LARGE SCREEN DISPLAY 46” + led backlight: CRADLE TO
GATE CHAIN ANALYSIS REPORT
Issued by: QSM
Date: 09/09/2013
TABLE OF CONTENTS
1.
INTRODUCTION ............................................................................................... 1
1.1
References .................................................................................................... 2
2.
OBJECTIVE OF THE CHAIN ANALYSIS ...................................................... 2
3.
DEFINING THE SCOPE OF THE ANALYSIS ................................................ 3
4.
SYSTEM BOUNDARIES AND PARTNERS IN THE LIFE CYCLE.............. 3
4.1
Methodology for the analysis relevant to purchased materials ..................... 3
4.2
Materials and energy flows ........................................................................... 4
4.3
Step 1: Purchased materials CO2 emissions.................................................. 6
4.4
Step 2: Transportation & Distribution (Up-stream) ...................................... 7
4.5
Step 3: Production ........................................................................................ 9
5.
ALLOCATION ................................................................................................. 10
6.
DATA COLLECTION AND DATA QUALITY .............................................. 10
7.
QUANTIFICATION OF CO2 EMISSIONS .................................................... 11
8.
COMPARISON BETWEEN CHAIN ANALYSIS 1 AND CHAIN ANALYSIS 3
9.
RESULTS .......................................................................................................... 12
12
10. DISCUSSION .................................................................................................... 12
11. POSSIBLE REDUCTIONS .............................................................................. 13
12. REDUCTION GOALS ...................................................................................... 13
13. CONCLUSION .................................................................................................. 13
14. REFERENCES .................................................................................................. 13
1.
INTRODUCTION
It’s GDS Group ambition to maintain level 4 of CO2 Performance Ladder. An important part to
achieve level 4 of the CO2 Performance Ladder is obtaining an understanding of the Scope 3
emissions of the organization. Scope 3 emissions categories have been identified, according to the
1
steps as described in the Corporate Value Chain (Scope 3) standard of the GHG protocol. Their
impact on CO2 emissions in the GDS business model has been evaluated in “Scope 3 categories
ranking” report where the categories have been ranked according to the relevant CO2 emissions
figures and to the degree of influence that GDS exerts on them. Two of the six highest ranked
categories have been specifically included and analysed in this chain analyses.
1.1
References
The structure of this document is based on the Corporate Value Chain (Scope 3) standard [GHG,
2010a]. In addition, where necessary, the methodology of the Product Accounting & Reporting
Standard [GHG, 2010b] stands. The below table shows the relationship between GHG, 2010a, GHG
2010b and the present report’s chapters.
Corporate Value Chain (Scope
3) Standard
Product Accounting &
Reporting Standard
Chain Analysis:
H3. Business goals and Inventory
H3. Business Goals
design
Chapter 2
H4. Overview of Scope 3
emissions
-
See GDS doc: Scope 3
categories ranking
H5. Setting the Boundary
H7. Boundary Setting
Chapter 3 & Chapter 4
H6. Collecting Data
H9. Collecting Data & Assessing
Data Quality
Chapter 6
H7. Allocating Emissions
H8. Allocation
Chapter 5
H8. Accounting for Supplier
Emissions
-
NA: applies to CO2
Performance Ladder level 5.
H9. Setting a reduction target
[…]
-
2.
Chapter 11
OBJECTIVE OF THE CHAIN ANALYSIS
The main objective for performing chain analyses is to identify GHG reduction opportunities, to
define reduction targets and to monitor the progress of the consequent reduction activities.
On the basis of the understanding of the Scope 3 emissions and by means of the chain analyses,
reduction targets can be set-up. Within the Energy Management Program proper activities are
defined, based on the set targets, in order to reduce the Scope 3 emissions.
The information from this analysis is used to start a dialog between supply chain’s partners and it
hopefully contributes in general to support similar analyses helping to achieve CO2 reduction
targets.
2
3.
DEFINING THE SCOPE OF THE ANALYSIS
Chosen product is G4600061.
These size of displays is used for public information in railway stations.
The unit of analysis is an individual piece, so the analysis’ outcome will be CO2 unitary emissions
per piece.
4.
SYSTEM BOUNDARIES AND PARTNERS IN THE LIFE CYCLE
The starting point of this analysis was to search for a product inside the organizational and
operational boundaries described in document ”GEQP 4A-1 Att. n. 1 Legal structure and
boundaries”. Hence Displays manufactured in Italy and Romania and sold in Europe have been
considered. The life cycle steps considered for the chosen product are:



Step 1: Material acquisition and reprocessing
Step 2: Upstream materials transportation & Distribution
Step 3: Production
So the present analysis is “cradle-to- gate one” and it stops with at GDS finished products
warehouse.
4.1
Methodology for the analysis relevant to purchased materials
Due to the numbers of parts that contains the KIT, some filtering criteria have been adopted to focus
the analysis on the most significant materials.
From a first evaluation of the weight of each material and the energy effort estimated in the relevant
production processes, a list of the “most significant” materials has been drawn-up.
In the list are present those materials that have a higher impact as weight contribution on the total
weight and that require the most energy intensive upstream operations.
Total product weight is 75 Kg.
The selected materials account for about the 90% of the total weight.
The remaining materials have been deemed to be less significant for weight or the basis of energy
Notes: W = weight; E = energy For Suppliers names and data refer to the original internal
document.
3
Material component
GDS P/N
LCD 46" Panel + Led
Backlight
Heat sink Box (2x)
Rear Box
Rear Metal Sheet
Front Panel
Glass
Gel
Printed wiring boards
and components
LCA00088
Cables
Fans
Power supplies
PAR 1861
PAR 1863
MTW03993
PAR1865
GLA00286
BRD00142
BRD00144
BRD00148
BRD01211
BRD01205
BRD00835
BRD01218
BRD00261
BRD01273
BRD01272
FAN00088
(x4)
PSU00090
PSU00112
Sub-component
Decision
rule
E,W
Weight
(Kg)
16,5
Weight
%
22
Aluminium
Aluminium
Aluminium
Aluminium
W
W
W
W
E,W
E,W
E,W
1,875
7,5
5,25
6,75
13,5
3,75
1,275
2,5
10
7
9
18
5
1,7
E,W
E,W
5,25
2,25
7
3
E,W
3
4
67 kg
90%
Gel
PWB + electronic
components
PWB + electronic
components
Table 4.1-A Selected purchased materials
4.2
Materials and energy flows
In the diagram 4.2-A, the selected materials flow to build-up the final display, along with the
required energy for their development, are depicted.
For the selected parts, the main constituent sub-materials/ sub-products have been indicated. The
central block, blue highlighted, represent the internal GDS process.
Exclusions:
powder coating, gel and fans have not been analyzed as:
 both primary and secondary data is not present and
 extrapolation and ' proxy ' data (General sector numbers) cannot be identified to supplement
the shortage of data.
4
UPSTREAM – CRADLE TO GATE
Iron
Electronic
components
Led
Glass
sheets
Electricity
PWB
TFT panel
Backlight
Gas/ fuel
Glass
Gas/ fuel
Polarizer
LCD panel
Electricity
Gas/ fuel
Electricity
Gas/ fuel
Gas/ fuel
Aluminium
Powder coating
Aluminium
Front panel
Rear box
Electricity
Electricity
Gel
Gas/ fuel
Aluminium
PWB
Aluminium
Gas/ fuel
Display
manufacturing
Power supplies
Rear metal sheet
Electricity
Electricity
Fans
PWB
Gas/ fuel
Gas/ fuel
Heatsink
Electricity
Plastics
Printed wiring
boards
Cable wires
Aluminium
Copper
Electricity
Gas/ fuel
5
Electricity
Fig. 4.2-A Materials and energy flows
4.3
Step 1: Purchased materials CO2 emissions
The CO2 emissions have been carried out using conversion factors from EcoInvent V2.0 database.
Material
component
LCD 46"
Panel + Led
Backlight
Heat sink Box
(2x)
GDS P/N
Rear Box
PAR 1863
Subcomponent
LCA00088
PAR 1861
Weight
(Kg)
15,84
Aluminium
1,8
Aluminium
7,2
Rear Metal
Sheet
MTW03993 Aluminium
Front Panel
PAR1865
5,04
Aluminium
6,48
Glass
GLA00286
Gel
-
Gel
Printed wiring
boards and
components
PWB +
electronic
components
Cables
-
Fans
FAN00088
(x4)
PSU00090
PSU00112
Power
supplies
12,96
Backlight, LCD
screen, at plant/GLO
U
Aluminium product
manufacturing,
average metal
working/RER U
Aluminium product
manufacturing,
average metal
working/RER U
Aluminium product
manufacturing,
average metal
working/RER U
Aluminium product
manufacturing,
average metal
working/RER U
Tempering, flat
glass/RER U
3,6
Kg/Kg
10,7
CO2
emissions
169,488
3,34
6,012
3,34
24,048
3,34
16,8336
3,34
21,6432
0,233
NA
3,01968
0
155
1,224
5,04
2,16
PWB +
electronic
components
Conversion factor
2,88
Printed wiring board,
mixed mounted,
unspec., solder mix, at
plant/GLO U
189,72
Cable, ribbon cable,
20-pin, with plugs, at
plant/GLO U
NA
9,21
Desktop computer,
without screen, at
plant/GLO U
135
NA
46,4184
0
388,8
865,9829
Table 4.3-A Purchased materials CO2 emissions
6
4.4
Step 2: Transportation & Distribution (Up-stream)
The transportations from the first tier Suppliers have been analysed.
In fig. 4.4-A, the flow of the selected materials has been depicted:
Electronic
Components
Supplier (Far East)
Lcd Panel
Supplier
(Far East)
PSU Supplier
(Italy)
20000 km
20000 km
1200 km
GDS Arad
1050 km
GDS Cornedo
Fan Supplier
(Italy)
1200 km
1200 km
Aluminium
Parts Supplier
(Italy)
1200 km
Glass Supplier
(Italy)
1200 km
Gel Supplier
(Italy)
Fig. 4.4-A
Based on the analyzed transportation patterns, total distances have been carried out and listed in
Table 4.4-A.
It shall be said that preferred Suppliers have been considered, in some cases there can be some
alternative Supplier.
For electronic components, it has been assumed that the majority of them come from Far-East and
the shipment is by sea.
Exclusions:
No transportation relevant to raw materials have been considered, due to the need of conduct a more
deep and time consuming analysis along with Suppliers. No quick service has been evaluated, as it
requires a more complex analysis.
All the parts are delivered directly to Arad with exclusion of the LCD panels that arrive in Italy
from Far-East and then are sent to Arad.
7
Part Type
Weigh
t (Kg)
Supplier
Distance
km
Tons*k
m
CO2
emissions(kg
)
316,8
SKA
O
Facto
r
45
LCD 46" Panel
+ Led
Backlight
LCD 46" Panel
+ Led
Backlight
LCD 46" Panel
+ Led
Backlight
Heatsink Box
(2x)
Rear Box
15,84
Lcd
Supplier
Far East to
sea port
20000
15,84
Lcd
Supplier
Sea port to
Cornedo
300
4,752
300
1,4256
15,84
Lcd
Supplier
Cornedo to
Arad
1050
16,632
130
2,16216
1,8
Rear Metal
Sheet
Front Panel
5,04
Glass
12,96
Gel
3,6
Mech.Suppl
ier
Mech.Suppl
ier
Mech.Suppl
ier
Mech.Suppl
ier
Glass
supplier
Gel supplier
1200
2,16
130
0,2808
1200
8,64
130
1,1232
1200
6,048
130
0,78624
1200
7,776
130
1,01088
1050
13,608
130
1,76904
1200
4,32
130
0,5616
Electronic
componenst
Supplier to
Arad
Supplier to
Arad
Supplier to
Arad
Supplier to
Arad
Supplier to
Arad
Supplier to
Arad
Far East to
sea port
Printing wiring
boards and
components
Printing wiring
boards and
components
Cables
1,224
20000
24,48
45
1,1016
1,224
Electronic
componenst
Sea port to
Arad
300
0,3672
300
0,11016
5,04
Cables
Supplier to
supplier
Arad
Fan supplier Supplier to
Arad
1150
5,796
300
1,7388
Electrical Parts
/ Parti
Elettriche
Electrical Parts
/ Parti
Elettriche
Finished
Product
2,16
1300
2,808
130
0,36504
2,88
Psu supplier
1300
3,744
130
0,48672
75
Arad to
Cornedo
1100
82,5
130
10,725
7,2
6,48
Supplier to
Arad
14,256
37,90284
8
4.5
Step 3: Production
Product manufacturing inside GDS Group concerns the assembly of GDS design’s printed circuit
boards and the assembly operations of the LCD panel and of mechanical parts for the display.
The boards that constitute the product involve SMT and or Pin-through-hole assembly phases,
depending on the board type.
Assembly of mechanical and optical parts is split in pre-assembly and final assembly operations.
After an analysis of the absorption of the involved equipment based on the “Energy Inventory
database” and on the production cycles, some production steps have carried out to be insignificant
from an energy point of view.
The most relevant energy consuming steps have been highlighted in Fig. 4.5-A.
The energy consumption has been scaled taking into account that, for certain steps, consumption is
shared between more pieces. This is for instance the case of reflow ovens.
On the contrary, set-up times have not been considered.
I
N
I
S
H
E
M
A
F
FINAL
ASSY
PRE-ASSY
BURN
- IN
D
T
P
E
R
SMT
PLACEMENT
REFLOW
ICT
AOI
FCT
R
I
O
A
D
L
MANUAL
WAVE
U
VISUAL
C
S
T
Fig. 4.5-A Production steps
The overall data are the following:
Assembly section
Absorbed energy/ piece
Electronic boards
Optical and mechanical –
final assembly
TOTAL
2,5 kWh
10 kWh
SKAO Conversion
factor
455 g CO2 / kWh
455 g CO2 / kWh
CO2 emissions (kg)/ piece
1,13
4,55
5,68
Table 4.5-B CO2 emissions form production in GDS facilities.
As the manufacturing process in Arad is remained the same since 2011, we can assume as CO2
emissions values the same used in the Chain Analysis 1 2011. In fact time and energy to produce a
board and to assemble a monitor is quite the same.
9
5.
ALLOCATION
For allocation method refer to chapter 8 of the Product Accounting & Reporting Standard is used.
Allocation has been used to quantify three production steps:
 Reflow
 Wave-soldering
 Pre-assembly
as, for these steps, the use of the relevant equipment/ structure serves more product units
concurrently.
As reflow and wave soldering machine processing times are longer than the upstream production
steps, more pieces are processed during machine time and the machine’s absorbed energy has been
accordingly scaled by the number of pieces concurrently present inside the machine. This number
has been derived dividing the machine’s processing time by the upstream cycle time.
Similarly, pre-assembly in clean room hosts more parts, in this case they are processed in parallel.
For the remaining production steps, the energy absorption has been calculated as the product of the
power times the single piece cycle-time, so no allocation has been necessary.
6.
DATA COLLECTION AND DATA QUALITY
The strong preference to the data collection lies with the use of primary data. Secondary (proxy)
data is used only if no other information is present. The order in which the data collection is carried
out is located in the following list:
1) primary data measured on the basis of CO2 emissions data.
2) primary data on the basis of fuels/energy consumption. CO2 emissions shall be calculated by
a conversion factor.
3) secondary data measured on the basis of CO2emissions data.
4) secondary data on the basis of fuel/energy consumption. CO2 emissions shall be calculated
by a conversion factor.
5) secondary data on CO2 emissions from general (sector) databases.
A starting point in each chain analysis is that the CO2 emissions, within the chain steps object of the
chain analysis, should be based on primary data. For this reason it has been made use of secondary
data in the form of fuel/energy consumption of similar equipment and/or (sector) databases.
Within this chain analysis is used the EcoInvent 2.0 database [Ecoinvent v2]. This database
contains a lot of CO2 emissions data, mainly on the extraction of raw materials, production and
transport to a usage location of many types of materials. With reference to the criteria mentioned in
the GHG protocol Product Accounting and Reporting Standard, features of this database are:
 technological representative: the EcoInvent database contains information about many
different production methods, that usually prevents information technological representative.
 temporal representative: the EcoInvent database uses data of usually less than 10 years old.
 geographical representative: chosen for production methods where possible is representative
of Western Europe.
 completeness: CO2 emissions data in the database are very complete in the number of
processes that is taken into account.
 precision: CO2 emissions data in the database are based on literature with mostly a
uncertainty of < 5%.
10
7.
QUANTIFICATION OF CO2 EMISSIONS
PHASE
Purchased
Goods &
Services
Transportation
& Distribution
upstream
Product
manufacturing
CO2 emissions/ product
unit
865,9829 Kg/piece
37,9 Kg/piece
5,68 Kg/piece
Data Quality
100% secondary data on CO2
emissions from general
(sector) databases
primary data on the basis of
fuels/energy consumption.
CO2 emissions shall be
calculated by a conversion
factor
primary data on the basis of
fuels/energy consumption.
CO2 emissions shall be
calculated by a conversion
factor.
909,56 kg/piece
11
Scope 3 ranking
(reference to GDS
report “Scope 3
categories
ranking”)
Scope 3 category
rank 2
Scope 3 category
rank 3
8.
COMPARISON
ANALYSIS 3
BETWEEN
CHAIN ANALYSIS
1 AND
CHAIN
Here below we can compare the results of the Chain Analysis 1 with the result of this Chain
analysis. In 2011 we have analyzed a LCD Monitor + CCFL backlight. In this Chain analysis is
under inspection a LCD Monitor + Led Backlight.
PHASE
Purchased
Goods &
Services
Transportation
& Distribution
upstream
Product
manufacturing
9.
CO2 emissions/ product
unit
(Monitor Led)
865,9829 Kg/piece
CO2 emissions/ product
unit
(Monitor CCFL)
856,18 Kg/piece
37,9 Kg/piece
46,47 Kg/piece
5,68 Kg/piece
5,55 Kg/piece
909,56 kg/piece
908 Kg (0,90 tons) / piece
RESULTS
Purchased Goods & Services gives the main contribution to CO2 emissions. It weighs about 95% of
the total of the three considered Scope categories. In both cases. As we can see the total value is
quite the same .
As we use aluminium in most part of the mechanical elements, the monitor with Led Backlight is
lighter than previous version but, due to the conversion factor used, the CO2 emissions in the phase
“Purchased Good & Services”, are bigger.
Is evident also the contribution in reduction of the emissions due to the simplification of the
logistic. Most part of the suppliers used for the monitor analysed in this report send their material
directly to Arad.
10. DISCUSSION
Data uncertainty is due to the following reasons:
1. shortage of some data in the evaluation of the emissions of some purchased materials. We
have use, for the Lcd Panel + Led the same conversion factor used with the Lcd Panel +
CCFL.
2. secondary data referring to EcoInvent 2.0 database are declared with a < 5% uncertainty
3. Energy used in production to assemble boards and monitor is estimated taking in
consideration the data used in 2011.
The following improvement action is devised:
12
to investigate, in the next chain analysis, the Electrical Energy used to assemble a large screen
monitor.
11. POSSIBLE REDUCTIONS
The analysed product has just been back from a design effort that has simplified materials and upstream processes. So, it’s difficult at the moment to expect further significant improvements,
nevertheless GDS technical office will continue to pursue in this direction.
About the process, absorptions from clean room and for burn-in are unavoidable as linked to
necessary processes.
Some further improvements can be done in simplification of logistics. Now we are sending directly
to Arad most parts of the components of a monitor. Anyway our suppliers are still far from the
plant. Next step could be have suppliers in Romania. We are working in this direction.
12. REDUCTION GOALS
A target is set to reduce within 2016 Scope 3 CO2 emissions related to “Transportation &
Distribution upstream” . See the Energy Management Program to have a detail of the target.
13. CONCLUSION
A chain analysis has been carried out on a GDS 46 with Led Backlight” display product,
characterized by a revised design and a new technology. This screen size model is increasing in the
e-signage market, that it properly represents.
The chain analysis confirms that Scope 3 emissions are predominant ones compare to Scope 1 and 2
emissions and a possible reduction measure has been devised affecting a further simplification of
logistics.
Our Supply Chain, Logistics and D&D departments are in charge of this activity, that is already in
progress.
14. REFERENCES
Ref.
1
Handboek CO2-prestatieladder 2.0, 23 juni 2011
Stichting Klimaatvriendelijk Aanbesteden &
Ondernemen
2
Corporate Accounting & Reporting standard
GHG-protocol, 2004
3
Corporate Value Chain (Scope 3) Accounting and
Reporting Standard
GHG-protocol, 2010a
4
Product Accounting & Reporting Standard
GHG-protocol, 2010b
5
Nederlandse norm Environmental management – Life
Cycle assessment – Requirements and guidelines
NEN-EN-ISO 14044
6
www.ecoinvent.org
Ecoinvent v2
13