Design for Disassembly Design for Disassembly (DFD)(DFD)

By Tyler BrittenBy Tyler Britten

OISM 470 WOISM 470 W

What will be covered:What will be covered:

• What is DFD?What is DFD?• Why DFD?Why DFD?• How does DFD work?How does DFD work?• Who currently uses DFD?Who currently uses DFD?• How can you use DFD?How can you use DFD?• Resistance to DFDResistance to DFD• SummarySummary

What is DFD? What is DFD? (1/3)(1/3)

Design for Disassembly(DFD) is:Design for Disassembly(DFD) is:• A type of green manufacturingA type of green manufacturing• Products are designed to be taken apart, Products are designed to be taken apart,

so that they can be used in later so that they can be used in later generations of products. generations of products.

• Also known as Design for Remanufacture Also known as Design for Remanufacture or Reuse.or Reuse.

What is DFD?What is DFD? (2/3)(2/3)

““The goal is to close the production loop, The goal is to close the production loop, to conceive, develop, and build a to conceive, develop, and build a product with a long-term view of how its product with a long-term view of how its components can be refurbished and components can be refurbished and reused--or disposed of safely--at the end reused--or disposed of safely--at the end of the product's life…..”of the product's life…..”

What is DFD?What is DFD? (3/3)(3/3)

“…“…In a world where the costs of disposal In a world where the costs of disposal are rising, ease of destruction becomes are rising, ease of destruction becomes as important as ease of construction.”as important as ease of construction.”

-Gene Bylinsky, -Gene Bylinsky, FortuneFortune

Why DFD?Why DFD?

• Unlike other green business Unlike other green business programs, DFD has financial programs, DFD has financial benefits as well as environmental benefits as well as environmental ones.ones.

Why DFD?Why DFD?

Why include recycling/reuse plans in Why include recycling/reuse plans in the design process? the design process?

• Thinking problems through Thinking problems through beforehand can lower recycling beforehand can lower recycling costs dramatically and reduce costs dramatically and reduce environmental hazards.environmental hazards.

Why DFD?Why DFD?

• New laws across Europe will soon New laws across Europe will soon require manufacturers to take back used require manufacturers to take back used product. product.

• In Germany, manufacturers are already In Germany, manufacturers are already responsible for the final fate of their responsible for the final fate of their products' packaging.products' packaging.

• Similar legislation is expected in the US Similar legislation is expected in the US in the not-to-distant future.in the not-to-distant future.

Why DFD?Why DFD?

““The Germans have established a de facto The Germans have established a de facto global manufacturing standard. U.S. global manufacturing standard. U.S. companies wishing to compete globally companies wishing to compete globally must start making products that will must start making products that will comply with the green dictates of the comply with the green dictates of the huge European market” huge European market” -Gene Bylinsky, -Gene Bylinsky, FortuneFortune

Green Product DesignGreen Product Designfrom a Environmental Perspectivefrom a Environmental Perspective

Design for DisassemblyDesign for Disassembly• Slows the depletion of Natural Mineral Slows the depletion of Natural Mineral

ResourcesResources• Lower Amounts of trash to already crowed Lower Amounts of trash to already crowed

landfillslandfills

According to the National Academy of Sciences, According to the National Academy of Sciences, 94% of the materials that are pulled out of the 94% of the materials that are pulled out of the earth enter the waste stream within months.earth enter the waste stream within months.

Green Product DesignGreen Product Designfrom a Business Perspectivefrom a Business Perspective

The main principles of DFD and The main principles of DFD and green manufacturing also fit into green manufacturing also fit into modern efforts to make assembly modern efforts to make assembly more efficient, such as concurrent more efficient, such as concurrent engineering and total quality engineering and total quality control.control.

Green Product DesignGreen Product Designfrom a Business Perspective (cont.)from a Business Perspective (cont.)

Used or refurbished parts sometimes Used or refurbished parts sometimes work better than new ones.work better than new ones.

Among Integrated Circuits, 5% of Among Integrated Circuits, 5% of new chips fail, but in comparison, new chips fail, but in comparison, used chips only fail 2% of the timeused chips only fail 2% of the time

How Does DFD work?How Does DFD work?

Design for Disassembly/Green Design:Design for Disassembly/Green Design:• Emphasis on reducing partsEmphasis on reducing parts• Rationalizing materialsRationalizing materials• Reusing components Reusing components • Green Products more efficientGreen Products more efficient

to build and distribute than conventional to build and distribute than conventional ones ones

How Does DFD work? How Does DFD work?

Design for Disassembly/Green Design:Design for Disassembly/Green Design:• DFD experts fit into Concurrent DFD experts fit into Concurrent

Engineering teams easilyEngineering teams easily• DFD reduces waste, which is an enemy DFD reduces waste, which is an enemy

of total quality managementof total quality management

Examples of DFDExamples of DFD

• Eastman-KodakEastman-Kodak• Hewlett PackardHewlett Packard• Vehicle Recycling Development Vehicle Recycling Development

CenterCenter

Eastman-KodakEastman-Kodak

• The Fling - first disposable cameraThe Fling - first disposable camera• Angered EnvironmentalistsAngered Environmentalists• Funsaver Panoramic - very popularFunsaver Panoramic - very popular• Name Wastemaker of the YearName Wastemaker of the Year• In 1990, Kodak had converted the disposable In 1990, Kodak had converted the disposable

cameras to recyclable ones.cameras to recyclable ones.• Now 87% of the Cameras are either reused or Now 87% of the Cameras are either reused or

recycled.recycled.

Hewlett-PackardHewlett-Packard

• Depending on the Depending on the model, hp is able to model, hp is able to recycle up to 65% of recycle up to 65% of the print cartridge by the print cartridge by weight. The weight. The remaining parts that remaining parts that cannot be recycled cannot be recycled are disposed of in an are disposed of in an environmentally environmentally responsible manner.responsible manner.

Hewlett-PackardHewlett-Packard

• Each month, HP Each month, HP reuses or recycles reuses or recycles more than 3.5 million more than 3.5 million pounds of material in pounds of material in their U.S. and their U.S. and European product-European product-recovery centers.recovery centers.

• Recycled over 39 Recycled over 39 million hp LaserJet million hp LaserJet cartridges worldwidecartridges worldwide

• HP’s workstation HP’s workstation designers’ new designers’ new chassis reduces chassis reduces transport packaging transport packaging by 30%, while by 30%, while disassembly time has disassembly time has been cut 90%. been cut 90%.

Vehicle Recycling Vehicle Recycling Development CenterDevelopment Center

• Established in 1994Established in 1994• Joint venture of GM, Chrysler, & FordJoint venture of GM, Chrysler, & Ford• Goals of VRDC:Goals of VRDC:

1.1. Finding ways to recycle automobile "fluff"--the 25% Finding ways to recycle automobile "fluff"--the 25% or so of material remaining after recycling of the or so of material remaining after recycling of the ferrous, nonferrous, and other readily recycled ferrous, nonferrous, and other readily recycled components.components.

2.2. Finding ways to more cost-effectively disassemble Finding ways to more cost-effectively disassemble cars, including removal of fluids.cars, including removal of fluids.

How to implement DFDHow to implement DFD

• DFD is easily DFD is easily implemented in implemented in most Quality most Quality StrategiesStrategies

• DFD involves DFD involves considering the considering the products’ entire products’ entire life cycle.life cycle.

How to implement DFDHow to implement DFD

• DFD includes looking at the impact of DFD includes looking at the impact of design decisions not only as they relate design decisions not only as they relate to a specific product attribute, but in the to a specific product attribute, but in the broader sense of environmental impact broader sense of environmental impact over the entire product life from over the entire product life from procured parts to disposal.procured parts to disposal.

Collecting Data for DFDCollecting Data for DFD

1.1. Cost in the form of complexity and timeCost in the form of complexity and time2.2. Revenues provided in respect to the Revenues provided in respect to the

materials that can be liberatedmaterials that can be liberated3.3. Environmental impact in the form of Environmental impact in the form of

residual material disposal residual material disposal 4.4. Technical difficulty in the form of Technical difficulty in the form of

special tools, material handling, special tools, material handling, material identificationmaterial identification

Resistance to DFDResistance to DFD

• Xerox is one of the companies meeting Xerox is one of the companies meeting some resistance to selling refurbished some resistance to selling refurbished products. products.

““There are pockets in the consumer base There are pockets in the consumer base that keep saying, 'We only want 100% that keep saying, 'We only want 100% new products.’”new products.’”

-Jack C. Azar, Xerox-Jack C. Azar, Xerox

SummarySummary

• DFD involves examining a DFD involves examining a product’s entire life cycleproduct’s entire life cycle

• DFD’s benefit, both financial and DFD’s benefit, both financial and ecological, outweigh the costsecological, outweigh the costs

• DFD is important part of a firm’s DFD is important part of a firm’s quality strategy.quality strategy.

Summary Summary (cont.)(cont.)

• Many European Countries will Many European Countries will soon require DFD by lawsoon require DFD by law

• Germany is the worldwide leader Germany is the worldwide leader in DFDin DFD

• There is a resistance to DFD by There is a resistance to DFD by United States consumers who United States consumers who want 100% new productswant 100% new products

BibliographyBibliography

S. Thomas Foster, S. Thomas Foster, Managing QualityManaging Quality (Prentice Hall 2001) (Prentice Hall 2001)

Bylinski, G., “Manufacture for Reuse,” Bylinski, G., “Manufacture for Reuse,” FortuneFortune (Feb 6, (Feb 6, 1995)1995)

Hewlett Packard (Hewlett Packard (http://www.hp.comhttp://www.hp.com))

Eastman-Kodak (Eastman-Kodak (http://www.kodak.comhttp://www.kodak.com))

General Motors (General Motors (http://www.gm.comhttp://www.gm.com))

National Academy of Science (National Academy of Science (http://www4.nationalacademies.org/nas/http://www4.nationalacademies.org/nas/))