The operational processes in the supply chain offer numerous starting points for decarbonisation and the reduction of the consumption of raw materials and energy. In this way, they can also make a significant contribution to achieving the sustainability goals of companies and complying with legal requirements. Promising opportunities for improvement arise above all through the design of the manufacturing footprint, through lean processes geared towards avoiding waste, through the digitalisation of physical processes, and through the adaptation of the product portfolio and product development, including new utilisation concepts.
ROI-EFESO has a comprehensive portfolio of methods and tools to conduct a holistic sustainability analysis of existing processes and structures and to realise the identified potentials. In doing so, we focus in particular on the following topics:
- Identification of losses of production resources such as energy, water, raw material and input materials in the entire value chain and uncovering of re-manufacturing potentials
- Overall cost assessment of the production and logistics network and evaluation of the impact of the existing footprint (locations, suppliers, technologies, product portfolio, processes) on environmental, social and technological sustainability goals
- Analysis of the Industrie 4.0 maturity level and description of digitalisation potentials for the substitution of physical processes, or their optimisation from a sustainability point of view
- Assessment of the management system and the implementation of measures with regard to applicable compliance principles (e.g. ISO 26000), reporting obligations and general political restrictions (e.g. Paris Agreement, national legislation).
- Analysis of strategic sustainability initiatives and their level of maturity, e.g. with regard to CO2 neutrality and conformity with future regulatory requirements.
- Definition of sustainability initiatives and target systems within the framework of the corporate strategy, integration into investment planning and the management system and reporting system
- Development of compensation strategies and measures for a balanced emissions balance and the fulfilment of legal requirements
- Assessing the sustainability of the manufacturing footprint through technical energy audits and process analysis, as well as auditing and developing the supplier network to meet sustainability requirements.
- Development and implementation of new pricing and utilisation concepts with a focus on the entire product life cycle and a sustainable circular economy
- Optimisation of the entire value-added cycle through avoidance of raw material and energy waste, use of renewable energies, creation of closed raw material cycles, and establishment of a remanufacturing supply chain through integration of dismantling and reprocessing (recycling).
- Increasing the utilisation of plants, machines, means of transport to reduce emissions and environmental impact and sustainability-oriented optimisation of processes through the use of TQM, Industry 4.0, advanced analytics and AI
- Establish teams of experts to integrate sustainability aspects into the production system and create structural and organisational conditions for continuous improvement initiatives.
Realignment of the product portfolio:
- Consideration of the company's sustainability goals in the products / product development
- Development of climate-neutral and sustainable products (reduction of resources, energy use) and introduction of "sustainability by product design" approaches
- Extension of the value creation analysis to include sustainability criteria and the consideration of the potential of the circular economy.
- Reduction of the proportion of critical and non-recyclable materials in products and packaging and increased use of standard, carry-over or recycled parts and components (frugal development).
- Transparency about the "sustainability index" of products and their use for customers as well as consideration of the customer experience of sustainable products (Sustainability Payback)
Adaptation of product development structures:
- Digitalisation of product development, e.g. through digital "sustainability twins", simulation and virtualisation to reduce physical waste (e.g. through prototyping).
- Early structural integration of Sustainability & EHS functions in the development and industrialisation of products
- Orientation of product design towards recyclability, long service life, reparability, simplicity and upgradeability, as well as ecologically sustainable product use (e.g. through share use).
- Management of technical and environmental compliance (e.g. REACH) and certification of products and development processes
- Transparency about the ecological footprint in the entire product life cycle Procurement, production, consumption, recycling, reuse) and comparison with life cycle costs of traditional products