Sustainability in Manufacturing: Saving Now to Save the World Later

The manufacturing industry is a major contributor to greenhouse gas emissions, and it has been called upon to play an important role in reducing these emissions.

In the US, manufacturing accounts for almost a quarter (23%) of direct carbon emissions, according to the Environmental Protection Agency. In Europe the situation is equally dire: the industry emits an annual total of 880 million tonnes of carbon dioxide equivalents making it one of the largest emitters of greenhouse gases on the continent. ~ WeForum

Manufacturers have already begun to take action towards sustainability.

In our recent #USAMfgHour chat, the Team at Obsidian Manufacturing, led by Sue Nordman, Ben Norman and Emily Kite, hosted a chat segment on conversation sustainability in manufacturing.

The chat went over the basics of manufacturing sustainably; then the conversation shifted to its importance, examples, hurdles and company practices.

Sustainability | What it Means

Sue Nordman from Obsidian Manufacturing said, “To maintain at a certain or set level. In manufacturing, I feel that it means to make responsible choices in all areas of your business to better the environment for everyone.”

Chase Bodor from Plastic Plus Technology, Inc added, “... I think this is said perfectly. Make responsible choices for your business, people, and environment. Also, evaluating the impact of those decisions is a key component of this.”

Rebecca Prox from DSI/Dynamic in Wisconsin shared here view, “Sustainability, to me, means that something is good for the earth and doesn’t deplete resources.”

Ruby Rusine from Social Success Marketing answered, “Generally, it refers to the ability of systems - be they ecological, social, economic, or others - to function & thrive into the future. Often includes considerations of stewardship & responsible use of resources, as well as intergenerational equity.”

Bill Garland from New Mexico said, “Balancing environmental concerns with cost, reliability, and customer requirements.”

Rick of PlastTechServices, Inc. said, “Sustainability is to prolong the life of a facility or equipment that results in to protect natural resources and preserve the wellbeing of the environment.”

While Tuffaloy Products Inc responded, “The quality of not being harmful to the environment or depleting natural resources!”

Paul Kiesche from Aviate Creative said,"?Being able to continue and thrive rather than use, abuse and lose. If it’s not sustainable, it will die out or run out."

Also, Matt from Aviate Creative added, “I hate to answer questions by using the terms of the word, but literally the ability to sustain a certain level of stability, usually making use of supplies acquired with relative efficiency.”

Manufacturers' News, Inc. said, “A sustainable system is one that avoids waste, so that it can “live on” indefinitely without doing damage to the planet."

Why care??

The Obsidian Manufacturing Team said, “Finding more ways to be sustainable in manufacturing decreases the amount of waste produced. According to the United States Environmental Protection Agency, in 2018 metal waste was 8.76% of the total waste generated or 25,600,000 tons. In 2018, metals accounted for 12.62% or 8,720,000 of recycled goods.”

Also, they said that, “The United Sates ranks #3 for countries that produce the most waste as of 2019!”?

Prox responded, “We’re really big (in geography and population), so I’m sure that has something to do with it. I’m not sure I like being ranked in that, though.”

Rusine chimed in, “Hmmmm...so if that is the case [regarding rank], how are we regarding re-purposing, recycling and upcycling waste compared to other countries? Where do we rank?”

Bodor shared a link in response to Rusine’s question, “I’d check sources on this. Just did a quick search.”

Lou from Allway Tools Inc said. “To emphasize sustainability is to emphasize our customers, employees and communities. To consider sustainability is to think long-term.”

Whitney Koch from Welker, Inc. said, “More and more consumers are looking for products that are made sustainably. If you don’t work to find more sustainable ways to manufacture, you’ll likely start to lose customers”

Adam Baker from Schooley Mitchell responded, “Sustainability in manufacturing helps change the image of manufacturing. Outsiders think of the “old” manufacturing of the industrial revolution but today’s it’s the new manufacturing of being a positive contributor to the environment."

Manufacturers’ News, Inc. added,"Given that manufacturers make A LOT of stuff, manufacturers can also create a lot of waste. But with so many new sustainable manufacturing technologies, manufacturers can now serve a seriously impactful role in sustainability."

Kati McDermith from Manufacturers’ News Inc. added, “Let’s not forget the impact we have as buyers and consumers. Are we purchasing responsibly? Are you buying from mfgs that use sustainable operations?

Janice from Burger & Brown Engineering, Inc, said, “If we can’t manufacture sustainably, we are pushing off future environmental issues to our kids.”

While Sherri Darby from WiscoLift said, “In manufacturing, sustainability could improve your public image as well as help support the health of your employees and customers.”

Future Negative Outcomes If We Do Not Manufacture More Sustainably

Technology has made leaps and bounds in recent years. We’ve seen a huge shift in how products are designed and manufactured. As we move forward into the future, we need to understand the potential negative outcomes of manufacturing.?

Sue Nordman from Obsidian Manufacturing said, “Taking care of our world is a global responsibility. Sustainable manufacturing can also increase employee, community, and product safety. Also, it can substantially help a company’s bottom line, if done correctly.”

Bodor said, “Bonus: Environmental impact is up there near the top: less clean resources, more waste, global environmental impact (deforestation, climate, etc) The social impact: Poorer working conditions, a less enthusiastic workforce, overconsumption, unhappy people.”

Kirsten Austin from DCSC Inc. said, “The obvious is business failure and non-renewable resource depletion.”

Rusine, “It can help to improve our quality of life. When we live sustainably, we make choices that help us conserve energy and water, eat healthy foods, and breathe clean air. This can lead to a healthier and happier lifestyle.”

Kieshche said, “Oh it’s about to get dark. :( What would happen to the earth & people if it becomes uninhabitable? I’ve been in cities where you can’t go out because the air is so bad, in oceans that trash floats next to you, in lakes where the water isn’t drinkable. Not good.”

Packer said, “It is all about the long game. Over the last 30 years there has been too much emphasis on short term quick gains and not enough thought given to the long game. As I said in A1. Sustainability is “Will the business be here in 20, 50, 100, 500 years time?”

Bigger responded to Packer, “Everything is long game Nigel. If you aren’t playing that, you are playing the WRONG game.”

Bodor said, “Sustainability helps keep us within the limits of overusing our planet’s resources and find cleaner, effective ways to make products. It also challenges us to find better ways of doing things.”

Prox said, “Benefits: healthier people, stronger earth... leading to better manufacturing as a whole. Negatives: If we aren’t employing sustainable practices, the future will be grim. The earth won’t be able to give us what we need to be healthy or strong.”

Baker said, “Sustainable operations become less costly overtime, providing better budget control. If you don’t become more sustainable, your budgets are constantly at risk of ballooning and forcing unanticipated changes.”

Koch said, “If we don’t work on this in the USA, I can see more conscious consumers looking elsewhere for their products. Even if a company can “catch up” in sustainability practices, it will be very far behind in terms of customer perception.”

DuraTech Industries from Wisconsin said, “Sustainable practices are usually more economical in the long run! Also, the value of preserving environmental quality shouldn’t be overlooked. Companies can market their sustainable practices as well, as people are becoming more environmentally conscious!”

PlastTech Services, Inc. said, “The failure to protect and preserve our natural resources through sustainability is to undermine the very resources that provide our profitability.”

Allway Tools Inc. said, “Benefits: Reduced costs and waste. A3 Negatives: Increased costs and waste.”

Burger & Brown Engineering, Inc. said, “For us, when we recycle metals, we receive money back from the recycler, but resources are finite and should be respected.”

Brett Kramer from FreightPop said, “Sustainable practices are usually more economical in the long run! Also, the value of preserving environmental quality shouldn’t be overlooked. Companies can market their sustainable practices as well, as people are becoming more environmentally conscious!”

How the #USAMfgHour Community of Companies Currently Practice Sustainability

The manufacturing companies and its advocates were asked this: Is your company doing anything to be more sustainable??

Rusine said, “Our company uses a WFH setup, so we primarily work online. That means we don’t need to go out or use vehicles to go to work, which leads to lesser carbon emissions on our part. Aside from that, we encourage eco-friendliness in our team.”

Bigger said, “Yup, we are a software company that assists with supply chains and helping to cut waste by grouping projects/orders in sequence by scheduling and planning to be optimized.”

Austin replied to Bigger”... and we’re a software company that takes the redundant paper processes in picking, shipping, manufacturing, receiving etc. away! Less paper, is better all the way around.

Prox said, “Yes! Example: We repair and refurbish old units often! We don’t replace unless we absolutely have to. Our units last decades, too, so there isn’t a high turnover of product.”

Aviate Creative said, “We WFH. As such, everything is conducted online, so our sustainability relates to time efficiencies, and how much we can personally reduce. My work commute consists of walking 10ft across my living room so it’s quite ecologically friendly.”

Nordman said, “Corporate Social Responsibility, Lean manufacturing, ISO certification, Green Procurement, Zero Waste, Remanufacturing, and so much more! “

Koch said, “We’ve launched products to help our customers with their ESG commitments. Internally, several departments have worked on going paperless.”

Bodor said, “I’m part of Operation Clean Sweep for my company - an org dedicated to keeping plastic pellets out of the ocean."

Manufacturers’ News, Inc. said, “We are not a manufacturer, but are a supporter of manufacturers, and do see a growing number of U.S. manufacturing companies promoting their sustainable practices, and there are many other on the cutting edge of developing new green technologies.”

Baker said, “Examples of sustainable efforts are returnable packaging and warehouse installing solar panels to generate their own electricity.”

Manufacturers’ Hurdles to Sustainability

A big hurdle is getting buy-in from management. There needs to be a culture change. It also requires more than just a few employees to make a difference. It has to be a corporate-wide initiative.

Nordman said, “First one I would say is making financial changes to support a company’s efforts. It takes a conscious effort to make better choices in all areas of the business. Sometimes the best way to get started is baby steps.”

Rusine answered:

• Financial barriers
• Transitioning to sustainable manufacturing can lead to a major overhaul in systems, plans & strategies
• A lack of time and devotion to find ways to properly implement sustainability into the company’s strategy.

Prox said, “Cost prohibits 100% sustainability.”

Baker said, “Recyclable items change frequently, and if you don’t stay up on it, companies risk incurring contamination fees that make recycling a financial liability.”

Packer said, “Refocusing supply chains and product manufacture to find new materials and systems that take waste out of the system. It has the potential to increase profits as well.”

Koch said, “Good question… I think a lot of it comes down to work styles and preferences. Some people (myself included) have a hard time letting go of paper processes and moving to digital.

Darby answered, “Equipment has kept us from being completely sustainable. It’s more efficient sometimes to purchase newer equipment and so we have to find a way to discard the old.”

Brash Inc. said, “Batteries. Recycling batteries is not easy.”

Burger & Brown Engineering said, “We manufacture with sometimes exotic metals and high tech ceramic materials. Complete sustainability to me would mean zero impact. I’m not sure this is possible. Sustainability is subjective.”

#USAMfgHour Community of Companies Individual Sustainabilty Goal/s

Nordman answered, “ISO Cert. But before we can get there, we need to structure things differently in our processes. Our brands are very well established. Manufacturing products today that were invented in 1916 is challenging but can be done. We are better than we were yesterday!”

Bodor said, “We have what we call the 4Z’s quality objectives. Two of those Z’s are “Zero pellets lost” and “Zero defects”. These are both sustainability goals to reduce the waste of plastic through our operation."

Bigger said, “I don’t have a good answer to this. All I can do is do what I do here to help where and when I can and pass along information like what is being presented in this chat.”

Rusine said, “Keep doing what we are currently doing - and improve along the way.”

Koch said, “Good question! I am not sure if we have an specific goals at this time. But that gives me an idea for encouraging more sustainable personal habits within our company.”?

Conclusion

The goal of this discussion was to get everyone thinking about how they could incorporate sustainability into their daily lives. The goal was to spark ideas on how to move forward towards becoming more sustainable companies. If you liked the recap, come join the chat.

Contact or follow the Twitter chat co-chairpersons for updates:

• Kirsten Austin | DCSC Inc. ~ Suppy Chain Management Software
• Julie Radwell | Radwell International -Manufacturing and Factory Optimization Specialists
• Dan Bigger | Optessa ~ ERP Software
• Ruby Rusine | Social Success Marketing ~ B2B Social Selling Specialists