Design For Environment MPD575 Design for X Jonathan Weaver 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 2 Design for Environment (DfE) • • • • • • • Introduction to DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes DfE Design Guidelines Case Studies References 3 Introduction to Design for Environment (DfE) Dr. Seuss’ The Lorax (1971) “an amusing exposition of the ecology crisis."--School Library Journal. 4 Introduction to DfE Underlying premises • Environmental Quality is compatible with industrial development • Industrial systems can be designed to achieve both Environmental Quality and Economic Efficiency 5 Introduction to DfE Underlying premises • Sustainable Development through EcoEfficiency 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 6 Introduction to DfE What is DfE? Definition #1: A specific collection of design practices aimed at creating eco-efficient products and processes 7 Introduction to DfE Definitions: 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 8 Introduction to DfE Definitions: 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. 9 Introduction to DfE Characteristics 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) 10 Introduction to DfE Characteristics of DfE • Acknowledges the importance of environmental preservation while supporting industrial growth • Integrates environmental knowledge and risk analysis with concurrent engineering concepts (i.e. "system engineering") 11 Introduction to DfE Characteristics of DfE • 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 12 Introduction to DfE Characteristics of DfE The “Crossroad” Sustainable Development Enterprise Integration Design for Environment Integrated Product Development Total Quality Management Pollution Prevention Environmental Stewardship 13 Introduction to DfE Characteristics of DfE • 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) 14 Introduction to DfE Characteristics of DfE • 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 15 Design for Environment (DfE) • • • • • • • Introduction to DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes DfE Design Guidelines Case Studies References 16 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) 17 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 18 Motivations for DfE • • • • • • Reduced Future Liability Reduced Regulatory Impact Reduced Time to Market Reduced Cost Corporate Image and Market Position Enhanced Profitability 19 Motivations for DfE Reduced 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 20 Motivations for DfE Reduced 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 21 Motivations for DfE Regulations and Standards Some Government and International Regulations and Standards: – US Environmental Protection Agency (EPA) – Product “Take-Back" Policies in Europe – ISO 14000 standards 22 Motivations for DfE Regulations and Standards 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) 23 Motivations for DfE Regulations and Standards 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 24 Motivations for DfE Regulations and Standards 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 25 Motivations for DfE Reduced 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 26 Motivations for DfE Reduced 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 27 Motivations for DfE High 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 28 Motivations for DfE Corporate 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 29 Motivations for DfE Enhanced 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) 30 Motivations for DfE Corporate 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 31 Motivations for DfE Corporate 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 32 Design for Environment (DfE) • • • • • • • Introduction to DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes DfE Design Guidelines Case Studies References 33 Key Principles of DfE • Eco-Efficiency Approaches • Product Life Cycle Perspective • Integrated Cross-Functional Product Development 34 Key Principles of DfE Eco-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) 35 Key Principles of DfE Eco-Efficiency Approaches • 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 36 Key Principles of DfE Eco-Efficiency Approaches 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-oflife use and recovery 37 Key Principles of DfE Eco-Efficiency Approaches Sustainable Resource Use (Industrial Ecology) – Evaluate product and production system as a whole – Includes supplier and customer impacts on resource consumption 38 Key Principles of DfE EPA’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 39 Key Principles of DfE EPA’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. 40 Key Principles of DfE Eco-Efficiency ApproachesAluminum Example: Evolution of Automotive Heat Exchangers Aluminum, Copper-brass with silver and lead solder cleaned with TCE 1973 Aluminum, cleaned with TCE and coated with iron cyanide and chromium cleaned with TCE and coated with chromium 1986 Aluminum alloy improvement not coated; cleaned with TCE 1993 alloy improvement not requiring coating; cleaned with water and detergent 1995+ TCE = Trichloroethylene 41 Key Principles of DfE Eco-Efficiency Approaches Example: Evolution of Automobile Aluminum and new alloys Steel Frame introduced Vehicles 1970 DfE used to improve Thermoset and technologies to recycled aide the impact on Enhanced Al plastics used as the environment and Molded component Plastics replacing metal materials components 1980 1990 1999+ Ref, Dr. Norm Gjostein 1998 (UMTRI) 42 Key Principles of DfE Life 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 43 Key Principles of DfE Life 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. 44 Key Principles of DfE Energy Recovery Life Cycle Perspective Part Recycling Part / Process Design Mfg. Inputs • Raw Materials • Packaging • Energy • Water Manufacture/ Assembly Delivery Hazardous & External & Industrial Internal Material Waste Disposal Recycling System Use Packaging Waste End of Life Air Emissions 45 Key Principles of DfE Integrated 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 46 Design for Environment (DfE) • • • • • • • Introduction and Definition of DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes DfE Design Guidelines Case Studies References 47 DfE Tools and Processes • Environmental Performance Metrics • Environmental Design Practices • Environmental Analysis Methods • Environmental Information Infrastructure 48 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 49 DfE Tools and Processes Environmental Performance Metrics 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 50 DfE Tools and Processes Environmental Performance Metrics 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 51 DfE Tools and Processes Environmental Performance Metrics 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 52 DfE Tools and Processes Environmental Performance Metrics Source Volume • Total product mass • Useful operating life of product • Percent of product disposed or incinerated • Percent of packaging recycled during life cycle 53 DfE Tools and Processes Environmental Performance Metrics Exposure and Risk • Ambient concentrations of hazardous byproducts in various media • Estimated annual population incidence of adverse effects to humans or environment 54 DfE Tools and Processes Environmental Performance Metrics 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 55 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 56 DfE Tools and Processes Design 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 57 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 58 DfE Tools and Processes Design for Disassembly • Design for Simplicity – Reduce product complexity – Reduce number of parts – Design multifunctional parts – Utilize common parts 59 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 60 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 61 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 62 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 63 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 64 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 65 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 66 DfE Tools and Processes Design 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 67 DfE Tools and Processes Example: 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 68 DfE Tools and Processes Design Practices for Eco-Efficiency 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 69 DfE Tools and Processes Design Practices for Eco-Efficiency Cleaner Products • Design for separability and disassembly • Design for disposability • Design for energy recovery 70 DfE Tools and Processes Design Practices for Eco-Efficiency Sustainable Resource Use • Substance Use Reduction • Energy use reduction • Design for recyclability • Design for reusability • Design for remanufacture 71 DfE Tools and Processes Environmental Analysis Methods • Life Cycle Assessment – Goal Definition – Inventory – Interpretation – Impact Analysis • Qualitative Assessment • Environmental Accounting 72 DfE Tools and Processes Life 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 73 DfE Tools and Processes Life Cycle Assessment • 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 74 DfE Tools and Processes Life Cycle Assessment: Electric Vehicle QUESTION: Is this a “Zero Emissions” Vehicle? Ford Ecostar (electric vehicle) 75 DfE Tools and Processes Life Cycle Assessment: Electric Vehicle E L E C T R I C I T Y } 76 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 77 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 78 DfE Tools and Processes Life 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. 79 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 80 DfE Tools and Processes Life Cycle Assessment - Goal Definition • 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. 81 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. 82 DfE Tools and Processes Life Cycle Stage Energy Product Material Inputs (including reuse and recycle from another Stage) Process Materials, Reagents, Solvents and Catalysts Reuse/Recycle this stage Single Product Stage or Operation Reuse/Recycle For a different stage Primary Product Useful Co-product Treated Waste Reuse/Recycle This stage Fugitive and Untreated Waste 83 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. 84 DfE Tools and Processes Impact Analysis • 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 85 DfE Tools and Processes Impact Analysis 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 86 DfE Tools and Processes Impact Analysis 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 87 DfE Tools and Processes Impact Analysis 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 88 DfE Tools and Processes Impact Analysis 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 89 DfE Tools and Processes Qualitative 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 90 DfE Tools and Processes Qualitative Assessment • Examples – Material Selection Criteria Checklists – Design Criteria Checklists – Trade-off or Decision Matrices – Multi-Criteria Requirement Matrix (MCRM) 91 DfE Tools and Processes Qualitative Assessment MCRM adapted from Life Cycle Design Manual, US EPA, 1993. LEGAL QUALITY COST PERFORMANCE Vehicle Recycling Green Initiatives Mfg. Plant Concerns ENVIRONMENT Regulatory Requirement Raw Materials Manufacturing and Assembly System Use End of Life 92 DfE Tools and Processes Qualitative Assessment Development of weightings for the Eco-Indicator En viro n m e nt Effe ct Greenhous e Effec t Oz one Lay er Deplet ion Ac i di fic ati on W e ig htin g F actor Cr ite ri a 2.5 0.1 N Y ri s e every 10 y ears . 5% ec os y s tem degredati on 100 10 Eutrophic ati on 5 Sum m er s m og 2.5 W inter s m og Pes ti c ides 5 25 Probabi li ty of 1 fat ali ty per y ear per m i ll ion inhabit ant s 5% ec os y s tem degredat ion Ri vers and lak es degredat ion of an unk now n num ber of aquat ic ecos y s tem s Oc c urrence of sm og peri ods health c om plai nts parti c ularly am ongs t as thm a pat ient s and the el derl y preventi on of agri c ultural dam age Oc c urrence of sm og peri ods, healt h c om pl aints , parti c ularly am ongs t as thm a pat ient s and the el derl y 5% ec os y s tem degredat ion Ai rborne heavy m etal s W at erborne heavy m etal s Carc i nogeni c subs t anc es 6 5 10 Lead c ontent i n c hi ldern's bl ood, reduc ed l i fe ex pec tanc y and learning perform anc e in unk now n num ber of peopl e Cadm i um c ont ent i n ri vers ult im at ely al s o i m pac ts on peopl e Probabi li ty of 1 fat ali ty per y ear per m i ll ion peopl e 93 DfE Tools and Processes Environmental 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 94 DfE Tools and Processes Environmental Accounting 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 95 DfE Tools and Processes Environmental Accounting 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) 96 DfE Tools and Processes Environmental Information Infrastructure Necessary Capabilities of an Environmental Information Infrastructure – On-line Design Guidance – Predictive Assessment Tools – Integration with CAE/CAD Framework 97 DfE Tools and Processes Environmental Information Infrastructure 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’ 98 DfE Tools and Processes Environmental Information Infrastructure On-line Design Guidance forms: – Web-based hypertext systems with crossreferenced ‘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) 99 ENVIRONMENTAL EVALUATION PROCESS SECTION 1. TARGETED SUBSTANCES 1.0 Does Product or Process contain or use target substances? No 1.1 Evaluate Leading Edge “Clean Technology” YES 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 1.2 Involve Suppliers & Researchers 2B. Manufacturing Packaging / Process Materials a) Supply reusable / returnable packaging b) Utilize readily recyclable packaging SECTION 3. Evaluate Potential to Improve Energy Efficiency a) Request alternative material b) Solicit alternatives from other suppliers c) Requests internal studies/research 1.3 Benchmark comparable a) Compare competitive alternatives b) Evaluate other industry & industry alternatives non-competitor alternatives Yes a) Product b) Manufacturing a) Review technical research for potential opportunities 1.4 Select alternative that DOES NOT contain or use target substances NO 1.5 Evaluate & Engineer a Process to Reuse/Recycle the target substance at its source and/or to minimize its release/waste 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. 100 DfE Tools and Processes Environmental Information Infrastructure 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 101 DfE Tools and Processes Environmental Information Infrastructure Predictive Assessment Tool Example: Environmental Information and Management Explorer ™ from Ecobilan, S.A. www.ecobalance.com/software/eime 102 DfE Tools and Processes Environmental Information Infrastructure Description • 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 103 DfE Tools and Processes Environmental Information Infrastructure Features • 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 104 DfE Tools and Processes Environmental Information Infrastructure Features • 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 105 DfE Tools and Processes Environmental Information Infrastructure Design Inputs Product designs are represented by: • Materials • Components • Links • Processes From the extensive EIME™ database 106 107 DfE Tools and Processes Environmental Information Infrastructure 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 108 DfE Tools and Processes Environmental Information Infrastructure 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) 109 110 111 DfE Tools and Processes Environmental Information Infrastructure 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) 112 113 DfE Tools and Processes Environmental Information Infrastructure 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 114 DfE Tools and Processes Environmental Information Infrastructure 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 115 Design for Environment (DfE) • • • • • • • Introduction to DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes DfE Design Guidelines Case Studies References 116 Design Guidelines For DfE -- For Product Structure • • • • 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. 117 Design Guidelines For DfE -- For Product Structure • 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. 118 Design Guidelines For DfE -- For Product Structure • 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 119 Design Guidelines For DfE -- For Material Selection • 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. 120 Design Guidelines For DfE -- For Labeling and Finish • 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. 121 Design for Environment (DfE) • • • • • • • Introduction to DfE Motivations for DfE Key Principles of DfE DfE Tools and Processes Design Guidelines for DfE Case Studies References 122 Case Studies • • • • Xerox Industry Trends S.C. Johnson Wax The Auto Industry Pollution Prevention Project 123 Case Studies • • • • Xerox Industry Trends S.C. Johnson Wax The Auto Industry Pollution Prevention Project 124 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 125 Case Study - XEROX Missions on Environment, Health, and Safety • To become a waste-free company. • To protect the environment and the health and safety of its employees, customers, and neighbors. • Reduce, reuse, recycle. 126 Case Study - XEROX Corporate Policy on Environment, Health, and Safety • 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. 127 Case Study - XEROX Corporate Policy on Environment, Health, and Safety • 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. 128 Xerox Site Operations 129 XEROX Reuse/Recycle Management Process 130 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 131 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. 132 Eco-Efficiency Beneficially managed 96% of hazardous waste through treatment, recycling or fuels blending. Recycled 80% of nonhazardous 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). 133 Clean Air The majority of energy consumed in research and manufacturing operations is supplied by electricity 134 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 135 Waste Recycle 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 136 Energy conservation Reduce energy used By 6% in 1999 from 1998 and by 19% Since 1996 137 Water conservation Reduce water usage By 5% in 1999 from 1998 and by 32% Since 1993 138 Waste to landfills Customers worldwide returned more than 7 million cartridges and toner containers to Xerox in 2000 to be remanufacture d or recycled 139 Saving in recycle $47 million in 1999 $45 million in 1998 Additional $5 million was realized. 140 Case Studies • • • • Xerox Industry Trends S.C. Johnson Wax The Auto Industry Pollution Prevention Project 141 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. 142 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 143 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 144 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 145 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 146 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 147 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 148 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 149 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% 150 Case Studies • • • • Xerox Industry Trends S.C. Johnson Wax The Auto Industry Pollution Prevention Project 151 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 152 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 153 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 154 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% 155 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 156 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 157 Case Studies • • • • Xerox Industry Trends S.C. Johnson Wax The Auto Industry Pollution Prevention Project 158 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” 159 Auto Project Auto Project – Ford • Great Lakes Persistent Toxic (GLPT) substances • Toluene & Trichloroethylene (TCE) highest volume of releases according to Toxic Release Inventory (TRI) 160 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 161 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 162 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 163 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 164 The End? “UNLESS someone like you cares a whole awful lot, Nothing is going to get better. It’s not.” - The Once-ler 165 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 166 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 167 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 168 References • Greenhaven Press, The Environmental Crisis 1986 • Earth in the Balance, Senator Al Gore 1992 169 DfE Tools and Processes Environmental Analysis Methods • Life Cycle Assessment – Goal Definition – Inventory – Interpretation – Impact Analysis • Qualitative Assessment • Environmental Accounting 170 DfE Tools and Processes Life 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 171 DfE Tools and Processes Life 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. 172 DfE Tools and Processes Life Cycle Assessment - Goal Definition • 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. 173 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. 174 DfE Tools and Processes Life Cycle Stage Energy Product Material Inputs (including reuse and recycle from another Stage) Process Materials, Reagents, Solvents and Catalysts Reuse/Recycle this stage Single Product Stage or Operation Reuse/Recycle For a different stage Primary Product Useful Co-product Treated Waste Reuse/Recycle This stage Fugitive and Untreated Waste 175 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 176 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. 177 DfE Tools and Processes Impact Analysis • 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 178 DfE Tools and Processes Impact Analysis 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 179 DfE Tools and Processes Qualitative Assessment Development of weightings for the Eco-Indicator En viro n m e nt Effe ct Greenhous e Effec t Oz one Lay er Deplet ion Ac i di fic ati on W e ig htin g F actor Cr ite ri a 2.5 0.1 N Y ri s e every 10 y ears . 5% ec os y s tem degredati on 100 10 Eutrophic ati on 5 Sum m er s m og 2.5 W inter s m og Pes ti c ides 5 25 Probabi li ty of 1 fat ali ty per y ear per m i ll ion inhabit ant s 5% ec os y s tem degredat ion Ri vers and lak es degredat ion of an unk now n num ber of aquat ic ecos y s tem s Oc c urrence of sm og peri ods health c om plai nts parti c ularly am ongs t as thm a pat ient s and the el derl y preventi on of agri c ultural dam age Oc c urrence of sm og peri ods, healt h c om pl aints , parti c ularly am ongs t as thm a pat ient s and the el derl y 5% ec os y s tem degredat ion Ai rborne heavy m etal s W at erborne heavy m etal s Carc i nogeni c subs t anc es 6 5 10 Lead c ontent i n c hi ldern's bl ood, reduc ed l i fe ex pec tanc y and learning perform anc e in unk now n num ber of peopl e Cadm i um c ont ent i n ri vers ult im at ely al s o i m pac ts on peopl e Probabi li ty of 1 fat ali ty per y ear per m i ll ion peopl e 180