DF Environment June 2007

7/27/2019 DF Environment June 2007

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Design For Environment

MPD575 Design for XJonathan Weaver


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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


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Design for Environment (DfE)

Introduction to DfE

Motivations for DfE

Key Principles of DfE

DfE Tools and Processes

DfE Design Guidelines Case Studies

References


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Introduction to DfE

Underlying premises Environmental Quality is compatible with

industrial development

Industrial systems can be designed toachieve both Environmental Quality and

Economic Efficiency


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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


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Introduction to DfE

What is DfE?Definition #1:

A specific collection of design practicesaimed at creating eco-efficient productsand processes


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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


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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.


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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)


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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")


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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


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Introduction to DfE

Characteristics of DfE

SustainableDevelopment

EnterpriseIntegration

Design forEnvironment

Pollution

Prevention

Integrated Product

Development

EnvironmentalStewardship

Total QualityManagement

The Crossroad


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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)


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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


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Introduction to DfE

Motivations for DfE



DfE Design Guidelines Case Studies

References


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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)


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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


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Motivations for DfE

Reduced Future Liability

Reduced Regulatory Impact

Reduced Time to Market

Reduced Cost

Corporate Image and Market Position

Enhanced Profitability


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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


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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


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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


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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)


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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


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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


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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


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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


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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


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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


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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)


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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


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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


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Introduction to DfE

Motivations for DfE



DfE Design Guidelines

Case Studies

References


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Eco-Efficiency Approaches

Product Life Cycle Perspective

Integrated Cross-Functional Product

Development


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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)


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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


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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


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Eco-Efficiency ApproachesSustainable Resource Use

(Industrial Ecology)

Evaluate product and production system asa whole

Includes supplier and customer impacts onresource consumption


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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


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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.


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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


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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)


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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


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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.


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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


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Introduction and Definition of DfE

Motivations for DfE




Case Studies

References


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Environmental Performance Metrics

Environmental Design Practices

Environmental Analysis Methods

Environmental Information Infrastructure


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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


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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


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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


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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


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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


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Environmental Performance MetricsExposure and Risk

Ambient concentrations of hazardousbyproducts in various media

Estimated annual population incidence ofadverse effects to humans or environment


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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


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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


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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


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Design for Disassembly Design for Simplicity

Reduce product complexity

Reduce number of parts Design multifunctional parts

Utilize common parts


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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


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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


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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


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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


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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


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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


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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


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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


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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


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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


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Design Practices for Eco-EfficiencyCleaner Products

Design for separability and disassembly

Design for disposability Design for energy recovery


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Design Practices for Eco-EfficiencySustainable Resource Use

Substance Use Reduction

Energy use reduction Design for recyclability

Design for reusability

Design for remanufacture


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DfE Tools and ProcessesEnvironmental Analysis Methods

Life Cycle Assessment

Goal Definition

Inventory

Interpretation

Impact Analysis

Qualitative Assessment

Environmental Accounting



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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


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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



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Ford Ecostar (electric vehicle)

QUESTION: Is this a Zero Emissions Vehicle?

DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle

DfE T l d P


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E

CT

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DfE Tools and ProcessesLife Cycle Assessment: Electric Vehicle


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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


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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


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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


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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


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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


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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.



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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


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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


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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


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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


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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


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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


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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


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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


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Examples

Material Selection Criteria Checklists

Design Criteria Checklists

Trade-off or Decision Matrices

Multi-Criteria Requirement Matrix (MCRM)

DfE T l d P


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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



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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


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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


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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


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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


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DfE Tools and ProcessesEnvironmental Information Infrastructure

Necessary Capabilities of anEnvironmental Information Infrastructure

On-line Design Guidance

Predictive Assessment Tools

Integration with CAE/CAD Framework



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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



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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


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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



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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



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Predictive Assessment Tool Example:

Environmental Information and Management Explorer

from Ecobilan, S.A.

www.ecobalance.com/software/eime



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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



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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



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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



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Product designs are represented by: Materials

Components

Links Processes

From the extensive EIME database

Design Inputs


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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


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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)


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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



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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 )


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Introduction to DfE

Motivations for DfE

Key Principles of DfE DfE Tools and Processes


Case Studies References

Design Guidelines For DfE


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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



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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.




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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




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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



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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)


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Introduction to DfE

Motivations for DfE

Key Principles of DfE DfE Tools and Processes

Design Guidelines for DfE

Case Studies

References

C St di


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Case Studies

Xerox

Industry Trends

S.C. Johnson Wax The Auto Industry Pollution Prevention

Project

C St di


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Case Studies

Xerox

Industry Trends


Project

Case Study - XEROX


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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


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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


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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


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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


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XEROX Reuse/Recycle Management Process


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XEROX Environmental Performance

C E i l S i f i


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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


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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


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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


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The majorityof energyconsumedin research and

manufacturingoperations issupplied byelectricity

Air Emissions


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Xerox hasreducedemissions of dustby 55 percent andozone by 70percent from its

office andproductionproducts,compared with

1990 baselineemissions


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E ti


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Energy conservation

Reduce energy usedBy 6% in 1999 from1998 and by 19%Since 1996

Water conservation


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Reduce water usageBy 5% in 1999 from

1998 and by 32%Since 1993

Waste to landfills


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Customers

worldwidereturned morethan 7 millioncartridges and

tonercontainers toXerox in 2000to beremanufactured or recycled

Saving in recycle


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Saving in recycle

$47 million in 1999

$45 million in 1998

Additional $5 millionwas realized.

Case Studies


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Case Studies

Xerox

Indus try Trends


Project

DfE Success - Industry Trends


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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


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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


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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


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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


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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


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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


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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


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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


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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


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Case Studies

Xerox

Industry Trends


Project

S C Johnson Wax


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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


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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


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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


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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


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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


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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


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Case Studies

Xerox

Industry Trends

S.C. Johnson Wax The Au to Industry Pol lu t ionPrevent ion Project

Auto Project


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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


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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


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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


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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


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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


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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?


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UNLESS someone like you cares a whole awful lot,Nothing is going to get better.Its not. - The Once-ler

References


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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


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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


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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


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Greenhaven Press, The Environmental Crisis1986

Earth in the Balance, Senator Al Gore 1992

DfE Tools and ProcessesEnvironmental Analysis Methods


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Environmental Analysis Methods


Goal Definition

Inventory

Interpretation

Impact Analysis

Qualitative Assessment

Environmental Accounting


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DfE Tools and ProcessesLife Cycle Assessment Goal Definition


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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


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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


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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.


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DfE Tools and ProcessesLife Cycle Assessment Goal Definition


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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


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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.



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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



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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


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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


prevention of agricu ltural dam age

W inter smog 5

Occ urrence of sm og periods, health com plaints,


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

DF Environment June 2007

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Transcript of DF Environment June 2007