罗兰贝格-工业企业的循环经济解决方案（英）-2023

What

goes

aroundcomes

aroundThecircular

economyinindustrial

manufacturingTHE

BIGCOMPANIES

MAKEAMBITIOUS

STATEMENTSON

DECARBONIZATIONMany

resourcesare

already

scarceSecondary

materialsare

theanswerCircularity

is

the

keyCIRCULARITY

MEANSMORE

THAN

JUSTRECYCLING

WASTEReusing,

repairing

and

refurbishingcan

change

the

worldContentsThecircular

economy

inindustrial

manufacturing|

Think:Act

31

–

PAGE

4

Whatis

thecircular

economy

–

And

why

isitsoimportant

for

industrial

manufacturers?

2

–

PAGE

8

Thetechnical

cycle–Four

levers

for

changing

the

world

PAGE

15Interview

with

Andrew

Morlet

3

–

PAGE

17

Whatcan

we

do?Real-lifeexamplesof

circularity

4

–

PAGE

21

Theimpactonbusiness–How

thecircular

economy

affectsindustrialmanufacturers5

–

PAGE

22

A

task

for

the

wholecompany

–To

do's

by

business

function

PAGE

24

Inconclusion–A

checklist

for

decisionmakers4Think:Act

|

Whatgoesaroundcomesaround1

–

Whatis

thecirculareconomy

–

And

why

isitsoimportant

for

industrialmanufacturers?BACK

IN

1966,

renowned

English-born

Americaneconomist

Kenneth

E.

Boulding

described

the

closedeconomy

of

the

future

as

a

spaceman

economy,

one

inwhichthe

Earth

"has

become

a

single

spaceship,

without

unlimitedreservoirsofanything,eitherforextractionorforpollution[…]."

He

contrasted

this

with

the

cowboy

economy

of

the

past,inwhichresourcesappearedinfiniteandillimitable.The

evidence

is

clear

that

we

have

now

entered

this

neweconomic

phase:

Unless

we

clean

up

our

act

urgently

andstop

acting

like

cowboys,

we

will

soon

have

to

abandon

ship

THE

CIRCULAR

ECONOMY

EXPLAINEDpollution

and

harms

the

health

of

local

workers.

For

example,according

to

the

International

Resource

Panel,

the

toxicextraction

and

processing

of

metal

resources

is

responsiblefor

39

percent

of

particulate

matter

health

effects.

And

theimpactgoesfarbeyondlocalworkers:Researchcarriedoutat

the

University

of

Chicago

found

that

pollution

reducesglobal

life

expectancy

by

2.2

years,

an

effect

89

times

asimpactfulasthatofglobalconflictandterrorism.and

search

for

a

new

planet.

Today,

91

percent

of

materialflows

in

the

economy

are

linear,

meaning

that

they

aremined,

used

and

disposed

of

in

a

single

flow.

Ourunidirectional

produce-to-waste

approach

destroys

socio-ecological

systems

and

the

complex

and

interdependentnetwork

of

ecosystems

that

we

inhabit.

The

extraction

andprocessing

of

natural

resources

for

the

production

of

goodsis

responsible

for

an

estimated

50

percent

of

globalgreenhouse

gases

(GHG),

and

sooner

or

later

these

resourceswill

become

unavailable.

For

example,

the

EuropeanChemical

Society

foresees

that

half

of

the

92

naturallyoccurring

elements

on

Earth

are

at

risk

of

future

shortage–

with

17

of

the

roughly

30

elements

currently

used

insmartphonesalreadyfacingprospectivesupplyconcerns.Environmental

damage

goes

hand

in

hand

with

damageto

societies

and

individuals,

of

course.

Linear

resourceextraction,

production

and

disposal

heavily

impactsmarginalized

communities.

Chemical-intensive

processingand

the

improper

handling

of

waste

creates

high

risks

ofThe

solution

lies

in

the

creation

of

a

circulareconomy.

Thisis

the

idea

that

instead

of

extracting

resources

to

buildproducts

that

we

later

discard,

we

should

aim

to

maintainthe

value

of

resources,

materials

and

products

in

theeconomyforaslongaspossibleinacircularprocess.The

circular

economy

consists

of

two

fundamentalcycles,

as

described

in

the

standard

"butterfly"

frameworksuggested

by

the

Ellen

MacArthur

Foundation.

The

first

is

abiological

cycle,in

which

nutrients

from

consumed

productssuch

as

food

and

other

biodegradable

materials,

once

theycan

no

longer

be

used,

return

to

the

soil.

The

second

is

atechnical

cycle,

in

which

products

that

are

not

naturallybiodegradable

are

reused,

repaired,

refurbished

or

recycledso

that

they

can

remain

inuse

rather

than

becoming

waste.The

technical

cycle

is

of

key

importance

for

productsmanufactured

by

industrial

firms,

which

are

the

focus

of

thisstudy

–

automobiles,

factory

equipment

and

machines,consumer

electronics

and

the

like.

Reusing,

repairing,Thecircular

economy

inindustrial

manufacturing|

Think:Act

5refurbishingandrecyclingsuchproductscanbefacilitatedcontributing

to

and

exacerbating

the

other.

But

embracingby

a

number

of

supporting

mechanisms,

such

as

redesigning,

circularity

is

not

just

good

citizenship,

it

is

also

goodreducing

and

rethinking

ownership

(see

Chapter

2:

Thetechnical

cycle).

The

gold

standard,

however,

is

to

remainwithin

the

inner

circles

of

the

framework

–

that

is,

reuse

orbusiness.The

additional

benefits

for

industrials

of

becomingmore

circular

include

cost

savings,

as

companies

can

savemoney

on

procurement

by

reducing

waste

and

retainingmaterials.

Thus,

the

European

Economic

and

SocialCommittee

estimates

that

by

improving

resource

efficiencyby

30

percent

by

deploying

circular

economy

mechanisms,EuropeanindustrycouldsaveasmuchasEUR600billionannually.

Companiesthat

go

green

also

enjoy

reputationalbenefits:

Consumers

are

increasingly

looking

for

firms

thathave

a

positive

environmental

and

social

impact,

and

thoserepair

–asthisenablesmaximumvaluetoberetained.AWHAT'SGOOD

FOR

THE

CLIMATE

IS

GOOD

FORBUSINESSReducing

environmentally

and

socially

harmful

resourceextraction

and

energy-intensive

processing

is

crucial

if

weare

to

overcome

today's

cluster

of

global

risks,

each

oneAFrom

a

linear

to

a

circular

economyTHE

TECHNICAL

CYCLE

OF

CIRCULARITYRawmaterialsPartsmanufacturerRedesignRecycleProductmanufacturerENABLERSRefurbishReduceRepairReuseUser/consumerRethinkownershipSystemicwasteSource:EllenMacArthurFoundation;RolandBerger6Think:Act

|

Whatgoesaroundcomesaroundcompanies

that

doMoreover,

businesses

that

have

a

purpose

other

than

simplymakingaprofitactivists

and

resource-related

growth

boundaries,

areincreasingly

demanding

action

by

business.

For

example,the

European

Union

has

adopted

a

Circular

Economy

ActionPlan

as

a

prerequisite

to

achieving

its

2050

climate

neutralitytarget,

and

the

United

States

and

China

have

enacted

similarlegislation(seebox:Key

legislation).fortalent.Not

only

that,

beingcircularenablesregulatorycompliance.Regulators,

themselves

facing

growing

pressure

fromKey

legislationEUROPEAN

UNIONlife

products.

It

was

followed

in

2017

by

the

OperationThe

European

Union's

Green

Deal

entails

the

region

National

Sword

initiative,

which

regulates

the

import

ofbecoming

net

zero

by

2050

and

decoupling

growth

from

waste,

effectively

banning

the

import

of

contaminatedresource

use.

One

of

the

building

blocks

of

the

plan

is

the

secondary

materials,

such

as

difficult-to-recycle

low-gradesecond

Circular

Economy

Action

Plan,

addressing

all

the

plastics.

This

policy

dramatically

impacted

European

andsteps

along

product

value

chains.

Besides

non-legislative

North

American

waste

management

approaches.

China'sactions,

such

as

gearing

public

spending

towards

renewable

current

circular

economy

strategy

is

largely

coveredby

theproducts,

the

Plan

includes

developing

legislation

in

areas

14th

Five-Year

Plan

(2021-25),which

serves

as

a

directivesuch

as

product

design,

information,

circular

production,

for

regional

regulations.

In

line

with

its

ambition

to

achievewaste

management

and

key

value

chains.

In

the

area

of

carbon

neutrality

by

2060,

the

Plan

outlines

qualitativeproduct

design,

the

aim

is

to

increase

durability,

reusability,

ambitions

for

improved

waste

recycling,

reuse

andupgradability,repairability,energy

andresourceefficiency,

refurbishment,

and

aims

to

increase

energy

and

resourcerecyclability

and

remanufacturing

of

products

from

the

efficiency.

It

also

sets

fixed

targets

for

the

five-year

period,design

stage

onwards.

Regarding

information,

EU

consumer

such

as

reducing

energy

consumption

per

unit

of

GDP

bylaw

will

be

revised

to

empower

consumers

to

make

circular

13.5

percent

and

utilizing

320

million

metrictons

ofscrapchoices,

with

increased

requirements

for

information

on

steel,

equivalentto

23

percent

of

China's

annual

output

inproduct

lifespans

and

repairability.

The

Plan

also

includes

2021.action

on

circularity

in

production,

establishing

circulareconomy

practices

in

Best

Available

Techniques

documents,

UNITED

STATESpromoting

tracking

and

tracing

resources,

and

working

In

the

absence

of

strict

Federal

legislation

on

circularity,

thetowards

industrial

reporting

and

certification

schemes.

In

US

Environmental

Protection

Agency

(EPA)

drives

thethe

area

of

waste

management,

the

aim

is

to

harmonize

country's

circular

economy

ambitions.

The

EPA's

Nationalwastemanagementsystemsandenhancetheimplementation

Recycling

Strategy

(2021)

aims

to

achieve

a

50

percentof

extended

producer

responsibility

schemes.

Finally,

the

recycling

rate

by

developing

improved

infrastructure,Plan

focuses

on

high-impact

industries

and

includes

reducingcontaminationandstandardizingdatacollection.sectoral

actions,

such

as

developing

a

new

regulatory

In

addition,

the

Federal

government

provides

grants

forframework

for

batteries,

reviewing

end-of-life

vehicle

rules,

developing

improved

recycling

infrastructure.

It

is

alsoreviewing

packaging

requirements

and

setting

mandatory

starting

to

embed

the

idea

of

a

circular

economy

in

itsrequirementsonrecycledplasticscontent.environmental

ambitions,

announcing

an

InteragencyPolicyCommittee

on

Plastic

Pollution

and

a

Circular

Economy

inApril

2023.

Stricter

action

on

the

circular

economy

is

beingCHINAChina

enacted

its

Circular

Economy

Promotion

Law

in

taken

at

state

level.

In

California,

for

example,

State

Bill

542009.

Among

other

things,

this

legislation

introduced

established

producer

responsibility

and

set

targets

forproducer

responsibilityfor

recycling

and

disposal

of

end-of-

reducingsingle-useplasticpackaging.Thecircular

economy

inindustrial

manufacturing|

Think:Act

7CIRCULARITY

COMES

WITH

CHALLENGESBAchieving

full

circularity

is

likely

to

prove

an

impossible

taskdue

to

physical

limitations.

Above

all,

the

resources

and

energyneeded

to

recover

and

recycle

used

materials

grow

in

a

non-linear

fashion

as

the

share

of

recycled

materials

increases.However,

it

is

crucial

that

maximum

circularity

–at

levels

thatwill

depend

on

the

precise

material

in

question

–is

top

of

theagenda

for

industrial

companies

and

policymakers

alike.Circularity

supports

decarbonization

by

removing

certainsteps

in

the

value

chain.

For

example,

recycling

aluminumavoids

using

bauxite

("aluminum

ore"),

the

mining

of

whichis

highly

energy-intensive

and

therefore

carbon-intensive.

Thesituation

is

similar

for

other

metals,

and

for

industrialproducts

in

general:Reusing

these

items

means

that

only

theirinitialproduction

generates

carbon

emissions.

However,notall

circular

technologies

reduce

emissions

at

present,

leadingto

a

certain

tension

in

the

pursuit

of

circularity.

Thus,chemically

recycled

plastics

currently

generate

significantlymore

GHG

than

plastics

produced

from

crude

oil

naphtha.While

the

higher

emissions

from

recycled

production

arebalanced

out

by

lower

emissions

compared

to

incineration,this

exemplifies

the

need

for

further

technologicaladvancement

–

and

careful

comparison

of

environmentalimpactsacrossdifferent

approaches.Industrials

have

a

critical

role

to

play

in

creating

a

circulareconomy.

According

to

the

World

Economic

Forum,

in

theautomotive

industry

–

responsible

for

around

ten

percent

ofindustrial

emissions

–

materials

are

contributing

less

andless

to

the

total

lifetime

emissions

of

vehicles

over

time,

andby

2040willaccountforjust60percentofthetotallifetimeemissions.

This

reduction

is

being

driven

by

thebattery-electric

vehicles

(BEVs)

and

greener

energy

duringthe

use

phase.

If

the

industry

introduced

cost-neutral,circular

approaches

to

address

the

growing

need

forsustainable

materials,

material-related

emissions

could

bereducedby

amassive97percentassoonas2030.MilestonesTHE

IDEA

OF

CIRCULARITY

HAS

BEENTHERE

FORA

LONG

TIME1966KennethE.Bouldingpopularizes

the

termSpaceship

Earth

todescribehumanity's

need

to

conserve

natural

resources1987The

Report

of

the

World

Commission

on

Environment

and

Development:Our

Common

Future,

commonly

knownas

theBrundtland

Report,recognizes

theecological

limits

toeconomicgrowthandestablishestheidea

of

"sustainable

development",

whichitdefinesas"development

thatmeets

theneedsof

thepresent

withoutcompro-mising

theability

of

futuregenerations

tomeet

their

ownneeds"1990Theterm

"circular

economy"

is

firstdefined,inNatural

Resourcesand

the

Environment

byR.Kerry

TurnerandDavidPearce1999Theidea

of

"natural

capital"

ashumanity'sscarcestresourceisestablishedbyPaulHawken,

Amory

LovinsandL.Hunter

Lovins2002WilliamMcDonoughandMichael

Braungartpublishamanifesto

for

eliminating

waste

inCradle

to

Cradle:Remaking

the

Way

WeMake

Things2009After

initial

regionalpilots,China

passes

its

Circular

EconomyPromotion

Law,

pioneeringdedicatedlegislationonamajor

scale2010Professional

sailor

Dame

Ellen

MacArthur,

havingexperienced

theimportanceof

resourceconservation

whilesailingsingle-handedlyaround

the

world,

launches

the

thought-leading

Ellen

MacArthurFoundation2015TheEuropean

Union

adoptsits

firstCircular

Economy

Action

Plan,aiming

to

transition

toacircular

economy

throughlegislativeandnon-legislativeaction.Later,in2020,itisrevisedandextendedaspartof

theEuropean

Green

DealOf

course,

responsibility

for

the

circular

economy

doesnot

lie

solely

with

industrial

companies.

Other

stakeholdersalso

have

a

role

to

play.

As

discussed

above,

the

technicalcycle

for

industrial

products

involves

four

mechanisms:reuse,

repair,

refurbish

and

recycle.

The

latter

two

mechanismsdepend

mainly

on

decisions

by

industrial

companies.

Butthe

formertwo–

reuseand

repair–

depend

on

decisions

byservice

providers

and

users.

That

said,

even

here

industrialscan

play

a

role

through

supporting

mechanisms,

redesigningtheir

products

and

motivating

customers

to

reduceconsumptionandrethinkownership.2022TheEuropean

Commission

proposesnew

regulationoneco-design

requirements,

emphasizing

thestructuralimpactof

redesigningproducts2023US

legislation

on

thecircular

economy

increasingly

rises

toFederallevel,

with

the

WhiteHouseannouncinganInteragencyPolicy

Committee

on

Plastic

Pollution

and

a

Circular

Economy8Think:Act

|

Whatgoesaroundcomesaround2

–

The

technical

cycle

–FourRs

for

changing

the

worldAS

OUTLINED

BRIEFLY

IN

CHAPTER

1,

the

technicalcycle

involves

reusing,

repairing,

refurbishing

or

recyclingproducts

that

are

not

naturally

biodegradable,

so

that

theycan

continue

to

be

used

rather

than

going

to

landfill

orincineration.

Industrial

manufacturing

companies

need

totake

urgent

action

here.

Below,

we

discuss

in

detail

what

thataction

might

look

like.

For

each

of

the

four

Rs,

we

divide

oursuggested

actions

into

"small

steps",

"big

leaps"

and"moonshots"

–

the

last

of

these

being

ambitious,

innovativeandsuchas

replacing

the

battery,

changing

the

screen

and

so

on.This

is

an

area

where

companies

can

take

action:

Extendingthe

lifespan

of

the

cellphones

they

give

employees

would

notonly

reduce

resource

consumption,

it

would

also

save

themmoneyby

reducing

theiroverallspend.Businesses

can

take

many

immediate

small

steps

in

the

areaof

reuse

to

improve

circularity.

We

recommend

looking

firstat

the

main

resources

consumed

by

the

firm's

manufacturingoperations.

For

example,

unpolluted

cooling

water

can

bereused

to

clean

production

equipment,

as

is

done

by

leadingconsumer

goods

brand

L'Oréal.

Another

easy

win

is

to

reusenon-production

materials

(NPM),

such

as

unused

equipment.Companies

can

utilize

resell/sharing

marketplaces

totransfer

or

sell

used

equipment,

such

as

ffuturebutwhoseimpactisdifficulttopredictatpresent.#1

ReuseTheideaofreusingproductsisquitesimpleintheory.Inanarrowdefinition,productsareusedagainintheiroriginalpurposeprolonging

their

lifetime.

An

example

might

be

a

cell

phonethat

is

reusedcompanies,

a

second,

broader

definition

of

"reuse"

exists,

inwhich

products

are

used

again

but

for

a

slightly

differentpurpose.

An

example

would

be

a

car

battery

that

is

reusedfor

stationary

energy

storage

at

home.

Besides

reducing

oravoiding

use

altogether,

reuse

is

the

only

lever

that

does

notrequireanynewmaterialinputs.furniture,

to

other

divisions

within

the

company

or

externalparties.

Besides

impacting

emissions,

this

can

generate

adirect

monetary

benefit

in

the

form

of

additional

revenuesandreducedspendingonNPM.Big

leaps

could

involve

using

the

same

productionequipmentforother

products,

forexample.

Here,

creativityis

key:

Who

would

have

thought,

for

example,

that

theGerman

liquor

company

known

for

its

brand

Jägermeisterwould

produce

over

100,000

liters

of

alcohol

for

the

medicalsector

during

the

COVID-19

epidemic?

Similarly,

theintroduction

of

bi-directional

charging

in

the

automotiveLet's

look

more

closely

at

the

example

of

cellphones.

In

industry

enables

vehicle

batteries

to

be

used

as

home

storagethe

United

States

the

average

lifespan

of

such

phones

–

that

for

energy,

as

mentioned

above.

When

renewable

sourcesis,

the

moment

from

which

they

are

sold

to

the

moment

when

produce

more

energy

than

needed,

the

car

battery

can

storetheyarediscarded–

hasbeenjusttwo

anda

halfyears,

since

the

surplus

and

at

night

households

can

use

it

to

run2014.

According

to

market

data

platform

Statista,

this

lifespan

domesticelectricalappliances.is

expected

to

drop

to

2.3

years

by

2025.

For

companies

thatprovide

cellphonesto

theiremployees,

the

expected

lifespanIn

the

future,

industrials

should

aim

to

integrate

circularityinto

the

design

phase

of

product

development.

Rather

thanis

even

shorter:

Cellphones

are

replaced

on

average

ten

just

defining

first-phase

uses,

design

engineers

should

definepercent

faster

by

companies

than

by

consumers.

Yet,

most

use

cases

for

the

following

phases.

Initially,

this

will

make

lifephones

are

still

working

wellmore

challenging

for

engineers

and

developers,

but

it

will

alsothose

that

are

not

are

generally

easy

to

fix

with

minor

repairs,

significantlyeasethetransitionfromthefirst-usephasetoaThecircular

economy

inindustrial

manufacturing|

Think:Act

9second-use

phase.

To

build

the

foundation

for

this

change,companies

should

rethink

their

current

developmentless

adhesive

connections,

good

physical

accessibility

ofmachine

parts

and

easier

access

for

third

parties

to

performprocesses

from

a

holistic

perspective

–

for

example,

integrating

repair

tasks.

Governments

and

industry

associations

shouldmarket

researchandstrategyintotheprocess.

support

this

with

easier

certification

of

third-party

repairMoonshots

are

ideas

whose

ultimate

impact

is

difficult

to

and

maintenance

staff.

The

EU

vehiclepredict

today.

In

the

area

of

reuse,

we

can

imagine

a

device

that

thatthisisfeasible,asdemonstratedby

its2002regulationscans

a

complex

product

(for

example,

a

vehicle

and

its

sub-

ensuringthird-partyaccesstotechnicalrepairinformationcomponents)

and

identifies

pieces

that

can

be

reused

in

other

and

regulation,

ensuring

that

vehicles

can

be

serviced

bycontexts

–

such

as

reusing

automotive

LiDAR

(light

detection

third-partyshopswithoutinvalidatingtheirwarranty.and

ranging)

sensors

in

surveillance

cameras,

traffic

flowOne

technological

advancement

that

is

key

for

repair

ismanagement

or

crowd

control.

Or

a

universal

wear

tracker,

used

the

use

of

augmented

reality

(AR).

AR

can

perform

or

trainto

gather

information

on

use

types,

use

cycles

and

mechanical

repair

tasks

on

products

and

components.

For

example,stress.

Wear-tracking

hardware

andaieasily

be

integrated

into

products

to

estimate

their

potential

AR

training

tool

together

with

mixed

reality

developer

Objectfor

reuse.

In

the

automotive

industry,

for

instance,

this

could

Theory

that

allows

its

customers'

trainee

mechanics

to

worktake

the

form

of

a

single,

small

trip

recorder

that

translates

usage

onaipatterns

into

reuse

assessments

for

surface

materials,air

filters,brake

discs,

brake

calipers,

and

rubber

and

plastic

pipes.Fullypredictivemaintenancewillbethenextbigleap

inthe

field

of

repair,

reducing

repair

activity

and

at

the

sametimeextendingproductlife.Forexample,Germannationalrailroad

company

Deutsche

Bahn

has

been

employingpredictive

maintenance

for

a

number

of

years

already

but

isstill

some

way

off

fleet-wide

implementation.

By

using

adigital

twin

of

a

train,

various

subsystems

such

as

doors

andair

conditioning

can

be

simulated

using

real-time

data.Maintenance

tasks

are

no

longer

performed

in

fixed

cyclesbutonlywhenabreakdownisexpected.New

technology,

such

as

additive

manufacturing

(3Dprinting),

is

also

set

to

revolutionize

production

processes.Additive

manufacturing

reduces

the

size

of

spare

partinventories

and

leads

to

much

lighter,

less

carbon-intensivecomponents,

among

other

things.

Mercedes

Benz

Group,for

instance,

is

already

implementing

3D

printing

on

a

smallscale

for

a

range

of

spare

parts

in

their

trucks

and

buses.Besides

freeing

up

space,

this

approach

generates

monetarybenefitsandreducesoverallemissions.In

terms

of

moonshots,

self-healing

materials

could

be

thenext

big

thing,

making

repair

effectively

obsolete.

Self-healingmaterials

includepolymers,

metals

and

ceramics

that

first

fill

indamaged

areas

and

then

restore

the

structure

itself.

Joint

studiesby

companies

and

research

facilities

have

already

demonstratedthe

feasibility

of

such

materials.

While

the

technology

is

stillin

its

infancy,

experts

expect

initial

applications

to

make

theirway

onto