Design for Disassembly
(DFD)
By Tyler Britten
OISM 470 W
What will be covered:
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What is DFD?
Why DFD?
How does DFD work?
Who currently uses DFD?
How can you use DFD?
Resistance to DFD
Summary
What is DFD?
(1/3)
Design for Disassembly(DFD) is:
• A type of green manufacturing
• Products are designed to be taken
apart, so that they can be used in
later generations of products.
• Also known as Design for
Remanufacture or Reuse.
What is DFD?
(2/3)
“The goal is to close the production
loop, to conceive, develop, and build
a product with a long-term view of
how its components can be
refurbished and reused--or disposed
of safely--at the end of the product's
life…..”
What is DFD?
(3/3)
“…In a world where the costs of
disposal are rising, ease of
destruction becomes as important as
ease of construction.”
-Gene Bylinsky, Fortune
Why DFD?
• Unlike other green business
programs, DFD has financial
benefits as well as
environmental ones.
Why DFD?
Why include recycling/reuse plans
in the design process?
• Thinking problems through
beforehand can lower recycling
costs dramatically and reduce
environmental hazards.
Why DFD?
• New laws across Europe will soon
require manufacturers to take back
used product.
• In Germany, manufacturers are
already responsible for the final fate
of their products' packaging.
• Similar legislation is expected in the
US in the not-to-distant future.
Why DFD?
“The Germans have established a de
facto global manufacturing standard.
U.S. companies wishing to compete
globally must start making products
that will comply with the green
dictates of the huge European
market” -Gene Bylinsky, Fortune
Green Product Design
from a Environmental Perspective
Design for Disassembly
• Slows the depletion of Natural Mineral
Resources
• Lower Amounts of trash to already crowed
landfills
According to the National Academy of
Sciences, 94% of the materials that are
pulled out of the earth enter the waste
stream within months.
Green Product Design
from a Business Perspective
The main principles of DFD and
green manufacturing also fit into
modern efforts to make
assembly more efficient, such
as concurrent engineering and
total quality control.
Green Product Design
from a Business Perspective (cont.)
Used or refurbished parts
sometimes work better than
new ones.
Among Integrated Circuits, 5% of
new chips fail, but in
comparison, used chips only fail
2% of the time
How Does DFD work?
Design for Disassembly/Green Design:
• Emphasis on reducing parts
• Rationalizing materials
• Reusing components
• Green Products more efficient
to build and distribute than
conventional ones
How Does DFD work?
Design for Disassembly/Green Design:
• DFD experts fit into Concurrent
Engineering teams easily
• DFD reduces waste, which is an
enemy of total quality management
Examples of DFD
• Eastman-Kodak
• Hewlett Packard
• Vehicle Recycling Development
Center
Eastman-Kodak
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The Fling - first disposable camera
Angered Environmentalists
Funsaver Panoramic - very popular
Name Wastemaker of the Year
In 1990, Kodak had converted the disposable
cameras to recyclable ones.
• Now 87% of the Cameras are either reused
or recycled.
Hewlett-Packard
• Depending on the
model, hp is able to
recycle up to 65%
of the print
cartridge by
weight. The
remaining parts
that cannot be
recycled are
disposed of in an
environmentally
responsible
manner.
Hewlett-Packard
• Each month, HP
reuses or recycles
more than 3.5
million pounds of
material in their
U.S. and European
product-recovery
centers.
• Recycled over 39
million hp LaserJet
cartridges
worldwide
• HP’s workstation
designers’ new
chassis reduces
transport
packaging by 30%,
while disassembly
time has been cut
90%.
Vehicle Recycling
Development Center
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Established in 1994
Joint venture of GM, Chrysler, & Ford
Goals of VRDC:
1. Finding ways to recycle automobile "fluff"--the
25% or so of material remaining after recycling
of the ferrous, nonferrous, and other readily
recycled components.
2. Finding ways to more cost-effectively
disassemble cars, including removal of fluids.
How to implement DFD
• DFD is easily
implemented in
most Quality
Strategies
• DFD involves
considering the
products’ entire
life cycle.
How to implement DFD
• DFD includes looking at the impact of
design decisions not only as they
relate to a specific product attribute,
but in the broader sense of
environmental impact over the entire
product life from procured parts to
disposal.
Collecting Data for DFD
1. Cost in the form of complexity and
time
2. Revenues provided in respect to the
materials that can be liberated
3. Environmental impact in the form
of residual material disposal
4. Technical difficulty in the form of
special tools, material handling,
material identification
Resistance to DFD
Xerox is one of the companies
meeting some resistance to selling
refurbished products.
“There are pockets in the consumer
base that keep saying, 'We only
want 100% new products.’”
-Jack C. Azar, Xerox
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Summary
• DFD involves examining a
product’s entire life cycle
• DFD’s benefit, both financial
and ecological, outweigh the
costs
• DFD is important part of a
firm’s quality strategy.
Summary
(cont.)
• Many European Countries will
soon require DFD by law
• Germany is the worldwide
leader in DFD
• There is a resistance to DFD by
United States consumers who
want 100% new products
Bibliography
S. Thomas Foster, Managing Quality (Prentice Hall
2001)
Bylinski, G., “Manufacture for Reuse,” Fortune (Feb 6,
1995)
Hewlett Packard (http://www.hp.com)
Eastman-Kodak (http://www.kodak.com)
General Motors (http://www.gm.com)
National Academy of Science
(http://www4.nationalacademies.org/nas/)