred energy source is fossil fuel, which is incredibly damaging. Using fossil fuels as an energy source is one of the major drivers of climate change.

Fossil fuels release tons of carbon emissions, producing harmful particles and soot that clog the atmosphere. Renewable energy sources like solar or wind don't cause similar environmental issues. 

These greener sources are energy extracted from the sun, air, water, and land that do not produce greenhouse gases. Some types of renewable energy include hydropower, which uses a waterfall or artificial dam to generate energy; wind energy from wind turbines; and solar energy, which converts sunlight into energy.

Renewable energy reduces the energy costs of the manufacturing sector because it is more sustainable and practical. As a growing number of companies pivot to a solar power system or wind turbine, they minimize waste and make manufacturing operations easier. 

3. Proper waste management

Waste reduction is a crucial part of sustainability. The manufacturing industry produces several types of waste, which are problematic for the environment and society. Factories must implement processes that minimize waste during a product's production process and after the consumer uses and discards the product. 

Waste management covers reducing waste generated, properly disposing of toxic and non-toxic waste, and recycling and reusing waste products. Factories can reduce waste at post-consumer levels by sourcing sustainable materials that will last longer.

They also invest in sustainable packaging methods that are biodegradable and recyclable. Factories could also reduce the quantity of packaging materials used to deliver goods to consumers—they should be much more efficient to reduce waste. 

Another proper waste management practice is properly treating hazardous waste before releasing it to landfills. Factories should also establish appropriate waste channels for chemical waste to prevent it from contaminating water bodies. Correct waste management ensures the earth's ecosystems and inhabitants' safety. 

4. Operational efficiency

Next on our list of sustainable manufacturing processes is operational efficiency. It refers to using raw materials and resources effectively to produce at the lowest production costs while maintaining the product's quality.

It is based on how safe and secure your production process is for employees and focuses better on achieving efficient operations with reduced energy costs. Some examples of operational efficiency are the implementation and increase of automation systems. 

Manufacturers should define sustainability goals and milestones. It helps prioritize areas that require the most sustainable actions. It also includes the various sectors within the manufacturing industry holding themselves accountable by creating sustainability reports of their processes to help measure their impact on the environment. 

5. Transparent supply chain

The supply chain is one of the industry's crucial parts. A company with a sustainable supply chain knows everything in its manufacturing processes through open communication and factual information. This builds trust between consumers, companies, and suppliers. 

Companies gather and analyze supply chain data, improve efficiency where appropriate, and pass the data-backed report to consumers, employees, regulators, and investors.   Companies can map out their supply chain to ensure a transparent supply chain to reduce supply chain risk. 

They can also implement innovative technology solutions to analyze data accurately. A transparent supply chain shows how a sustainable manufacturing business is committed to holding itself accountable for sustainable production goals.

6. Employee training and public awareness

Lastly, green production practices must raise public awareness about sustainability goals, objectives, and progress. Leaders should train employees within the supply chain to reflect the company's sustainability goals and the sustainability initiatives used to attain them. 

The employees understand the need for sustainability and actively work towards achieving sustainable manufacturing solutions, while public awareness serves as an accountability partner.

Examples of Brands with Sustainable Manufacturing Practices

Electrolux Group

Electrolux Group is an electronics household equipment manufacturer with sustainability initiatives to reduce the impact of its production process on the environment. The company started its sustainability journey around 2008, attempting to reduce energy consumption.  

Electrolux reported it had reduced its energy consumption from 2008 to 2010 by almost 16% and natural gas consumption by 30%. The company keeps improving its sustainability goals and approaches to achieving them. For example, 60% of the energy used in Electrolux factories was from renewable sources.

In 2023, Electrolux reduced its carbon footprint by 33% and hopes to have reduced 85% of its emissions by 2030. It also improved its energy and fossil fuel use efficiency by 5.7% and 13%. Also, water efficiency during production has increased by 48% since 2015, while 71% of its factories have gotten the Zero Waste to Landfill program certification.

The certification shows that Electrolux sends less than 1% of its waste to landfills. It also includes recycling initiatives in its production process, earning Electrolux a European Plastic Recycling Award for creating Electrolux fridge liners.

Patagonia

Patagonia is a fashion company with vast supply chains. Its core belief is that everything it makes impacts the planet. To this end, Patagonia has explored various sustainability initiatives to create economically sound processes that minimize negative ecological impact and reduce waste. 

Patagonia adheres to all the principles of sustainable manufacturing that were previously listed. As of 2022, it ensured that 34% of its apparel-assembling factory workers received fair living wages. The company promotes the reuse and repair of fashion items. In 2023, the fashion company facilitated the repair of 63,000 clothing items.

Patagonia's sustainability initiatives include using 100% virgin cotton grown organically. They even created a Regenerative organic certified cotton program with over 2000 farmers. Apart from using natural resources, Patagonia recycles marine plastic waste into fashion gear. They have recycled over 1,400 tons of plastic since 2021.

They also prioritize public awareness and inform consumers about their sustainability initiatives and supply chain processes. Patagonia is accountable for reducing carbon emissions using the Science Based Target Initiative (SBTi). The company also makes financial donations to support environmental groups on the frontlines of solving environmental crises.

Beyond Leather Materials

Beyond Leather Materials is a fabric manufacturing company located in Copenhagen, Denmark. The company aims to find ways to create leather materials sustainably. In 2017, they launched Leap, a sustainable fabric made from apple waste. Leap is short for leftover apples. 

The fashion company exhibited transparency in its supply chain. It is interested in transforming the garment industry by upcycling common organic waste material. Its product design is very sustainable and promotes a closed-loop economy.

Leap uses less water and has a lower carbon footprint than traditional leather production methods. Beyond Leather Materials is an excellent source of sustainable raw materials for the fashion industry. 

Ikea

This well-known household brand produces various household items. They create furniture, lighting, home decor, kitchenware, and tableware, even smart home accessories, and home improvement tools. Ikea tailored its sustainability strategy to the Sustainable Development Goals (SDGs) to promote sustainability in various households. 

According to Ikea's 2023 sustainability insights, it reduced its carbon footprint by 12% compared to 2022 statistics and 22% compared to 2016's figures. They also created a product series, Silversida, that uses ceramic waste to produce new tableware. Ikea used 65-75% of factory waste materials for production.

Ikea launched a global wood supply map to increase further transparency about how and where it sources the wood used for production. It also dabbled in waste reduction by using 47% less plastic for packaging materials. 

From the 2022 sustainability report, Ikea learned that most of its emissions were from glue used in almost all stages of production in the factories. So, it created a new bio-based glue that will reduce glue emissions by 30% in the coming years. 

Ikea utilizes a lot of renewable energy for its production and logistics services. It used up to 77% renewable energy for retail, 90% for logistic services, and 63% to 71% for production. Ikea always finds new ways to reduce its environmental impacts. It also contributes to society by creating a Skills for Employment program to support asylum seekers and refugees.

Conclusion  

Green manufacturing is crucial to the survival of humanity and the earth's ecosystems. The manufacturing industry is one of the largest contributors to greenhouse gases, a harmful factor responsible for climate change. Creating eco-friendly manufactured products without cutting corners and reducing costs promotes a closed-loop economy. 

Unfortunately, the cost of finding alternative means of sustainable production is too much for some to bear. Furthermore, some parts of the manufacturing industry lack awareness of sustainability concepts and the possibilities of sustainable innovations. 

Luckily, more manufacturers are learning the importance of green manufacturing. New technological innovations monitor supply chains and decrease pollution in the environment. We, the consumers, should also hold the industry accountable to sustainability goals and standards.