Download - DF Environment June 2007
-
7/27/2019 DF Environment June 2007
1/180
Design For Environment
MPD575 Design for XJonathan Weaver
-
7/27/2019 DF Environment June 2007
2/180
2
Development History
Originally developed by Cohort 1 team:Tom Boettcher, Al Figlioli, John Rinke
Revised by Cohort 2 team: NadaShaya, Craig Pattinson, Jesse Ruan,Vince Cassar
-
7/27/2019 DF Environment June 2007
3/180
3
Design for Environment (DfE)
Introduction to DfE
Motivations for DfE
Key Principles of DfE
DfE Tools and Processes
DfE Design Guidelines Case Studies
References
-
7/27/2019 DF Environment June 2007
4/180
-
7/27/2019 DF Environment June 2007
5/180
5
Introduction to DfE
Underlying premises Environmental Quality is compatible with
industrial development
Industrial systems can be designed toachieve both Environmental Quality and
Economic Efficiency
-
7/27/2019 DF Environment June 2007
6/180
6
Introduction to DfE
Underlying premises Sustainable Development through Eco-Eff ic iencycan be a competitive
advantage in Resource Management andEnvironmental Stewardship
Eco-Eff ic iency Ability to simultaneously
meet cost, quality, and performance goals,reduce environmental impacts, andconserve resources
-
7/27/2019 DF Environment June 2007
7/180
7
Introduction to DfE
What is DfE?Definition #1:
A specific collection of design practicesaimed at creating eco-efficient productsand processes
-
7/27/2019 DF Environment June 2007
8/180
8
Introduction to DfE
Definitions: What is DfE?Definition #2:
A systematic consideration of designperformance with respect toenvironmental, health, and safety
objectives, over the full product andprocess life cycle
-
7/27/2019 DF Environment June 2007
9/180
9
Introduction to DfE
Definitions: What is DfE?Definition #3:
The integration of health and environmentalconsiderations into design decisions. Riskmanagement that promotes reducing risk tohuman health and the environment throughpollution prevention or source reductioninstead of relying on end-of-the-pipe pollutioncontrol.
-
7/27/2019 DF Environment June 2007
10/180
10
Introduction to DfE
Characteristics of DfE Natural resources are transformed into
useful goods and harmful by-products
Our economic system measures theefficiency of production or productivity
in a way that keeps better track of thegood things we produce than the bad
(Source: SenatorAl Gore Earth in the Balance, 1992)
-
7/27/2019 DF Environment June 2007
11/180
11
Introduction to DfE
Characteristics of DfE Acknowledges the importance of
environmental preservation while
supporting industrial growth
Integrates environmental knowledge and
risk analysis with concurrent engineeringconcepts (i.e. "system engineering")
-
7/27/2019 DF Environment June 2007
12/180
12
Introduction to DfE
Characteristics of DfE It is both a management approach and
an engineering discipline
Ideal point of application is early in theproduct realization process
Combines concepts ofEnterpriseIntegration and Sustainable Development
-
7/27/2019 DF Environment June 2007
13/180
13
Introduction to DfE
Characteristics of DfE
SustainableDevelopment
EnterpriseIntegration
Design forEnvironment
Pollution
Prevention
Integrated Product
Development
EnvironmentalStewardship
Total QualityManagement
The Crossroad
-
7/27/2019 DF Environment June 2007
14/180
14
Introduction to DfE
Characteristics of DfE Stakeholders
Engineers (determine by-products of product andprocess)
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 environmentfrom process and product)
Suppliers (packaging of components)
-
7/27/2019 DF Environment June 2007
15/180
15
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
-
7/27/2019 DF Environment June 2007
16/180
16
Design for Environment (DfE)
Introduction to DfE
Motivations for DfE
Key Principles of DfE
DfE Tools and Processes
DfE Design Guidelines Case Studies
References
-
7/27/2019 DF Environment June 2007
17/180
17
Motivations for DfE
Manufacturing and supporting products canhave adverse impacts on the environment:
Waste generation Disruption of ecosystems
Depletion of Natural resources
Recent patterns of global industrialdevelopment exceed sustainable limits for:
Resource utilization (raw materials, fuel, water)
Waste management (landfills, incinerators)
-
7/27/2019 DF Environment June 2007
18/180
18
Motivations for DfE
Exceeding sustainable limits can threaten Climate
Vegetation and wildlife Agriculture
Quality of Life
Industry
Environmental Stewardship is in the bestinterest of companies producing goods
-
7/27/2019 DF Environment June 2007
19/180
19
Motivations for DfE
Reduced Future Liability
Reduced Regulatory Impact
Reduced Time to Market
Reduced Cost
Corporate Image and Market Position
Enhanced Profitability
-
7/27/2019 DF Environment June 2007
20/180
20
Motivations for DfE
Reduced Future Liability Informed decisions during the design
stage can avoid costly future liabilities
Eliminating toxic materials and designingmore recyclable products can reduceproduct disposal responsibility
Reducing toxic releases duringprocessing helps eliminate latertreatment of contaminated water or soil
-
7/27/2019 DF Environment June 2007
21/180
21
Motivations for DfE
Reduced Regulatory Impact DfE enables anticipation of future trends in
environmental regulations and standards
Proactive approach incorporates futureenvironmental demands and regulationsinto current product and process designs
Early cooperation with regulatory agenciescan be beneficial by allowing influence onimplementation timing and/or metrics
-
7/27/2019 DF Environment June 2007
22/180
22
Motivations for DfE
Regulations and StandardsSome Government and InternationalRegulations and Standards:
US Environmental Protection Agency (EPA)
Product Take-Back" Policies in Europe
ISO 14000 standards
-
7/27/2019 DF Environment June 2007
23/180
23
Motivations for DfE
Regulations and StandardsUnited States EPA
Toxic Release Inventory (TRI) reporting ofamounts of regulated substances released intoenvironment
Fuel Economy and Energy Efficiency legislation Emissions Regulations (air particulates,
greenhouse & ozone depleting gasses)
-
7/27/2019 DF Environment June 2007
24/180
24
Motivations for DfE
Regulations and StandardsProduct Take-Back Policies (Europe) Principle of Extended Producer Responsibility
(EPR) requires producers to be responsible forthe life-cycle environmental impacts of products
Take-back policies create incentive for producersto 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
-
7/27/2019 DF Environment June 2007
25/180
25
Motivations for DfE
Regulations and StandardsISO 14000 Standards First published in 1996, based on 1992 UN
Earth Conference in Rio de Janeiro Similar to ISO 9000 Quality Standards, withfocus on sustainable development
Covers a wide range of environmental
management topics, including: environmental performance evaluation
life cycle assessment
environmental auditing
-
7/27/2019 DF Environment June 2007
26/180
26
Motivations for DfE
Reduced Time to Market Hazardous or regulated substances in
products and production processes
often require permits and elaboratecontrol systems to meet regulations
Permits and controls take time andresources to obtain and establish
By designing out such substanceswherever possible, time to market canbe reduced
-
7/27/2019 DF Environment June 2007
27/180
27
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
-
7/27/2019 DF Environment June 2007
28/180
28
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
-
7/27/2019 DF Environment June 2007
29/180
29
Motivations for DfE
Corporate Image and Market Position Consumers are increasingly conscious of
environmental issues
Perceptions about environmentalresponsibility of a company may affectconsumer and government purchasedecisions
Environmental quality can be an effectivemarketing tool
-
7/27/2019 DF Environment June 2007
30/180
30
Motivations for DfE
Enhanced ProfitabilityStudies have shown that environmentallyresponsible 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)
-
7/27/2019 DF Environment June 2007
31/180
31
Motivations for DfE
Corporate ResponsesEvolution of corporate approaches toenvironmental 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
-
7/27/2019 DF Environment June 2007
32/180
32
Motivations for DfE
Corporate ResponsesImplementation Challenges of DfE
Shortage of environmental expertise among
product design and development teams Difficulty in analyzing and predicting
environmental impacts (i.e. what issustainable)
Complex economics of product life cycle
-
7/27/2019 DF Environment June 2007
33/180
33
Design for Environment (DfE)
Introduction to DfE
Motivations for DfE
Key Principles of DfE
DfE Tools and Processes
DfE Design Guidelines
Case Studies
References
-
7/27/2019 DF Environment June 2007
34/180
34
Key Principles of DfE
Eco-Efficiency Approaches
Product Life Cycle Perspective
Integrated Cross-Functional Product
Development
-
7/27/2019 DF Environment June 2007
35/180
35
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)
-
7/27/2019 DF Environment June 2007
36/180
36
Key Principles of DfE
Eco-Efficiency Approaches Cleaner Processes
(Pollution Prevention)
Assumes product function and concept arefixed
Usually involves incremental refinement ofproduction/manufacturing processes toreduce waste and its byproducts
-
7/27/2019 DF Environment June 2007
37/180
37
Key Principles of DfE
Eco-Efficiency ApproachesCleaner Products
(Environmental Responsibility)
Fundamental product designs are stilldynamic
Takes into account all stages of theproduct life cycle, from material selection toend-of-life use and recovery
-
7/27/2019 DF Environment June 2007
38/180
38
Key Principles of DfE
Eco-Efficiency ApproachesSustainable Resource Use
(Industrial Ecology)
Evaluate product and production system asa whole
Includes supplier and customer impacts onresource consumption
-
7/27/2019 DF Environment June 2007
39/180
39
Key Principles of DfE
EPAs role in DfEThe EPA responded to these Eco-Efficient
approaches in the early 1990s, manufacturers
started thinking in terms of "design for" qualitiesin their products and processes. The EPArecognized the need for competitive butenvironmentally preferable technologies. As a
result the EPA's Design for the Environment(DfE) Program was developed.
http://www.epa.gov/dfe
-
7/27/2019 DF Environment June 2007
40/180
40
Key Principles of DfE
EPAs role in DfEThe EPA: Assists companies to integrate health and
environment considerations into business
decisions. This is aimed at prevention beforepollution is created.
Examines the hazards of chemicals used in anindustry and pollution prevention.
Assesses alternative processes, formulations, andemerging technologies.
Promotes risk reduction through cleanertechnologies and safer chemical choices.
-
7/27/2019 DF Environment June 2007
41/180
41
Key Principles of DfE
Eco-Efficiency ApproachesExample: Evolution of Automotive
Heat Exchangers
Copper-brass
with silver andleadsolder
cleaned withTCE
19861973 1993 1995+
Aluminum,cleanedwith TCEandcoated withi ron cyanide
and
chromium
Aluminum,cleaned
with TCEandcoated withchromium
Aluminumalloyimprovementnot coated;
cleaned withTCE
Aluminumalloyimprovementnot requiringcoating; cleaned
with waterand detergent
TCE= Trichloroethylene
-
7/27/2019 DF Environment June 2007
42/180
42
Key Principles of DfE
Eco-Efficiency ApproachesExample: Evolut ion of Autom obi le
Steel Frame
Vehicles
19801970 1990 1999+
Aluminumand newalloysintroduced
Enhanced Al
and MoldedPlasticsreplacing metalcomponents
Thermoset andrecycled
plastics used ascomponentmaterials
DfE used toimprovetechnologies toaide the impact on
the environment
Ref, Dr. Norm Gjostein 1998 (UMTRI)
-
7/27/2019 DF Environment June 2007
43/180
43
Key Principles of DfE
Life Cycle PerspectiveLife 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
-
7/27/2019 DF Environment June 2007
44/180
44
Key Principles of DfE
Life CycleLife Cycle decision making capabilities can be a
management tool based on characterizing:
Technology Economy/Economics
Environment
By identifying these characteristics a holisticoptimization potential can be identified tooptimize the long term effects of new designs.
-
7/27/2019 DF Environment June 2007
45/180
-
7/27/2019 DF Environment June 2007
46/180
46
Key Principles of DfE
Integrated Product Development SystemDfE Enablers in Product Development
Integrated product realization process Concurrent development of product and
production processes
Environmental performance metricsAnalysis methods for comparing and
selecting alternatives
-
7/27/2019 DF Environment June 2007
47/180
47
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
-
7/27/2019 DF Environment June 2007
48/180
48
DfE Tools and Processes
Environmental Performance Metrics
Environmental Design Practices
Environmental Analysis Methods
Environmental Information Infrastructure
-
7/27/2019 DF Environment June 2007
49/180
49
DfE Tools and Processes
Environmental Performance MetricsEnergy 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
-
7/27/2019 DF Environment June 2007
50/180
50
DfE Tools and Processes
Environmental Performance MetricsNatural 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
-
7/27/2019 DF Environment June 2007
51/180
51
DfE Tools and Processes
Environmental Performance MetricsMaterial 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
-
7/27/2019 DF Environment June 2007
52/180
52
DfE Tools and Processes
Environmental Performance MetricsRecovery 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
-
7/27/2019 DF Environment June 2007
53/180
53
DfE Tools and Processes
Environmental Performance MetricsSource Volume
Total product mass
Useful operating life of product
Percent of product disposed or incinerated
Percent of packaging recycled during life cycle
-
7/27/2019 DF Environment June 2007
54/180
54
DfE Tools and Processes
Environmental Performance MetricsExposure and Risk
Ambient concentrations of hazardousbyproducts in various media
Estimated annual population incidence ofadverse effects to humans or environment
-
7/27/2019 DF Environment June 2007
55/180
55
DfE Tools and Processes
Environmental Performance MetricsEconomics
Average life-cycle cost incurred by manufacturer
Purchase and operating cost incurred by the
consumer
Cost savings associated with improvements inproduct and process designs
-
7/27/2019 DF Environment June 2007
56/180
56
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
-
7/27/2019 DF Environment June 2007
57/180
-
7/27/2019 DF Environment June 2007
58/180
58
DfE Tools and Processes
Design for Disassembly Facilitate Access to Components
Optimize disassembly sequence
Design for easy removalAvoid embedded parts
Simplify Component Interfaces
Avoid springs, pulleys, and harnessesAvoid adhesives and welds
Avoid threaded fasteners
-
7/27/2019 DF Environment June 2007
59/180
59
DfE Tools and Processes
Design for Disassembly Design for Simplicity
Reduce product complexity
Reduce number of parts Design multifunctional parts
Utilize common parts
-
7/27/2019 DF Environment June 2007
60/180
60
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
-
7/27/2019 DF Environment June 2007
61/180
61
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
-
7/27/2019 DF Environment June 2007
62/180
62
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
-
7/27/2019 DF Environment June 2007
63/180
63
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
-
7/27/2019 DF Environment June 2007
64/180
64
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
-
7/27/2019 DF Environment June 2007
65/180
65
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
-
7/27/2019 DF Environment June 2007
66/180
66
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
-
7/27/2019 DF Environment June 2007
67/180
67
DfE Tools and Processes
Design Practices for Eco-EfficiencyCleaner Processes Good Housekeeping Practices to reduce
accidental waste
Material Substitution to reduce the presence ofundesirable substances in production
Manufacturing Process Changes to reduce
resource use and simplify production Resource Recovery to capture and reuse waste
materials in production
-
7/27/2019 DF Environment June 2007
68/180
68
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 standardsfor fluid received from manufacturer
Nearly 370,000 gallons have been reclaimed
Savings are estimated at $2.00 per transmission
-
7/27/2019 DF Environment June 2007
69/180
69
DfE Tools and Processes
Design Practices for Eco-EfficiencyCleaner 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
-
7/27/2019 DF Environment June 2007
70/180
70
DfE Tools and Processes
Design Practices for Eco-EfficiencyCleaner Products
Design for separability and disassembly
Design for disposability Design for energy recovery
-
7/27/2019 DF Environment June 2007
71/180
71
DfE Tools and Processes
Design Practices for Eco-EfficiencySustainable Resource Use
Substance Use Reduction
Energy use reduction Design for recyclability
Design for reusability
Design for remanufacture
-
7/27/2019 DF Environment June 2007
72/180
72
DfE Tools and ProcessesEnvironmental Analysis Methods
Life Cycle Assessment
Goal Definition
Inventory
Interpretation
Impact Analysis
Qualitative Assessment
Environmental Accounting
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
73/180
73
Life Cycle Assessment
The SETAC (Society of Toxicology andChemistry) Approach consists of four steps:
Define goals, scope, and system boundaries Develop an inventory of environmental burdens
by identifying and quantifying energy andmaterials used and wastes released
Assess the impact of this inventory on theenvironment
Interpret and evaluate opportunities to improve
-
7/27/2019 DF Environment June 2007
74/180
74
DfE Tools and Processes
Life Cycle Assessment A methodology best applied to in-depth
environmental evaluation ofexistingproducts
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 LCAsand identify appropriate data
Design recommendations are made to improvethe environmental aspects of the product orprocess
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
75/180
75
Ford Ecostar (electric vehicle)
QUESTION: Is this a Zero Emissions Vehicle?
DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle
DfE T l d P
-
7/27/2019 DF Environment June 2007
76/180
76
E
L
E
CT
R
I
CI
T
Y
}
DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle
-
7/27/2019 DF Environment June 2007
77/180
77
DfE Tools and Processes
Life Cycle AssessmentAdvantages: Holistic life cycle thinking(no shifting of
environmental problems: media, region, or time related)
Identification of cost cutting potentials and hotspots
Early warning system concerning future legalrequirements & concerns of environmentalists
Identification of possibilities for processimprovements
-
7/27/2019 DF Environment June 2007
78/180
78
DfE Tools and Processes
Life Cycle AssessmentDisadvantages: Data-intensive and costly
Requires dedicated expertise to conduct Does not account for non-environmentalaspects of quality and cost
Cannot capture dynamics of changing markets
and technologies Difficult to translate into specific requirements
for designers to implement
-
7/27/2019 DF Environment June 2007
79/180
79
DfE Tools and Processes
Life Cycle Assessment - Goal Definition The first step in considering environmental
assessment in product design is to establishclear objectives. What is the purpose of theenvironmental analysis?
Example1: Reduce CO2 emissions and meet
certification Example2: Reduce energy use, reduce component
toxicity.
DfE T l d P
-
7/27/2019 DF Environment June 2007
80/180
80
DfE Tools and Processes
Life Cycle Assessment - Goal Definition
Within goal definition, clearly defined
engineering specification (metrics) areestablished to evaluate a product.
The goal should be refined and revisited
DfE T l d P
-
7/27/2019 DF Environment June 2007
81/180
81
DfE Tools and Processes
Life Cycle Assessment - Goal Definition Overall Product Function The next step
for a design team is to establish theboundary of the system to analyze.
The Functional Unit The design teammust then establish a functional unit.
Example: A functional unit for a coffee grinder might beone days worth of ground coffee, or one cup of
grounds.
DfE T l d P
-
7/27/2019 DF Environment June 2007
82/180
82
DfE Tools and Processes
Life Cycle Assessment - Inventory After establishing the system boundary and
functional unit, the system needs to bedescribed as a sequence of activities, eachcalled a life cycle stage.
Each life cycle stage takes in materials and
energy and produces the desired activityoutcome along with waste material andenergy.
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
83/180
83
Life Cycle Stage
Single ProductStage orOperation
Product Material Inputs(including reuse andrecycle from another
Stage)
Reuse/RecycleThis stage
EnergyProcess Materials, Reagents,Solvents and Catalysts
Fugitive andUntreated Waste
Treated Waste
Reuse/Recycle For
a different stagePrimary Product
Useful Co-product
Reuse/Recycle this stage
-
7/27/2019 DF Environment June 2007
84/180
84
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 toquantify these flows in termsenvironmental impact.
f
-
7/27/2019 DF Environment June 2007
85/180
85
DfE Tools and Processes
Impact Analysis The most challenging and controversial
stage of LCA
Impact of released materials can belocal, regional, or global in nature
Knowledge of environmental impacts is
fragmentary and largely theoretical
DfE T l d P
-
7/27/2019 DF Environment June 2007
86/180
86
DfE Tools and Processes
Impact AnalysisThere are 2 basic methods for analyzing
potential Impacts:
Risk Analysis
AT&Ts Environmentally Responsible ProductAssessment Methods
Motorolas Product Lifecycle Matrix
Environmental Impact Factors Analysis method Indexing and Scoring
DfE T l d P
-
7/27/2019 DF Environment June 2007
87/180
87
DfE Tools and Processes
Impact AnalysisRisk 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
DfE T l d P
-
7/27/2019 DF Environment June 2007
88/180
88
DfE Tools and Processes
Impact AnalysisIndexing 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 evaluatingresource depletion effects
DfE T l d P
-
7/27/2019 DF Environment June 2007
89/180
89
DfE Tools and Processes
Impact AnalysisIndexing and Scoring Example:
Volvo Environmental Priority Strategies (EPS)
Designed to provide feedback to design teams onoverall environmental impact of their product
Calculates Environmental Load Value (ELV) for eachcomponent, based on material inputs and manufacturing
processes ELV can be compared to similar products for relativeenvironmental performance objectives
DfE T l d P
-
7/27/2019 DF Environment June 2007
90/180
90
DfE Tools and ProcessesQualitative Assessment
Used to evaluate design choices among a set ofalternatives (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
DfE T l d P
-
7/27/2019 DF Environment June 2007
91/180
91
DfE Tools and ProcessesQualitative Assessment
Examples
Material Selection Criteria Checklists
Design Criteria Checklists
Trade-off or Decision Matrices
Multi-Criteria Requirement Matrix (MCRM)
DfE T l d P
-
7/27/2019 DF Environment June 2007
92/180
92
DfE Tools and ProcessesQualitative Assessment
QUALITYCOST
LEGAL
PERFORMANCEENVIRONMENT
VehicleRecycling
GreenInitiatives
Mfg. PlantConcerns
RegulatoryRequirement
MCRM adapted from Life Cycle Design Manual, US EPA, 1993.
Raw Materials
Manufacturingand Assembly
System Use
End of Life
DfE Tools and ProcessesQualitative Assessment
-
7/27/2019 DF Environment June 2007
93/180
93
Development of weightings for the Eco-Indicator
Environment
Effect
W e ighting
Factor
Criteria
Greenhouse
Effec t 2.5 0.1 NY ris e every 10 y ears . 5% ec os y s tem degredation
Ozone Layer
Deplet ion 100 Probabi li ty of 1 fat ali ty per y ear per m i ll ion inhabit ant s
Ac idific ati on 10 5% ec os y s tem degredat ion
Eutrophic ation 5
Rivers and lakes degredation of an unknown number of
aquat ic ecosy stem s
Summ er smog 2.5
Occ urrence of sm og periods hea lth c omp laintspart icularly am ongs t as thma pat ient s and the elderly
prevention of agricu ltural dam age
W inter smog 5
Occ urrence of sm og periods, health com plaints,
part icularly am ongs t as thma pat ient s and the elderly
Pes tic ides 25 5% ec os y s tem degredat ion
Airborne heavymetals 6
Lead c ontent in childern's blood, reduced l i fe ex pec tancyand learning perform anc e in unknow n number of peop le
W ate rborne
heavy metals 5
Cadmium content in rivers ult imate ly als o impac ts on
people
Carcinogenic
substances 10 Prob ability of 1 fat ality pe r year per m illion peopl e
DfE T l d P
-
7/27/2019 DF Environment June 2007
94/180
94
DfE Tools and ProcessesEnvironmental Accounting
Economic impact of a product on nonrenewableresources 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 ofenvironmental improvements toward profitability
Total Cost Assessment methods can show thefinancial benefits of environmental improvement
DfE T l d P
-
7/27/2019 DF Environment June 2007
95/180
95
DfE Tools and ProcessesEnvironmental Accounting
Total Costing is:
A systematic approach for analyzing allof the internal and external costsassociated with business processes,
including life cycle costs due toenvironmental and other factors.
Source: Ford Motor Company DFE Development Team
DfE T l d P
-
7/27/2019 DF Environment June 2007
96/180
96
DfE Tools and ProcessesEnvironmental 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)
DfE T l d P
-
7/27/2019 DF Environment June 2007
97/180
97
DfE Tools and ProcessesEnvironmental Information Infrastructure
Necessary Capabilities of anEnvironmental Information Infrastructure
On-line Design Guidance
Predictive Assessment Tools
Integration with CAE/CAD Framework
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
98/180
98
DfE Tools and ProcessesEnvironmental Information Infrastructure
On-line Design Guidance assists in: Selecting appropriate DfE design practices
Identifying interactions and trade-offsamong eco-efficiency, cost, quality, etc.
Assigning relative importance to categoriesof environmental impacts for trade-offs and
decision making Recording objectives and decisionrationales in corporate memory
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
99/180
99
DfE Tools and ProcessesEnvironmental Information Infrastructure
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 designsor technologies
Ford Example: Environmental QualityOffice Web Site (www-ese.ta.ford.com/eqo)
ENVIRONMENTAL EVALUATION PROCESS
SECTION 1. TARGETED SUBSTANCES
-
7/27/2019 DF Environment June 2007
100/180
100
2B. Manufacturing Packaging / ProcessMaterials
a) Supply reusable / returnable packagingb) Utilize readily recyclable packaging
SECTION 2. Recycl in g /
Acc ommodate Recyclabi l ity
2A. Accommodate Vehicle Recyclabilitya) Evaluate products for materials that
provide for their optimum recyclabilityb) Use recycled materials in product
SECTION 3. Evalu ate Poten tial
to Impro ve Energy Eff ic iency
a) Provide material recovery capability for target substance at ornear the source of release
b) Evaluate and engineer environmentally robust materialcollection, handling, recovery, treatment and disposalprocesses / procedures
c) Assure systems and procedures are in place to comply withregulations and with Company Policy and Directives.
1.5 Evaluate & Engineer a Process to Reuse/Recycle the targetsubstance 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
1.1 Evaluate Leading EdgeClean Technology
a) Review technical research forpotential opportunities
1.2 Involve Suppliers& Researchers
1.3 Benchmark comparableindustry alternatives
a) Compare competitive alternativesb) Evaluate other industry &
non-competitor alternatives
a) Request alternative materialb) Solicit alternatives from other suppliersc) Requests internal studies/research
1.0 Does Product or Process contain
or use target substances?
YESNo
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
101/180
101
DfE Tools and ProcessesEnvironmental Information Infrastructure
Predictive Assessment Tools use LCA andother data to provide:
Early assessment of anticipated wastestreams 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
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
102/180
102
DfE Tools and ProcessesEnvironmental Information Infrastructure
Predictive Assessment Tool Example:
Environmental Information and Management Explorer
from Ecobilan, S.A.
www.ecobalance.com/software/eime
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
103/180
103
DfE Tools and ProcessesEnvironmental Information Infrastructure
Originally developed for the Electronics Industryin 1997 testing automotive applications now
Integrates quantitative LCA information withinternal and regulatory standards, anddisassembly aspects, of product design
Does not require LCA expertise of users
Description
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
104/180
104
DfE Tools and ProcessesEnvironmental Information Infrastructure
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" remindersduring the product description process
Features
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
105/180
105
DfE Tools and ProcessesEnvironmental Information Infrastructure
Allows for the determination of environmentaltarget values to benchmark design alternatives
Database of 170 modules on commonly usedmaterials and sub-components, includingquantitative life-cycle flows, toxicology andregulatory information, product descriptions andend-of-life aspects
Features
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
106/180
106
DfE Tools and ProcessesEnvironmental Information Infrastructure
Product designs are represented by: Materials
Components
Links Processes
From the extensive EIME database
Design Inputs
-
7/27/2019 DF Environment June 2007
107/180
107
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
108/180
108
DfE Tools and ProcessesEnvironmental 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/orregulatory standards
Comparative analysis of design alternatives
-
7/27/2019 DF Environment June 2007
109/180
-
7/27/2019 DF Environment June 2007
110/180
110
-
7/27/2019 DF Environment June 2007
111/180
111
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
112/180
112
DfE Tools and ProcessesEnvironmental 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; numberof problematic links; number of distinct materials)
-
7/27/2019 DF Environment June 2007
113/180
113
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
114/180
114
DfE Tools and ProcessesEnvironmental Information Infrastructure
Benefits
Empowers product designers to evaluate theenvironmental 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
DfE Tools and Processes
-
7/27/2019 DF Environment June 2007
115/180
115
DfE Tools and ProcessesEnvironmental Information Infrastructure
Integration with CAE/CAD Framework
Avoid the islands of automation syndrome
Share common data models and interfacespecifications with other attribute tools
Key enabler of true integrated productdevelopment system
Not yet available in automotive application
f ( f )
-
7/27/2019 DF Environment June 2007
116/180
116
Design for Environment (DfE)
Introduction to DfE
Motivations for DfE
Key Principles of DfE DfE Tools and Processes
DfE Design Guidelines
Case Studies References
Design Guidelines For DfE
-
7/27/2019 DF Environment June 2007
117/180
117
Strive to be multifunctional.
Minimize the number of parts.
Create multifunctional parts. Embed springs, pulleys, or harness intoparts, avoid separating them.
Modularize with separate functions. Design reusable platforms and modules.
-- For Product Structure
Design Guidelines For DfE
-
7/27/2019 DF Environment June 2007
118/180
118
Locate unrecyclable parts in one systemthat can be quickly removed.
Locate parts with the highest value in easilyaccessible places.
Access and break points should be madeobvious.
Specify remanufactured parts.
-- For Product Structure
Design Guidelines For DfE
-
7/27/2019 DF Environment June 2007
119/180
119
In plastic parts, avoid embedded metalinserts or reinforcements.
Design power-down features for differentsubsystems in products when they are notin use.
Commonize the material of individual parts
-- For Product Structure
Design Guidelines For DfE
-
7/27/2019 DF Environment June 2007
120/180
120
Avoid regulated and restricted materials.
Minimize the number of different types ofmaterials.
Mark the material on all part. Use recycled materials.
Avoid composite materials.
Hazardous parts should be clearly markedand easily removed.
-- For Material Selection
Design Guidelines For DfE
-
7/27/2019 DF Environment June 2007
121/180
121
Ensure compatibility of ink where printing isrequired on parts.
Eliminate environmentally incompatiblepaints on parts.
Use unplated metals that are morerecyclable than plated.
Use electronic part documentation.
-- For Labeling and Finish
D i f E i t (DfE)
-
7/27/2019 DF Environment June 2007
122/180
122
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
C St di
-
7/27/2019 DF Environment June 2007
123/180
123
Case Studies
Xerox
Industry Trends
S.C. Johnson Wax The Auto Industry Pollution Prevention
Project
C St di
-
7/27/2019 DF Environment June 2007
124/180
124
Case Studies
Xerox
Industry Trends
S.C. Johnson Wax The Auto Industry Pollution Prevention
Project
Case Study - XEROX
-
7/27/2019 DF Environment June 2007
125/180
125
Business Summary
Xerox Corporation is engaged in the global documentmarket selling equipment and providing documentsolutions including hardware, services and softwareworld-wide. The Company's activities encompass
developing, manufacturing, marketing, servicing andfinancing of a complete range of documentprocessing products, solutions and services designedto make organizations around the world moreproductive.
XEROX Is A Document Company
Case Study - XEROX
-
7/27/2019 DF Environment June 2007
126/180
126
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
Case Study - XEROX
-
7/27/2019 DF Environment June 2007
127/180
127
Protection of the environment and the health andsafety of employees, customers, and neighborsfrom unacceptable risks takes priority overeconomic consideration and will not becompromised.
Operations must be conducted in a manner thatsafeguards health, protects the environment,conserves valuable materials and resources, andminimizes the risk of asset losses.
Corporate Policy on Environment, Health, and Safety
Case Study - XEROX
-
7/27/2019 DF Environment June 2007
128/180
128
To design, manufacture, distribute and marketproducts and processes to optimize resourceutilization and minimize environmental impact.
All operations and products are, at a minimum, infull compliance with applicable governmentalregulations and XEROX standards.
Continue to improve performance in environmenthealth and safety.
Corporate Policy on Environment, Health, and Safety
Xerox Site Operations
-
7/27/2019 DF Environment June 2007
129/180
129
XEROX Reuse/Recycle Management Process
-
7/27/2019 DF Environment June 2007
130/180
130
XEROX Environmental Performance
C E i l S i f i
-
7/27/2019 DF Environment June 2007
131/180
131
Customer Environmental Satisfaction
Eco-Efficiency
Clean Air and Air Emissions
Waste Recycle
Energy conservation
Water conservation
Waste to landfills
Saving in recycle
Customer Environmental
Satisfaction
-
7/27/2019 DF Environment June 2007
132/180
132
Prevented nearly 160 million poundsof material from entering landfills
through the reuse and recycling ofXerox equipment and supplies.
Increased the number of Xeroxproducts meeting the stringent
requirements of the internationalENERGY STAR, Canada'sEnvironmental Choice EcoLogo andGermany's Blue Angel ecolabels.
Enabled energy savings of more than800,000 megawatt hours through thesale of ENERGY STAR-qualifiedproducts.
Eco-Efficiency
-
7/27/2019 DF Environment June 2007
133/180
133
Beneficially managed 96% of
hazardous waste through
treatment, recycling or fuelsblending.
Recycled 80% of non-
hazardous solid waste.
Xerox's four equipmentrecovery 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).
Clean Air
-
7/27/2019 DF Environment June 2007
134/180
134
The majorityof energyconsumedin research and
manufacturingoperations issupplied byelectricity
Air Emissions
-
7/27/2019 DF Environment June 2007
135/180
135
Xerox hasreducedemissions of dustby 55 percent andozone by 70percent from its
office andproductionproducts,compared with
1990 baselineemissions
-
7/27/2019 DF Environment June 2007
136/180
E ti
-
7/27/2019 DF Environment June 2007
137/180
137
Energy conservation
Reduce energy usedBy 6% in 1999 from1998 and by 19%Since 1996
Water conservation
-
7/27/2019 DF Environment June 2007
138/180
138
Reduce water usageBy 5% in 1999 from
1998 and by 32%Since 1993
Waste to landfills
-
7/27/2019 DF Environment June 2007
139/180
139
Customers
worldwidereturned morethan 7 millioncartridges and
tonercontainers toXerox in 2000to beremanufactured or recycled
Saving in recycle
-
7/27/2019 DF Environment June 2007
140/180
140
Saving in recycle
$47 million in 1999
$45 million in 1998
Additional $5 millionwas realized.
Case Studies
-
7/27/2019 DF Environment June 2007
141/180
141
Case Studies
Xerox
Indus try Trends
S.C. Johnson Wax The Auto Industry Pollution Prevention
Project
DfE Success - Industry Trends
-
7/27/2019 DF Environment June 2007
142/180
142
An increasing number of contemporarycorporations are showing DfEproduct stewardshipand extended product responsibilitytrends.
Through public requests, pressure and pendingtake-backlegislation, corporations such asXEROX,Hewlett Packard, IBM, Sun Microsystems, GM,
Volkswagen, Ford and Goodyear, are finding theneed to adopt a DfE philosophy to meet evolvingciviland asset managementresponsibilities.
DfE Successes
-
7/27/2019 DF Environment June 2007
143/180
143
Goal zero materials to landfill
Set trends to reuse, recycle and remanufacturetheir products
Take accountability for products to end-of-life
New copiers have easily removed components
Disposable fuser rolls now made re-usable
Result - saved $100s of Millions to-date
DfE Successes
-
7/27/2019 DF Environment June 2007
144/180
144
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
DfE Successes
-
7/27/2019 DF Environment June 2007
145/180
145
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
DfE Successes
-
7/27/2019 DF Environment June 2007
146/180
146
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
DfE Successes
-
7/27/2019 DF Environment June 2007
147/180
147
Goals up-front DfE design, reuse and recycle
Developing energy & environmental impactsoftware with University of Tennessee
Track energy & environmental impact of everypart during cars life-cycle
Redesign parts to better reuse or recycle
Analyze environment component of everydesign decision
DfE Successes
-
7/27/2019 DF Environment June 2007
148/180
148
Goal 100% reusable/recyclable auto parts
Ensure environmental compatibility andconservative use of natural resources to
minimize environmental impact Contribute to resolution of environmentalproblems at regional and global levels
Balance customer expectations with
environmental compatibility Apply DfE to disassembly and recycling of
recovered materials in automobiles
DfE Successes
-
7/27/2019 DF Environment June 2007
149/180
149
Goals 100% recyclable vehicle Cross-functional recycling team since 1991
Plastic car bumpers recycled into tail lightsTaurus/Sable
2nd hand tires used to make parking brake pedalpads
Makes use ofnon-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
DfE Successes
-
7/27/2019 DF Environment June 2007
150/180
150
Goals develop used tires into a valuableresource 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%
Case Studies
-
7/27/2019 DF Environment June 2007
151/180
151
Case Studies
Xerox
Industry Trends
S.C. Johnson Wax The Auto Industry Pollution Prevention
Project
S C Johnson Wax
-
7/27/2019 DF Environment June 2007
152/180
152
S.C Johnson Wax
S.C. Johnson Wax - Introduction
Pioneer of eco-efficiency
1975 voluntarily eliminated CFC(chlorofluorocarbon) propellants from allaerosols
1990 established a centralizedenvironmental policy and strategy office
S C Johnson Wax
-
7/27/2019 DF Environment June 2007
153/180
153
S.C Johnson Wax
S.C. Johnson Wax - Worldwide
Reduced waste from products andprocesses by 420 million pounds since1992
More than 30 environmental awardsfrom agencies and governments since
1990 $125 million in savings since 1992
S C Johnson Wax
-
7/27/2019 DF Environment June 2007
154/180
154
S.C Johnson Wax
S.C. Johnson Wax Goals set in 1990
Cut virgin packing material use as aratio of total by 20% by 1995
Cut combined air & water emissionsand solid waste disposal by 50% by1995
Cut volatile organic compound (VOC)use by 25% by 2000
S C Johnson Wax
-
7/27/2019 DF Environment June 2007
155/180
155
S.C Johnson Wax
S.C. Johnson Wax by 1995
Cut virgin packing material by 26.8% by
using recycled containers and lighterweight containers
Cut air, water, and solid emissions by
46.7% Cut VOC ratio by 16.5%
S C Johnson Wax
-
7/27/2019 DF Environment June 2007
156/180
156
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
S.C Johnson Wax
-
7/27/2019 DF Environment June 2007
157/180
157
S.C Johnson Wax
S.C. Johnson Wax Aerosol products
Lighter plastic caps (2.4M lbs. Plastic)
Recycled shippers (1.2M lbs. Virgincorrugate)
Recycled scant flaps (110,000 lbs.)
Annual cast savings of $1.45 million
Case Studies
-
7/27/2019 DF Environment June 2007
158/180
158
Case Studies
Xerox
Industry Trends
S.C. Johnson Wax The Au to Industry Pol lu t ionPrevent ion Project
Auto Project
-
7/27/2019 DF Environment June 2007
159/180
159
Auto Project
Auto Project Introduction
Partnership between the State of Michiganand the auto industry started in 1991
Voluntarily focus source reduction efforts onpersistent toxic substances that adverselyaffect the Great Lakes
Partnership to benefit both economicdevelopment and the environment
Auto Project
-
7/27/2019 DF Environment June 2007
160/180
160
Auto Project
Auto Project Ford
Great Lakes Persistent Toxic (GLPT)
substances Toluene & Trichloroethylene (TCE)
highest volume of releases according to
Toxic Release Inventory (TRI)
Auto Project
-
7/27/2019 DF Environment June 2007
161/180
161
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
Auto Project
-
7/27/2019 DF Environment June 2007
162/180
162
Auto Project
Auto Project Ford
Used two TCE degreasers for cleaningoil from metal tubes
Pilot testing showed replacing with awater wash system could maintainproduct quality.
Reduced TCE releases by about 50,000pounds annually
Auto Project
-
7/27/2019 DF Environment June 2007
163/180
163
uto oject
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
Auto Project
-
7/27/2019 DF Environment June 2007
164/180
164
j
Auto Project GM
Successfully piloted a non-solvent basedadhesive 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
The End?
-
7/27/2019 DF Environment June 2007
165/180
165
UNLESS someone like you cares a whole awful lot,Nothing is going to get better.Its not. - The Once-ler
References
-
7/27/2019 DF Environment June 2007
166/180
166
K. Hockerts, et al., Beyond Life Cycle Assessment,an Integrative Design for Environment Approach forthe Automotive Industry, SAE 982228, 1998
H. Schoech, et al., LCA Based Design forEnvironment in the Automotive Industry,SAE 2000-01-0517, 2000
Environmental Defense Pollution Prevention AllianceInternet site, www.edf.org/PPA
ISO 14000 Internet site, www.iso14000.org
T. Seuss Geisel, The Lorax, Random House, 1971
References
-
7/27/2019 DF Environment June 2007
167/180
167
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 Toolfor Design for Environment, SAE 2000-01-1491, 2000
References
-
7/27/2019 DF Environment June 2007
168/180
168
Ecobilan Group Internet Site, EIME SoftwareDescription, www.ecobalance.com/software/EIME
World Business Council for Sustainable Developmentwww.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 Industryes.epa.gov/techinfo/case/michigan/michcs14.html
Yarwood, Jeremy M., and Eagan, Patrick D., Designfor Environment Toolkit, Minnesota Office ofEnvironmental Assistance
References
-
7/27/2019 DF Environment June 2007
169/180
169
Greenhaven Press, The Environmental Crisis1986
Earth in the Balance, Senator Al Gore 1992
DfE Tools and ProcessesEnvironmental Analysis Methods
-
7/27/2019 DF Environment June 2007
170/180
170
Environmental Analysis Methods
Life Cycle Assessment
Goal Definition
Inventory
Interpretation
Impact Analysis
Qualitative Assessment
Environmental Accounting
-
7/27/2019 DF Environment June 2007
171/180
DfE Tools and ProcessesLife Cycle Assessment Goal Definition
-
7/27/2019 DF Environment June 2007
172/180
172
Life Cycle Assessment - Goal Definition
The first step in considering environmentalassessment in product design is to establishclear objectives. What is the purpose of the
environmental analysis?
Example1: Reduce CO2 emissions and meetcertification
Example2: Reduce energy use, reduce componenttoxicity.
DfE Tools and ProcessesLif C l A t G l D fi iti
-
7/27/2019 DF Environment June 2007
173/180
173
Life Cycle Assessment - Goal Definition
Overall Product Function The next stepfor a design team is to establish theboundary of the system to analyze.
The Functional Unit The design teammust then establish a functional unit.
Example: A functional unit for a coffee grinder might be
one days worth of ground coffee, or one cup of
grounds.
DfE Tools and ProcessesLife C cle Assessment In entor
-
7/27/2019 DF Environment June 2007
174/180
174
Life Cycle Assessment - Inventory
After establishing the system boundary andfunctional unit, the system needs to bedescribed as a sequence of activities, each
called a life cycle stage.
Each life cycle stage takes in materials and
energy and produces the desired activityoutcome along with waste material andenergy.
-
7/27/2019 DF Environment June 2007
175/180
DfE Tools and ProcessesLife Cycle Assessment Goal Definition
-
7/27/2019 DF Environment June 2007
176/180
176
Life Cycle Assessment - Goal Definition
Within goal definition, clearly defined
engineering specification (metrics) areestablished to evaluate a product.
The goal should be refined and revisited
DfE Tools and ProcessesImpact Analysis
-
7/27/2019 DF Environment June 2007
177/180
177
Impact Analysis
Having mapped the system andidentified the flows in and out of eachlife cycle stage, the next step is toquantify these flows in termsenvironmental impact.
DfE Tools and ProcessesImpact Analysis
-
7/27/2019 DF Environment June 2007
178/180
178
Impact Analysis
The most challenging and controversialstage of LCA
Impact of released materials can belocal, regional, or global in nature
Knowledge of environmental impacts isfragmentary and largely theoretical
DfE Tools and ProcessesImpact Analysis
-
7/27/2019 DF Environment June 2007
179/180
179
Impact Analysis
There are 2 basic methods for analyzingpotential Impacts:
Risk Analysis
AT&Ts Environmentally Responsible ProductAssessment Methods
Motorolas Product Lifecycle Matrix
Environmental Impact Factors Analysis method
Indexing and Scoring
DfE Tools and ProcessesQualitative AssessmentDevelopment of weightings for the Eco-Indicator
Environment W e ighting Criteria
-
7/27/2019 DF Environment June 2007
180/180
Effect Factor
GreenhouseEffec t 2.5 0.1 NY ris e every 10 y ears . 5% ec os y s tem degredation
Ozone Layer
Deplet ion 100 Probabi li ty of 1 fat ali ty per y ear per m i ll ion inhabit ant s
Ac idific ati on 10 5% ec os y s tem degredat ion
Eutrophic ation 5
Rivers and lakes degredation of an unknown number of
aquat ic ecosy stem s
Summ er smog 2.5
Occ urrence of sm og periods hea lth c omp laints
part icularly am ongs t as thma pat ient s and the elderly
prevention of agricu ltural dam age
W inter smog 5
Occ urrence of sm og periods, health com plaints,
part icularly am ongs t as thma pat ient s and the elderly
Pes tic ides 25 5% ec os y s tem degredat ion
Airborne heavy
metals 6
Lead c ontent in childern's blood, reduced l i fe ex pec tancy
and learning perform anc e in unknow n number of peop le