KOHLER CO.: REDESIGNING ENGINES FOR CIRCULARITY
Since 1873, Kohler Co. has sought to provide a high level of gracious living to anyone touched by its products and services. From beautiful kitchen and bath products and innovative power solutions to developing clean water, sanitation, and community development solutions around the world, Kohler Co. believes that better business and a better world go hand in hand. It is Kohler’s goal to enhance the quality of life for current and future generations through design, craftsmanship, and innovation fueled by the passion of more than 37,000 associates worldwide.
Kohler’s Design for Environment Program
In 2011, Kohler Co. began using Life Cycle Inventory to understand the environmental impact of Kohler products and optimize the design of those products and the processes associated with manufacturing them. Circular economy principles directly correlate to what Kohler calls Design for Environment (DfE).
Design for Environment is exactly as it sounds. Kohler is designing new products and services with the environment in mind. The process starts by asking many questions, such as:
- What renewable materials can be used in this project?
- How can the company avoid creating a lot of waste?
- How can it be ensured that this product performs well but uses less water?
- How can the company design for serviceability?
The detailed step-by-step DfE model enables Kohler to make many improvements:
- Rethink design aspects, including materials, longevity, and disposal at the end of a product’s useful life.
- Focus on how consumers use Kohler products.
- Look for opportunities to minimize a product’s manufacturing, packaging, and transportation footprint.
As part of Kohler’s Positive by Design program, the company is reshaping how it approaches the design of everything. Kohler Co. has had many success stories using the DfE Model, but none so prestigious and impactful as the Crackle Collection Tile, in partnership with ANN SACKS. The WasteLAB at Kohler, in Kohler, Wisconsin uses pottery cull, iron slag, and left-over glazes and enamel powder to create this unique line of ceramic tiles. The tile is an example of looking at materials differently and diverting waste from going into the landfill.
The Circular Economy at Kohler Co.
Being a diverse organization provides Kohler Co. with a tremendous opportunity to innovate, especially in terms of environmentally mindful design and materials. As part of a regular evaluation of existing and new product design in 2011, the Kohler Engines team identified an opportunity to update engine housings, which were originally made from plastic virgin material.
A cross-functional team of engineers and supplier quality specialists based in Kohler, WI, collaborated with the housing manufacturer and resin supplier in Evansville, Indiana, to evaluate recyclable materials to replace the virgin plastic. Throughout the process, the team manufactured and tested a large quantity of parts for functionality and analyze dimensional capabilities. A polypropylene, made from post-consumer recycled waste, was selected during the first phase of the project.
Using post-consumer waste posed challenges to the team as the waste often contained nondesirable foreign materials, such as un-separated nylon, staples, and wood. These foreign objects shortened the life of the tooling equipment, leading to inefficiencies in the manufacturing process. Upon further evaluations and testing, the team changed the material to 100% post¬industrial regrind, made from recycled carpet waste. Using post-industrial waste is an example of industrial symbiosis, in which the consumption of energy and materials is optimized and the byproduct or waste of one industry serves as the raw material for another industry.
The team also reevaluated other engine parts, such as blower housing, air cleaner covers, and bases, which were subsequently switched over to the post-industrial material. Another learning curve for the team in using the recycled material was managing the tight dimensions with limited tolerance. The team mitigated this issue in 2013 by redesigning the 7000-series, this time with recycled materials in mind.
Minor adjustments were made to the recycled plastic parts, making it easier to assemble and accommodate how the material shrinks and distorts. Switching to the recycled material in 2011 took much effort, but no more than switching to a different manufacturer or grade of material.
