Design For Environment MPD575 Design for X Jonathan Weaver.

Design For Environment

MPD575 Design for XJonathan Weaver

2

Development History

• Originally developed by Cohort 1 team: Tom Boettcher, Al Figlioli, John Rinke

• Revised by Cohort 2 team: Nada Shaya, Craig Pattinson, Jesse Ruan, Vince Cassar

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Design for Environment (DfE)

• Introduction to DfE

• Motivations for DfE

• Key Principles of DfE

• DfE Tools and Processes

• DfE Design Guidelines

• Case Studies

• References

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Introduction to Design for Environment (DfE)

Dr. Seuss’ The Lorax (1971)

“an amusing exposition of the ecology crisis."--School Library Journal.

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Introduction to DfEUnderlying premises

• Environmental Quality is compatible with industrial development

• Industrial systems can be designed to achieve both Environmental Quality and Economic Efficiency

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Introduction to DfEUnderlying premises

• Sustainable Development through Eco-Efficiency can be a competitive advantage in Resource Management and Environmental Stewardship

• Eco-Efficiency – Ability to simultaneously meet cost, quality, and performance goals, reduce environmental impacts, and conserve resources

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Introduction to DfEWhat is DfE?

Definition #1:

A specific collection of design practices aimed at creating eco-efficient products and processes

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Introduction to DfEDefinitions: What is DfE?

Definition #2:

A systematic consideration of design performance with respect to environmental, health, and safety objectives, over the full product and process life cycle

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Introduction to DfEDefinitions: What is DfE?

Definition #3:

The integration of health and environmental considerations into design decisions. Risk management that promotes reducing risk to human health and the environment through pollution prevention or source reduction instead of relying on end-of-the-pipe pollution control.

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Introduction to DfECharacteristics of DfE

• Natural resources are transformed into useful goods and harmful by-products

• Our economic system measures the efficiency of production or “productivity” in a way that keeps better track of the good things we produce than the bad

(Source: Senator Al Gore – Earth in the Balance, 1992)

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• Acknowledges the importance of environmental preservation while supporting industrial growth

• Integrates environmental knowledge and risk analysis with concurrent engineering concepts (i.e. "system engineering")

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• It is both a management approach and an engineering discipline

• Ideal point of application is early in the product realization process

• Combines concepts of Enterprise Integration and Sustainable Development

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Sustainable Development

Enterprise Integration

Design for Environment

Pollution Prevention

Integrated Product Development

Environmental Stewardship

Total Quality Management

The “Crossroad”

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• Stakeholders– Engineers (determine by-products of product and

process)– Employees (interact with waste products)– Management (manage waste disposal and costs)– Shareholders (concerned with liabilities)– Consumers (end of life disposal of product)– Government (concerned with effect on environment

from process and product)– Suppliers (packaging of components)

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• Encompasses a variety of disciplines– Occupational health and safety– Consumer health and safety– Ecological integrity and resource protection– Pollution prevention and toxic use reduction– Transportability– Waste reduction or elimination– Disassembly and disposability– Recyclability and remanufacturability

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• Case Studies

• References

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Motivations for DfE

Manufacturing and supporting products can have adverse impacts on the environment:

– Waste generation– Disruption of ecosystems– Depletion of Natural resources

Recent patterns of global industrial development exceed sustainable limits for:

– Resource utilization (raw materials, fuel, water)– Waste management (landfills, incinerators)

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Motivations for DfE

Exceeding sustainable limits can threaten– Climate– Vegetation and wildlife– Agriculture– Quality of Life– Industry

Environmental Stewardship is in the best interest of companies producing goods

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Motivations for DfE

• Reduced Future Liability

• Reduced Regulatory Impact

• Reduced Time to Market

• Reduced Cost

• Corporate Image and Market Position

• Enhanced Profitability

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Motivations for DfEReduced Future Liability

• Informed decisions during the design stage can avoid costly future liabilities

• Eliminating toxic materials and designing more recyclable products can reduce product disposal responsibility

• Reducing toxic releases during processing helps eliminate later treatment of contaminated water or soil

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Motivations for DfEReduced Regulatory Impact

• DfE enables anticipation of future trends in environmental regulations and standards

• Proactive approach incorporates future environmental demands and regulations into current product and process designs

• Early cooperation with regulatory agencies can be beneficial by allowing influence on implementation timing and/or metrics

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Motivations for DfERegulations and Standards

Some Government and International Regulations and Standards:

– US Environmental Protection Agency (EPA)

– Product “Take-Back" Policies in Europe

– ISO 14000 standards

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United States EPA

• Toxic Release Inventory (TRI) reporting of amounts of regulated substances released into environment

• Fuel Economy and Energy Efficiency legislation• Emissions Regulations (air particulates,

greenhouse & ozone depleting gasses)

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Product “Take-Back” Policies (Europe)• Principle of Extended Producer Responsibility

(EPR) requires producers to be responsible for the life-cycle environmental impacts of products

• Take-back policies create incentive for producers to increase recyclability of products by setting targets for reduction of end-of-life waste

• Product take-back has been applied to packaging, electronics, and now automobiles

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ISO 14000 Standards• First published in 1996, based on 1992 UN

Earth Conference in Rio de Janeiro• Similar to ISO 9000 Quality Standards, with

focus on “sustainable development”• Covers a wide range of environmental

management topics, including:– environmental performance evaluation– life cycle assessment– environmental auditing

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Motivations for DfEReduced Time to Market

• Hazardous or regulated substances in products and production processes often require permits and elaborate control systems to meet regulations

• Permits and controls take time and resources to obtain and establish

• By designing out such substances wherever possible, time to market can be reduced

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Motivations for DfEReduced Cost

• Reduced production cost(by re-using or recycling content)

• Reduced waste management cost(less waste = less cost)

• Reduced product cost(through simplification and component integration)

• Reduced usage cost and end-of-life costs

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Motivations for DfEHigh Hidden Costs

• Potential spills• Clean-up of contaminated sites• Potential EOL vehicle take-back requirement • Special handling and materials management• Non-value added equipment for:

– Regulated substances– Environmental controls– Waste handling (removal, transportation, disposal)

• Potential loss of sales• Potential labeling of product due to material content

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Motivations for DfECorporate Image and Market Position

• Consumers are increasingly conscious of environmental issues

• Perceptions about environmental responsibility of a company may affect consumer and government purchase decisions

• Environmental quality can be an effective marketing tool

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Motivations for DfEEnhanced Profitability

Studies have shown that environmentally responsible companies have:

– 16.7% higher operating income growth– 9.3% higher sales growth– 3.9% higher return on investments– 2.2% higher return on assets– 1.9% higher asset growth

(Source: Green Manufacturing, February 3, 1996)

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Motivations for DfECorporate Responses

Evolution of corporate approaches to environmental issues

– Stage 1 – Problem Solving– Stage 2 – Managing for Compliance– Stage 3 – Managing for Assurance– Stage 4 – Managing for "Eco-efficiency"– Stage 5 – Fully Integrated

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Motivations for DfECorporate Responses

Implementation Challenges of DfE– Shortage of environmental expertise among

product design and development teams– Difficulty in analyzing and predicting

environmental impacts (i.e. what is “sustainable”)

– Complex economics of product life cycle

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• Case Studies

• References

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Key Principles of DfE

• Eco-Efficiency Approaches

• Product Life Cycle Perspective

• Integrated Cross-Functional Product Development

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Key Principles of DfEEco-Efficiency Approaches

• Cleaner Processes(Pollution Prevention)

• Reduced Emissions, Manufacturing and paint methods

Cleaner Products(Environmental Responsibility)

• Use of recycled products and environment friendly materials

• Sustainable Resource Use(Industrial Ecology)

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• Cleaner Processes (Pollution Prevention)

– Assumes product function and concept are fixed

– Usually involves incremental refinement of production/manufacturing processes to reduce waste and its byproducts

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Cleaner Products(Environmental Responsibility)

– Fundamental product designs are still dynamic

– Takes into account all stages of the product life cycle, from material selection to end-of-life use and recovery

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Sustainable Resource Use(Industrial Ecology)

– Evaluate product and production system as a whole

– Includes supplier and customer impacts on resource consumption

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Key Principles of DfEEPA’s role in DfE

The EPA responded to these Eco-Efficient approaches in the early 1990s, manufacturers started thinking in terms of "design for" qualities in their products and processes. The EPA recognized the need for competitive but environmentally preferable technologies. As a result the EPA's Design for the Environment (DfE) Program was developed.

http://www.epa.gov/dfe

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Key Principles of DfEEPA’s role in DfE

The EPA:• Assists companies to integrate health and

environment considerations into business decisions. This is aimed at prevention before pollution is created.

• Examines the hazards of chemicals used in an industry and pollution prevention.

• Assesses alternative processes, formulations, and emerging technologies.

• Promotes risk reduction through cleaner technologies and safer chemical choices.

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Example: Evolution of Automotive

Heat Exchangers

ENVIRONMENTAL IMPROVEMENTCopper-brasswith silver and lead soldercleaned with TCE

19861973 1993 1995+

Aluminum, cleaned with TCE and coated with iron cyanide and chromium

Aluminum,cleaned with TCE and coated with chromium

Aluminumalloy improvementnot coated;cleaned withTCE

Aluminumalloy improvement not requiringcoating; cleanedwith waterand detergent

TCE = Trichloroethylene

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Example: Evolution of Automobile

ENVIRONMENTAL IMPROVEMENT

Steel Frame Vehicles

19801970 1990 1999+

Aluminum and new alloys introduced

Enhanced Al and Molded Plastics replacing metal components

Thermoset and recycled plastics used as component materials

DfE used to improve technologies to aide the impact on the environment

Ref, Dr. Norm Gjostein 1998 (UMTRI)

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Key Principles of DfELife Cycle Perspective

Life Cycle Stages of a Product

– Component / Raw Material Acquisition• Material Development

– Product Manufacturing / Assembly– Product Delivery to Consumer– Product Use by Consumer– Product Disposal and/or Recovery

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Key Principles of DfELife Cycle

Life Cycle decision making capabilities can be a management tool based on characterizing:– Technology– Economy/Economics– Environment

By identifying these characteristics a holistic optimization potential can be identified to optimize the long term effects of new designs.

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Key Principles of DfELife Cycle Perspective

Part / ProcessDesign

Mfg. Inputs

Hazardous & Industrial

Waste Disposal

External & Internal Material

Recycling

PackagingWaste

Manufacture/Assembly

AirEmissions

Delivery

• Raw Materials

• Packaging• Energy• Water

Energy Recovery

Part Recycling

System Use

End of Life

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Key Principles of DfEIntegrated Product Development System

DfE Enablers in Product Development

– Integrated product realization process– Concurrent development of product and

production processes– Environmental performance metrics– Analysis methods for comparing and

selecting alternatives

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• Introduction and Definition of DfE





• Case Studies

• References

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DfE Tools and Processes

• Environmental Performance Metrics

• Environmental Design Practices

• Environmental Analysis Methods

• Environmental Information Infrastructure

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DfE Tools and Processes Environmental Performance Metrics

Energy Usage

• Energy consumed in product manufacturing

• Total energy consumed during product life cycle

• Renewable energy consumed during life cycle

• Power / fuel used during consumer operation

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Natural Resource Usage

• Amount of water consumed during manufacture

• Water consumption during product end use

• Mass or volume of nonrenewable material (i.e.

metal ore, petroleum) used in product life cycle

• Mass or volume of renewable raw material

(wood, oxygen) used in product life cycle

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Material Burden• Mass of toxic or hazardous materials used in

production processes• Total mass of waste generated in production• Hazardous waste generated in life cycle• Air emissions and water effluents generated• Greenhouse gases and ozone-depleting

substances released over life cycle

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Recovery and Reuse

• Product disassembly and recovery time

• Percent of recyclable materials at end of life

• Percent of product actually recovered and reused

• Purity of recovered recyclable materials

• Percent of recycled materials input to product

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Source Volume

• Total product mass

• Useful operating life of product

• Percent of product disposed or incinerated

• Percent of packaging recycled during life cycle

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Exposure and Risk

• Ambient concentrations of hazardous byproducts in various media

• Estimated annual population incidence of adverse effects to humans or environment

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Economics

• Average life-cycle cost incurred by manufacturer

• Purchase and operating cost incurred by the

consumer

• Cost savings associated with improvements in

product and process designs

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DfE Tools and Processes Environmental Design Practices

• Design for Recovery and Reuse

• Design for Disassembly

• Design for Waste Minimization

• Design for Energy Conservation

• Design for Material Conservation

• Design for Chronic Risk Reduction

• Design for Accident Prevention

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DfE Tools and ProcessesDesign for Recovery and Reuse

• Design for Material Recovery– Avoid Composite Materials– Specify Recyclable Materials– Use Recyclable Packaging Materials

• Design for Component Recovery– Design Reusable Containers– Design for Refurbishment– Design for Remanufacture

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DfE Tools and Processes Design for Disassembly

• Facilitate Access to Components– Optimize disassembly sequence– Design for easy removal– Avoid embedded parts

• Simplify Component Interfaces– Avoid springs, pulleys, and harnesses– Avoid adhesives and welds– Avoid threaded fasteners

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DfE Tools and Processes Design for Disassembly

• Design for Simplicity– Reduce product complexity– Reduce number of parts– Design multifunctional parts– Utilize common parts

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DfE Tools and Processes Design for Waste Minimization

• Design for Source Reduction– Reduce product dimensions– Specify lighter-weight materials– Design thinner enclosures– Increase liquid concentration– Reduce mass of components– Reduce packaging weight– Use electronic documentation

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DfE Tools and Processes Design for Waste Minimization

• Design for Separability– Facilitate identification of materials– Use fewer types of materials– Use similar or compatible materials

• Avoid Material Contaminants– Painting or labeling of recyclable materials

• Design for Waste Recovery and Reuse• Design for Waste Incineration

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DfE Tools and Processes Design for Energy Conservation

• Reduce Energy Use in Production• Reduce Product Power Consumption

– Use “standby” or “sleep” modes when possible

• Reduce Energy Use in Distribution– Reduce transportation distance– Reduce transportation urgency– Reduce shipping volume and mass required

• Use Renewable Forms of Energy

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DfE Tools and Processes Design for Material Conservation

• Design Multifunctional Components

• Specify Recycled Materials

• Specify Renewable Materials

• Use Remanufactured Components

• Design for Closed-Loop Recycling

• Design for Packaging Recovery

• Design Reusable Containers

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DfE Tools and Processes Design for Material Conservation

• Design for Product Longevity– Extend performance life– Use modular architecture– Design upgradeable components– Design reusable platforms– Design for serviceability– Design for durability

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DfE Tools and Processes Design for Chronic Risk Reduction

• Reduce Toxic Production Releases

• Avoid Hazardous Substances

• Avoid Ozone-Depleting Chemicals

• Use Water-Based Technologies

• Assure Product Biodegradability

• Assure Waste Disposability

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DfE Tools and Processes Design for Accident Prevention

• Good Housekeeping Standards in Plant

• Avoid Caustic and/or Flammable Materials

• Minimize Leakage Potential

• Use Fool-proof Closures

• Discourage Consumer Misuse

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DfE Tools and ProcessesDesign Practices for Eco-Efficiency

Cleaner Processes• Good Housekeeping Practices to reduce

accidental waste• Material Substitution to reduce the presence of

undesirable substances in production• Manufacturing Process Changes to reduce

resource use and simplify production• Resource Recovery to capture and reuse waste

materials in production

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DfE Tools and ProcessesExample: Ford Transmission Plants

• In Transmission Assembly Plants, every transmission is tested before shipment

• Transmission test fluid was disposed• Now it is re-processed and reused in vehicles• Re-processed fluid meets or exceeds standards

for fluid received from manufacturer• Nearly 370,000 gallons have been reclaimed• Savings are estimated at $2.00 per transmission

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Cleaner Products• Material Substitution: Replace materials to

improve recyclability or reduce resource usage

• Waste Source Reduction: Minimize product and packaging mass, thus reducing end of life waste

• Life Extension: Increase useful life of product, thus reducing end-of-life waste stream

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Cleaner Products• Design for separability and disassembly

• Design for disposability

• Design for energy recovery

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Sustainable Resource Use• Substance Use Reduction

• Energy use reduction

• Design for recyclability

• Design for reusability

• Design for remanufacture

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DfE Tools and ProcessesEnvironmental Analysis Methods

• Life Cycle Assessment

– Goal Definition

– Inventory

– Interpretation

– Impact Analysis

• Qualitative Assessment

• Environmental Accounting

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DfE Tools and ProcessesLife Cycle Assessment

The SETAC (Society of Toxicology and Chemistry) Approach consists of four steps:

• Define goals, scope, and system boundaries• Develop an inventory of environmental burdens by

identifying and quantifying energy and materials used and wastes released

• Assess the impact of this inventory on the environment

• Interpret and evaluate opportunities to improve

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• A methodology best applied to in-depth environmental evaluation of existing products

• LCA is done “in the background” to develop new standards and/or specifications

• Design and manufacturing engineers will not do LCA; other company operations perform LCAs and identify appropriate data

• Design recommendations are made to improve the environmental aspects of the product or process

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Ford Ecostar (electric vehicle)

QUESTION: Is this a “Zero Emissions” Vehicle?

DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle

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ELECTRICITY

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DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle

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DfE Tools and Processes Life Cycle Assessment

Advantages:• Holistic life cycle thinking (no shifting of

environmental problems: media, region, or time related)

• Identification of cost cutting potentials and hot spots

• Early warning system concerning future legal requirements & concerns of environmentalists

• Identification of possibilities for process improvements

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DfE Tools and Processes Life Cycle Assessment

Disadvantages:• Data-intensive and costly• Requires dedicated expertise to conduct• Does not account for non-environmental

aspects of quality and cost• Cannot capture dynamics of changing markets

and technologies• Difficult to translate into specific requirements

for designers to implement

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DfE Tools and ProcessesLife Cycle Assessment - Goal Definition

• The first step in considering environmental assessment in product design is to establish clear objectives. What is the purpose of the environmental analysis?

– Example1: Reduce CO2 emissions and meet certification

– Example2: Reduce energy use, reduce component toxicity.

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DfE Tools and Processes Life Cycle Assessment - Goal Definition

• Within goal definition, clearly defined engineering specification (metrics) are established to evaluate a product.

• The goal should be refined and revisited

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• Overall Product Function – The next step for a design team is to establish the boundary of the system to analyze.

• The Functional Unit – The design team must then establish a functional unit.

Example: A functional unit for a coffee grinder might be one day’s worth of ground coffee, or one cup of grounds.

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DfE Tools and Processes Life Cycle Assessment - Inventory

• After establishing the system boundary and functional unit, the system needs to be described as a sequence of activities, each called a life cycle stage.

• Each life cycle stage takes in materials and energy and produces the desired activity outcome along with waste material and energy.

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DfE Tools and ProcessesLife Cycle Stage

Single Product Stage or

Operation

Product Material Inputs(including reuse and recycle from another Stage)

Reuse/RecycleThis stage

Energy

Process Materials, Reagents, Solvents and Catalysts

Fugitive and Untreated Waste

Treated Waste

Reuse/Recycle Fora different stage

Primary Product

Useful Co-product

Reuse/Recycle this stage

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DfE Tools and Processes Impact Analysis

• Having mapped the system and identified the flows in and out of each life cycle stage, the next step is to quantify these flows in terms environmental impact.

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• The most challenging and controversial stage of LCA

• Impact of released materials can be local, regional, or global in nature

• Knowledge of environmental impacts is fragmentary and largely theoretical

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There are 2 basic methods for analyzing potential Impacts:

• Risk Analysis– AT&T’s Environmentally Responsible Product

Assessment Methods– Motorola’s Product Lifecycle Matrix– Environmental Impact Factors Analysis method

• Indexing and Scoring

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Risk Analysis takes into account:• Types and magnitudes of risk agents in a given

process or product• Possible initiating events, such as leaks, spills,

or explosions• Transport mechanisms for released agents• Categories of receptors that might be exposed• Possible exposure pathways for these receptors

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Indexing and Scoring:• Uses available data combined with subjective

judgments to derive numerical ratings• Used to distinguish relative environmental

impact of alternative approaches• Used in cases where quantitative risk

assessment is not possible, or when evaluating resource depletion effects

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Indexing and Scoring Example:Volvo Environmental Priority Strategies (EPS)• Designed to provide feedback to design teams on

overall environmental impact of their product• Calculates Environmental Load Value (ELV) for each

component, based on material inputs and manufacturing processes

• ELV can be compared to similar products for relative environmental performance objectives

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DfE Tools and ProcessesQualitative Assessment

• Used to evaluate design choices among a set of alternatives (screening and trade-offs)

• Includes Criteria Checklists and Matrices• Advantages:

– Require minimal data to apply– Can be useful in spite of large uncertainties

• Disadvantages:– Crude results due to lack of quantitative data– No guidance regarding relative importance of criteria– May stifle innovation with “plug and chug” approach

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• Examples

– Material Selection Criteria Checklists

– Design Criteria Checklists

– Trade-off or Decision Matrices

– Multi-Criteria Requirement Matrix (MCRM)

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QUALITYCOST

LEGAL

PERFORMANCEENVIRONMENT

VehicleRecycling

Green Initiatives

Mfg. PlantConcerns

RegulatoryRequirement

MCRM adapted from Life Cycle Design Manual, US EPA, 1993.

Raw Materials

Manufacturingand Assembly

System Use

End of Life

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Development of weightings for the Eco-Indicator

Environment Effect

Weighting Factor

Criteria

Greenhouse Effect 2.5 0.1 NY rise every 10 years. 5% ecosystem degredationOzone Layer Depletion 100 Probability of 1 fatality per year per million inhabitantsAcidification 10 5% ecosystem degredation

Eutrophication 5Rivers and lakes degredation of an unknown number of aquatic ecosystems

Summer smog 2.5

Occurrence of smog periods health complaints particularly amongst asthma patients and the elderly prevention of agricultural damage

Winter smog 5Occurrence of smog periods, health complaints, particularly amongst asthma patients and the elderly

Pesticides 25 5% ecosystem degredation

Airborne heavy metals 6

Lead content in childern's blood, reduced life expectancy and learning performance in unknown number of people

Waterborne heavy metals 5

Cadmium content in rivers ult imately also impacts on people

Carcinogenic substances 10 Probability of 1 fatality per year per million people

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DfE Tools and ProcessesEnvironmental Accounting

• Economic impact of a product on nonrenewable resources can be difficult to evaluate

• Consequently, environmental improvement project costs can be difficult to justify

• Using principles of Activity Based Costing, it is possible to capture the contributions of environmental improvements toward profitability

• Total Cost Assessment methods can show the financial benefits of environmental improvement

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Total Costing is:

A systematic approach for analyzing all of the internal and external costs associated with business processes, including life cycle costs due to environmental and other factors.

Source: Ford Motor Company DFE Development Team

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Environmental Aspects of Total Costing• Resource consumption• Marketability (purchasing preference)• Future liabilities from waste management• Materials Management• Facilities Management

- Waste collection and disposal- Energy supply

• Penalties and fines• Take-back / recycling procedures (Europe)

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DfE Tools and ProcessesEnvironmental Information Infrastructure

Necessary Capabilities of an Environmental Information Infrastructure

– On-line Design Guidance– Predictive Assessment Tools– Integration with CAE/CAD Framework

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On-line Design Guidance assists in:– Selecting appropriate DfE design practices– Identifying interactions and trade-offs

among eco-efficiency, cost, quality, etc. – Assigning relative importance to categories

of environmental impacts for trade-offs and decision making

– Recording objectives and decision rationales in ‘corporate memory’

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On-line Design Guidance forms:– Web-based hypertext systems with cross-

referenced ‘rules of thumb’ and ‘lessons learned’

– Interactive ‘expert’ systems that help to explore trade-offs among alternative designs or technologies

Ford Example: Environmental Quality Office Web Site (www-ese.ta.ford.com/eqo)

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2B. Manufacturing Packaging / Process Materials

a) Supply reusable / returnable packaging b) Utilize readily recyclable packaging

SECTION 2. Recycling / Accommodate Recyclability

2A. Accommodate Vehicle Recyclability a) Evaluate products for materials that provide for their optimum recyclability b) Use recycled materials in product

SECTION 3. Evaluate Potential to Improve Energy Efficiency

a) Provide material recovery capability for target substance at or near the source of release

b) Evaluate and engineer environmentally robust material collection, handling, recovery, treatment and disposal processes / procedures

c) Assure systems and procedures are in place to comply with regulations and with Company Policy and Directives.

1.5 Evaluate & Engineer a Process to Reuse/Recycle the target substance at its source and/or to minimize its release/waste

a) Productb) Manufacturing

1.4 Select alternative that DOES NOT contain or use target substances

NO

Yes

ENVIRONMENTAL EVALUATION PROCESS

1.1 Evaluate Leading Edge “Clean Technology”

a) Review technical research for potential opportunities

1.2 Involve Suppliers& Researchers

1.3 Benchmark comparable industry alternatives

a) Compare competitive alternatives

b) Evaluate other industry & non-competitor alternatives

a) Request alternative materialb) Solicit alternatives from other

suppliersc) Requests internal studies/research

SECTION 1. TARGETED SUBSTANCES

1.0 Does Product or Process contain or use target substances?

YESNo

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Predictive Assessment Tools use LCA and other data to provide:

– Early assessment of anticipated waste streams and emission rates

– Modeling of end-of-life costs– Profiling of life-cycle environmental and

financial implications of design alternatives– Rating of overall environmental performance

of designs

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Predictive Assessment Tool Example:Environmental Information and Management Explorer ™

from Ecobilan, S.A. www.ecobalance.com/software/eime

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• Originally developed for the Electronics Industry in 1997 – testing automotive applications now

• Integrates quantitative LCA information with internal and regulatory standards, and disassembly aspects, of product design

• Does not require LCA expertise of users

Description

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• Provides real time access to distributed data • Allows for the sharing of design data • Allows the comparison of the environmental

profiles of different design alternatives • Gives contextual warnings and "to do" reminders

during the product description process

Features

105


• Allows for the determination of environmental target values to benchmark design alternatives

• Database of 170 modules on commonly used materials and sub-components, including quantitative life-cycle flows, toxicology and regulatory information, product descriptions and end-of-life aspects

Features

106


Product designs are represented by:• Materials• Components• Links• ProcessesFrom the extensive EIME™ database

Design Inputs

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Output Metrics

• Life Cycle indicators from LCI analysis• Design indicators from product dismantling and

hazardous material handling assessment• Evaluation of compliance with internal and/or

regulatory standards• Comparative analysis of design alternatives

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Output Metrics

Life Cycle Indicators• Material depletion (raw materials, energy, water)• Potential impacts in the air (global warming, ozone

depletion, toxicity, acidity, smog)• Potential impacts in water (eutrophication, toxicity)• Production of Waste (hazardous waste)

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Output Metrics

Design Indicators• Physical characteristics (weight , recycled content,

hazardous matter, parts count)• Use characteristics (power consumption, radiation, noise)• End of life characteristics (weight ratios of hazardous,

reusable, recyclable components; ratio of waste; number of problematic links; number of distinct materials)

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Benefits• Empowers product designers to evaluate the

environmental impact of their design alternatives• Provides improvement suggestions• Ensures compliance with specifications, internal

environmental requirements, and regulations• No environmental expertise, LCA experience, or

data collection required

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Integration with CAE/CAD Framework• Avoid the ‘islands of automation’ syndrome• Share common data models and interface

specifications with other attribute tools• Key enabler of true integrated product

development system• Not yet available in automotive application

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• Case Studies

• References

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Design Guidelines For DfE

• Strive to be multifunctional.

• Minimize the number of parts.

• Create multifunctional parts.

• Embed springs, pulleys, or harness into parts, avoid separating them.

• Modularize with separate functions.

• Design reusable platforms and modules.

-- For Product Structure

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• Locate unrecyclable parts in one system that can be quickly removed.

• Locate parts with the highest value in easily accessible places.

• Access and break points should be made obvious.

• Specify remanufactured parts.


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• In plastic parts, avoid embedded metal inserts or reinforcements.

• Design power-down features for different subsystems in products when they are not in use.

• Commonize the material of individual parts


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• Avoid regulated and restricted materials.• Minimize the number of different types of

materials.• Mark the material on all part.• Use recycled materials.• Avoid composite materials.• Hazardous parts should be clearly marked

and easily removed.

-- For Material Selection

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• Ensure compatibility of ink where printing is required on parts.

• Eliminate environmentally incompatible paints on parts.

• Use unplated metals that are more recyclable than plated.

• Use electronic part documentation.

-- For Labeling and Finish

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• Design Guidelines for DfE

• Case Studies

• References

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Case Studies

• Xerox

• Industry Trends

• S.C. Johnson Wax

• The Auto Industry Pollution Prevention Project

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Case Studies

• Xerox

• Industry Trends



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Case Study - XEROX

Business Summary Xerox Corporation is engaged in the global

document market selling equipment and providing document solutions including hardware, services and software world-wide. The Company's activities encompass developing, manufacturing, marketing, servicing and financing of a complete range of document processing products, solutions and services designed to make organizations around the world more productive.

XEROX Is A Document Company

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Case Study - XEROX

• To become a waste-free company.

• To protect the environment and the health and safety of its employees, customers, and neighbors.

• Reduce, reuse, recycle.

Missions on Environment, Health, and Safety

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Case Study - XEROX

• Protection of the environment and the health and safety of employees, customers, and neighbors from unacceptable risks takes priority over economic consideration and will not be compromised.

• Operations must be conducted in a manner that safeguards health, protects the environment, conserves valuable materials and resources, and minimizes the risk of asset losses.

Corporate Policy on Environment, Health, and Safety

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Case Study - XEROX

• To design, manufacture, distribute and market products and processes to optimize resource utilization and minimize environmental impact.

• All operations and products are, at a minimum, in full compliance with applicable governmental regulations and XEROX standards.

• Continue to improve performance in environment health and safety.

Corporate Policy on Environment, Health, and Safety

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Xerox Site Operations

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XEROX Reuse/Recycle Management Process

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XEROX Environmental Performance

Customer Environmental Satisfaction

Eco-Efficiency

Clean Air and Air Emissions

Waste Recycle

Energy conservation

Water conservation

Waste to landfills

Saving in recycle

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Customer Environmental Satisfaction

Prevented nearly 160 million pounds of material from entering landfills through the reuse and recycling of Xerox equipment and supplies.

Increased the number of Xerox products meeting the stringent requirements of the international ENERGY STAR®, Canada's Environmental Choice EcoLogo and Germany's Blue Angel ecolabels.

Enabled energy savings of more than 800,000 megawatt hours through the sale of ENERGY STAR-qualified products.

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Eco-Efficiency

Beneficially managed 96% of hazardous waste through treatment, recycling or fuels blending.

Recycled 80% of non-hazardous solid waste. Xerox's four equipment recovery and recycle operations achieved a 95% recycle rate.

Increased the number of Xerox manufacturing sites registered to the ISO 14001 standard to 25 (out of 27).

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The majorityof energy consumed in research andmanufacturingoperations is supplied byelectricity

Clean Air

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Air Emissions

Xerox has reduced emissions of dust by 55 percent and ozone by 70 percent from its office and production products, compared with 1990 baseline emissions

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Ninety-six percent of hazardous waste generated by Xerox manufacturing facilities worldwide was treated, recycled or used as fuel; only 4 percent was sent to landfill

Waste Recycle

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Energy conservation

Reduce energy usedBy 6% in 1999 from 1998 and by 19%Since 1996

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Water conservation

Reduce water usageBy 5% in 1999 from1998 and by 32%Since 1993

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Customers worldwide returned more than 7 million cartridges and toner containers to Xerox in 2000 to be remanufactured or recycled

Waste to landfills

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Saving in recycle

$47 million in 1999

$45 million in 1998

Additional $5 millionwas realized.

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Case Studies

• Xerox

• Industry Trends



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DfE Success - Industry Trends

• An increasing number of contemporary corporations are showing DfE product stewardship and extended product responsibility trends.

• Through public requests, pressure and pending take-back legislation, corporations such as XEROX, Hewlett Packard, IBM, Sun Microsystems, GM, Volkswagen, Ford and Goodyear, are finding the need to adopt a DfE philosophy to meet evolving civil and asset management responsibilities.

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DfE Successes

• Goal – zero materials to landfill• Set trends to reuse, recycle and remanufacture

their products• Take accountability for products to end-of-life• New copiers have easily removed components• Disposable fuser rolls now made re-usable• Result - saved $100’s of Millions to-date

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DfE Successes

• Goals – reuse, recycle, less energy• Recycle plastics• Plastic parts marked & identified for recycling • Thin-walled molding process uses less plastic • Modular architecture• Few permanent screws• 80% less power than dot matrix models• 50% less power than other ink jet models

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DfE Successes

• Goals – reuse, recycle, less energy• On/off power programming• Coding of plastic parts for recycle• Improved acoustic foam removal• Recycled plastic in many product lines• Plastic kept free of paint & label contamination• Upgradeable printing systems• Powder coating of components

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DfE Successes

• Goals – implement DfE practices• Numerous product disassembly procedures• Used post-consumer plastics in new products• Heavy metal elimination from plastic, packaging,

inks, manuals• Reduce computer product end-of-life to landfills

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DfE Successes

• Goals – up-front DfE design, reuse and recycle• Developing energy & environmental impact

software with University of Tennessee• Track energy & environmental impact of every

part during cars life-cycle• Redesign parts to better reuse or recycle• Analyze environment component of every design

decision

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DfE Successes

• Goal – 100% reusable/recyclable auto parts• Ensure environmental compatibility and

conservative use of natural resources to minimize environmental impact

• Contribute to resolution of environmental problems at regional and global levels

• Balance customer expectations with environmental compatibility

• Apply DfE to disassembly and recycling of recovered materials in automobiles

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DfE Successes

• Goals – 100% recyclable vehicle• Cross-functional recycling team since 1991• Plastic car bumpers recycled into tail lights –

Taurus/Sable• 2nd hand tires used to make parking brake pedal

pads• Makes use of non-auto end-of-life materials

– Household carpet recycled into air cleaner housings & fan modules – Ford/Mercury/Lincoln

– Soda bottles into grille reinforcements & padding

• Recycling saves Ford $8M annually

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DfE Successes

• Goals – develop used tires into a valuable resource and lengthen expected tire life

• Tire carcasses into fish habitats, shore & highway barriers and playground equipment

• Shred tires into landscape materials• Convert tires into a fuel cleaner than coal for paper

& steel mills and cement kilns• Lengthened typical tire life by 100%

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Case Studies

• Xerox

• Industry Trends



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S.C Johnson Wax

S.C. Johnson Wax - Introduction

• Pioneer of eco-efficiency

• 1975 – voluntarily eliminated CFC (chlorofluorocarbon) propellants from all aerosols

• 1990 – established a centralized environmental policy and strategy office

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S.C Johnson Wax

S.C. Johnson Wax - Worldwide• Reduced waste from products and

processes by 420 million pounds since 1992

• More than 30 environmental awards from agencies and governments since 1990

• $125 million in savings since 1992

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S.C Johnson Wax

S.C. Johnson Wax – Goals set in 1990• Cut virgin packing material use as a

ratio of total by 20% by 1995• Cut combined air & water emissions

and solid waste disposal by 50% by 1995

• Cut volatile organic compound (VOC) use by 25% by 2000

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S.C Johnson Wax

S.C. Johnson Wax – by 1995

• Cut virgin packing material by 26.8% by using recycled containers and lighter weight containers

• Cut air, water, and solid emissions by 46.7%

• Cut VOC ratio by 16.5%

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S.C Johnson Wax

S.C. Johnson Wax – Glade candles

• 7% reduction in weight of the glass

• 6% reduction in weight of the candle

• Increased shipping carton efficiencies

• No impact on functionality

• Material reduction of 3 million pounds

• Annual cost savings of $3.6 million

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S.C Johnson Wax

S.C. Johnson Wax – Aerosol products

• Lighter plastic caps (2.4M lbs. Plastic)

• Recycled shippers (1.2M lbs. Virgin corrugate)

• Recycled scant flaps (110,000 lbs.)

• Annual cast savings of $1.45 million

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Case Studies

• Xerox

• Industry Trends



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Auto Project

Auto Project – Introduction• Partnership between the State of Michigan

and the auto industry started in 1991• Voluntarily focus source reduction efforts on

persistent toxic substances that adversely affect the Great Lakes

• “Partnership to benefit both economic development and the environment”

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Auto Project

Auto Project – Ford

• Great Lakes Persistent Toxic (GLPT) substances

• Toluene & Trichloroethylene (TCE) highest volume of releases according to Toxic Release Inventory (TRI)

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Auto Project

Auto Project – Ford

• Paint build up on fixtures was cleaned with a toluene based solvent

• Replaced with a molten salt

• Reduced the release of toluene by about 23,000 pounds annually

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Auto Project

Auto Project – Ford• Used two TCE degreasers for cleaning

oil from metal tubes• Pilot testing showed replacing with a

water wash system could maintain product quality.

• Reduced TCE releases by about 50,000 pounds annually

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Auto Project

Auto Project – GM

• Used adhesive in manufacturing hoods, trunk lids, and doors

• The solvent based adhesives contained 3.5 pounds of toluene per gallon all of which eventually evaporated into the air

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Auto Project

Auto Project – GM• Successfully piloted a non-solvent based

adhesive in 1989 and implemented plant wide by 1992

• Reduced release of toluene by 300 tons/yr• Adhesive residue no longer hazardous,

reduced hazardous waste from 3000 gallons to 400 gallons/yr

• The non-solvent based adhesive costs less

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The End?

“UNLESS someone like you cares a whole awful lot,Nothing is going to get better.

It’s not.” - The Once-ler

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References

• K. Hockerts, et al., ‘Beyond Life Cycle Assessment, an Integrative Design for Environment Approach for the Automotive Industry,’ SAE 982228, 1998

• H. Schoech, et al., ‘LCA Based Design for Environment in the Automotive Industry,’SAE 2000-01-0517, 2000

• Environmental Defense Pollution Prevention Alliance Internet site, www.edf.org/PPA

• ISO 14000 Internet site, www.iso14000.org• T. Seuss Geisel, The Lorax, Random House, 1971

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References

• J. Fiksel, editor, Design For Environment, McGraw-Hill, 1996

• Ford Motor Company DfE Development Team, DfE Course Material, 1998

• S. Adda, et al., ‘ TEIME: A Tool for Environmental Impacts Evaluation in Product Design,’ SAE 970691, 1997

• M. Finkbeiner, et al., ‘Life Cycle Engineering as a Tool for Design for Environment,’ SAE 2000-01-1491, 2000

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References

• Ecobilan Group Internet Site, EIME Software Description, www.ecobalance.com/software/EIME

• World Business Council for Sustainable Development www.wbcsd.ch/eedata/eecsindx.htm

• S.C. Johnson Wax Environmental Leadership, www.scjohnsonwax.com/community/com_env.asp

• Case Study: Source Reduction In the Auto Industry es.epa.gov/techinfo/case/michigan/michcs14.html

• Yarwood, Jeremy M., and Eagan, Patrick D., Design for Environment Toolkit, Minnesota Office of Environmental Assistance

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References

• Greenhaven Press, The Environmental Crisis 1986

• Earth in the Balance, Senator Al Gore 1992

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DfE Tools and ProcessesEnvironmental Analysis Methods

• Life Cycle Assessment

– Goal Definition

– Inventory

– Interpretation

– Impact Analysis

• Qualitative Assessment

• Environmental Accounting

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The SETAC (Society of Toxicology and Chemistry) Approach consists of four steps:

• Define goals, scope, and system boundaries• Develop an inventory of environmental burdens by

identifying and quantifying energy and materials used and wastes released

• Assess the impact of this inventory on the environment

• Interpret and evaluate opportunities to improve

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DfE Tools and ProcessesLife Cycle Assessment - Goal Definition

• The first step in considering environmental assessment in product design is to establish clear objectives. What is the purpose of the environmental analysis?

– Example1: Reduce CO2 emissions and meet certification

– Example2: Reduce energy use, reduce component toxicity.

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• Overall Product Function – The next step for a design team is to establish the boundary of the system to analyze.

• The Functional Unit – The design team must then establish a functional unit.

Example: A functional unit for a coffee grinder might be one day’s worth of ground coffee, or one cup of grounds.

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DfE Tools and Processes Life Cycle Assessment - Inventory

• After establishing the system boundary and functional unit, the system needs to be described as a sequence of activities, each called a life cycle stage.

• Each life cycle stage takes in materials and energy and produces the desired activity outcome along with waste material and energy.

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DfE Tools and ProcessesLife Cycle Stage

Single Product Stage or

Operation

Product Material Inputs(including reuse and recycle from another Stage)

Reuse/RecycleThis stage

Energy

Process Materials, Reagents, Solvents and Catalysts

Fugitive and Untreated Waste

Treated Waste

Reuse/Recycle Fora different stage

Primary Product

Useful Co-product

Reuse/Recycle this stage

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• Within goal definition, clearly defined engineering specification (metrics) are established to evaluate a product.

• The goal should be refined and revisited

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• Having mapped the system and identified the flows in and out of each life cycle stage, the next step is to quantify these flows in terms environmental impact.

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• The most challenging and controversial stage of LCA

• Impact of released materials can be local, regional, or global in nature

• Knowledge of environmental impacts is fragmentary and largely theoretical

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There are 2 basic methods for analyzing potential Impacts:

• Risk Analysis– AT&T’s Environmentally Responsible Product

Assessment Methods– Motorola’s Product Lifecycle Matrix– Environmental Impact Factors Analysis method

• Indexing and Scoring

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Development of weightings for the Eco-Indicator

Environment Effect

Weighting Factor

Criteria

Greenhouse Effect 2.5 0.1 NY rise every 10 years. 5% ecosystem degredationOzone Layer Depletion 100 Probability of 1 fatality per year per million inhabitantsAcidification 10 5% ecosystem degredation

Eutrophication 5Rivers and lakes degredation of an unknown number of aquatic ecosystems

Summer smog 2.5

Occurrence of smog periods health complaints particularly amongst asthma patients and the elderly prevention of agricultural damage

Winter smog 5Occurrence of smog periods, health complaints, particularly amongst asthma patients and the elderly

Pesticides 25 5% ecosystem degredation

Airborne heavy metals 6

Lead content in childern's blood, reduced life expectancy and learning performance in unknown number of people

Waterborne heavy metals 5

Cadmium content in rivers ult imately also impacts on people

Carcinogenic substances 10 Probability of 1 fatality per year per million people

Design For Environment MPD575 Design for X Jonathan Weaver.

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