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creative manufacturing
creative manufacturing Unexpected connections DESIGN DEVELOP Nottingham Spirk Innovation Center Combine facilities for Vertical Insights Design Engineering Prototyping Sourcing Innovation™ NEARLY 1,000 COMMERCIALIZED PATENTS “Working with Nottingham Spirk changed our business and my career. It is because of them that I’m where I am today. They helped change the culture within our company. They got us to think about the structure of the product differently.” Adam Chafe Vice President, Marketing Sherwin-Williams Why should you innovate? Worldwide Executive Survey Scale of 1 to 10 How important is innovation to the growth of your firm ? How satisfied are you with your current innovation process ? 1 2 1 3 2 4 3 4 5 5 6 6 7 7 8 8 9 9 10 10 Types of Innovation Models Core Innovation • Safe, low return • Incremental, improves existing products Adjacent Innovation • Expanding on current capabilities & customers • Attracts new customers Breakthrough Innovation • Leadership, game changing, high return • Invention, creates a new behavior or market that didn’t exist Innovation Areas breakthrough adjacent core 70% 20% 10% breakthrough adjacent 10% 20% 70% core Growth & ROI creative manufacturing Unexpected connections Partnerships in Innovation Over 40 partnerships outside the U.S. in countries such as: Australia, Canada, China, France, India, Japan, Mexico, Turkey, Thailand, and the United Kingdom Can manufacturing be as creative as the product itself? Question: How do you make a $5 toothbrush at a time when toothbrush “appliances” were $50–$100? Answer: Expected: Go to an appliance factory Unexpected: Go to a toy factory Result: SpinBrush Largest Selling Oral Care Appliance Patented “Try Me” Packaging Design Largest Selling Oral Care Appliance Largest Selling Oral Care Appliance Innovation Creates Growth Question: How do you manufacture the first pocket-size aerosol? Answer: Expected: Utilize aerosol can equipment Unexpected: Leverage marker pen equipment Pocket Size Standard Revolutionary Product Question: How do you manufacture a no-tools, no-drip paint can? Answer: Expected: Go to a metal paint can manufacturer Unexpected: Leverage liquid laundry detergent Twist & Pour appeals to the convenience customer Twist & Pour appeals to the convenience customer Attracting the Convenience Customer 23 Patents Revolutionizing DIY Painting The 10 Best Packages of the Decade Nottingham Spirk Innovates a Better Paint Can for Sherwin-Williams Question: How can you make lawn fertilizing convenient? Answer: Expected: Utilize standard bag equipment Unexpected: Leverage k-cup and stand-up pouch technology Scotts Snap a durable with ongoing consumables Scotts Snap a durable with ongoing consumables Question: How do you serve draft beer at home? Answer: Expected: Utilize aluminum kegs Unexpected: Leverage PET soda bottle technology Tap King home draft beer system Tap King home draft beer system Question: How do you manufacture a telemedicine kiosk? Answer: Expected: Start with a medical company Unexpected: Go to a truck cab interior fabricator HealthSpot Station HealthSpot Station Q&A Question: How do you deal with orange peel waste? Answer: Expected: Use it for cattle feed Unexpected: Use it to create energy Orange Peels to Energy Bob Godfroid, Ph. D. PepsiCo Advanced Research Over 20 billion dollar brands Over a billion consumer interactions per day One of the largest agricultural enterprises in the world Performance with Purpose -- The Promise of PepsiCo Grows or sources 4 million tons potatoes Sources 3 million tons of oranges, fruits and vegetables Uses 600,000 tons of oats for Quaker Has Ag operations in 30+ countries “produces 1.3 Billion pounds of orange peels per year” These could fill the Empire State Building Industry standard for 80 years… Hammer Mill Press Liq Evaporator D By-Product Amount (MM lbs) Water 1040 Dried peel 248 Limonene 12 Limonene Dryer Dried Peel 57 “produces 1.3 Billion pounds of orange peels per year” …which contain 2.0 Trillion BTUs of energy Anaerobic digestion • • • • Natural bacteria and process Makes methane Prolific in Europe Few non-landfill projects in US Capacity, MW Installations European biogas Driven by €10/mmbtu prices! Orange peel paradox • • • • • High in water High in sugars and cellulose No lignin Pumpable/stirable Steady, reliable stream • Limonene Limonene inhibition “There’s not a lot of tradition for fermenting citrus.” …Homebrew blogger “Since the middle ages essential oils have been used in bactericidal, viruscidal, fungicidal, antiparasitic, insecticidal and medicinal applications.” …Limonene research paper http://www.owensoundsuntimes.com/2013/04/03/ student-scientist-inspired-by-real-events Orange peel potential Biogas Generation Biogas Production (Nl/kg) Biogas generation 80 60 Theoretical 40 Fresh Pressed 20 Treated 0 1 2 3 4 15 16 17 Week 18 19 20 21 22 Scale-up options US natural gas prices, $/mmbtu $9.00 $8.00 $7.00 $6.00 $5.00 Fracking in US $4.00 $3.00 $2.00 $1.00 $0.00 2005 2006 2007 2008 2009 2010 2011 2012 2013 Positive impact • 208 CNG tractors in US • 7,863 tons CO2 reduction • 5 CNG filling stations • Biogas from potato peels • 35% plant power generation • Fertilizer for 110,000 acres
