Pfahl-Journey to a Sustainable World...

R.C.PfahlDecember 15, 2001

Slide 1

Journey to a Sustainable World

Dr. Robert C. PfahlDr. Robert C. PfahlDirector of Environmental TechnologyDirector of Environmental TechnologyMotorola Advanced Technology CenterMotorola Advanced Technology Center

Schaumburg, ILSchaumburg, IL

m

The Journey to a Sustainable World

ProgressFor 1999


Slide 2

Outline

• Environmental Drivers • Environmentally Preferred Product Attributes• Motorola’s Pb Replacement R&D• Motorola’s Design Tools

– The Green Design Advisor– Life Cycle Assessment

• Case Study• Conclusions


Slide 3

Environmental Drivers for Industry

• Societal Concerns– Sustainability– Global Warming– Pollution– Energy

• Societal Responses– Public Policy


Slide 4

Examples of Public Policy

• Geneva, Rio, and Kyoto Conventions• United States Clean Air Act• Japanese Home Electronics Recycling Law• Proposed European Waste Electrical and

Electronic Equipment (WEEE) Directive• Revision of U.S. Toxic Release Inventory

(report 100 lbs of Pb)• Proposed New England Hg Take-back

legislation


Slide 5

Environmental Drivers

• Societal Concerns– Sustainability– Global Warming– Pollution

• Societal Responses– Public Policy– Consumer Action


Slide 6

Consumer Behavior and the Environment

20%

45%50%

66%

76%

44%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1993 1998

Switch brands when price and quality are

equal.(Roper/Cone Poll)

Bought product because

environmentally safe or

biodegradable(Roper 96)

Consider environment

when purchasing(Roper 96)

Currently have product specifically because better for

environment(MORI 98)

Switched brands after discovering

harm to environment

(Environmental Research

Associates Inc. 99)


Slide 7

• Societal Concerns– Sustainability– Global Warming– Pollution

• Societal Responses– Public Policy– Consumer Action

• Regional Differences

Environmental Performance Drivers


Slide 8

Regional Differences

Regional Drivers

Global Solutions

Europe• Customer & Regulation

Driven• Academic Focus• R&D: Model Focused

– Life Cycle Analysis– Material Flow

Analysis

Japan• Government/Industry

Driven• Market Focus• R&D: Product

Focused – Hybrid Engines– Halogen Free Plastics– Pb-Free Products

United States• Regulation Driven • Factory Focus• R&D: Manufacturing

Focused– CFC Elimination– VOC Reduction


Slide 9

CustomerLoyalty

Cost/LiabilityReduction

Right toOperate

New Market Strategic Planning/Marketing

R&D/DesignEngineering/

Marketing

Manufacturing/Operations

Public Affairs/General Counsel

U.S.

Europe

Japan

The Business Value ModelFrom: The Next Bottom Line: Making Sustainable Development “Tangible” -Arnold & Day, 1998

Business Value Action Organizational Lead

– Environmental Restoration

– Social Reconstruction

– Step Change– Business

Redefinition

– Design for Environment

– Service Intensity

– Pollution Prevention

– Yield Improvement

– Waste Treatment– Compliance


Slide 10

Environmentally Preferred Product Attributes

• Use Non-Hazardous Materials• Minimize Use of Energy • Are Highly Recyclable• Minimize Use of Matter

1983First PortableCellular Phone

DynaTAC

1996First WearableCellular Phone

StarTAC®

1999


Slide 11

Summary of Drivers by Attribute:

Reduce Hazardous Materials

Increase Recycled Contents

BusinessTo

BusinessConsumer

Attributes Measured by Motorola

GovernmentRegulation

Improve Recyclability

Minimize Packaging

Label Plastics/Metals

Reduce Energy

Japan

EU


Slide 12

Motorola’s Pb Replacement R&D:Distribution of Pb in Motorola Products

Mass % of Lead (Pb)

0102030405060708090

100

Solder Components Ceramic

[%]


Slide 13

Motorola’s Pb Replacement R&D

• No Pb-free drop-in replacement for Pb-bearing solders for all applications

• There are optimal Pb-free alloys for given applications

Sn-0.7Cu for Wave Soldering and for Flip Chip

Sn-3.9Ag-0.6Cu for Surface Mount Reflow Soldering

Sn-Sb for Die Attach

Variety of alloys (Ni-Au, Ni-Pd, Sn, organic preservatives, Sn-Bi) for Surface Finish


Slide 14

Motorola’s Environmental Design Tools

• DfE – The Green Design Advisor

• LCA Studies – With Customers and Suppliers

• Creates Understanding, cooperation, and profit between Businesses

– LCA of Services• Could create alternative environmentally positive

solutions


Slide 15

Motorola’s “Green Design Advisor”

• Parts and Connectivity Model for analyzing recyclability• Evaluation of Hazardous Materials


Slide 16

Motorola’s DfE Tool:The Green Design Advisor (GDA)

Output from Green Design Advisor Analysis:Measurement of Eight Environmental Criteria• Number of Materials• Mass• Toxicity• Energy• Recycled Content• Disassembly Time• Cost of Disposal• Recyclability


Slide 17

Motorola’s Environmental Design Tools

• DfE – The Green Design Advisor

• LCA Studies – With Customers and Suppliers

• Creates Understanding, cooperation, and profit between Businesses

– LCA of Services• Could create alternative environmentally positive

solutions


Slide 18

Joint Motorola - Service Provider LCA ProjectLife Cycle of a Product

EngineeredMaterials

End of Life

Use & Service

Raw MaterialAcquisition

Manufacturing & Assembly

Energy

ProcessMaterials

AirEmissions

WaterEmissions

Products

SolidWaste

By-products

OutputsInputs

Life cycle phases studied

Focus of the Study

Hazardous Materials:• Material’s inherent toxicity• Determined by the Motorola Toxicity

Index

Energy Use:• Energy used for materials• Energy used for manufacturing of

components and product• Energy used during use phase (charging,

standby charger)


Slide 19

Life Cycle Assessment Result: Energy

• High energy use for raw materials

• High energy use for purchased components

• Use phase dominates due to:- Standby of the charger- Losses of the charger

0.01

0.1

1

1 0

100

2W St

andb

y (@1 y

ear) PW

B

Raw M

aterial

s IC's

Air Con

dition

ing Heating

Light/C

ompu

ters

Reflow Ove

n

2W St

andb

y (@ 1 d

ay)

Life Cycle Phase

Log

Ene

rgy

per

phon

e (k

Wh)


Slide 20

0

0.5

1

1.5

2

2.5

3

Br Pb Sb Others

Toxi

city

inde

x P

WB

(av

erag

e)Life Cycle Assessment Result: Material Toxicity (PWB)

Bromine (Br): Flame retardant in PWBsEU ban for certain Br containing flame retardants by 2008

Lead (Pb): Part of the solderEU ban for Pb in solder by 2008

Antimony (Sb): Flame retardant synergist in PWB and components

Others: e.g. Beryllium, trace materials


Slide 21

Case Study of the v.2288:Analyzed by the Green Design Advisor

Normalized Scores

00.20.40.60.8

1Number of Materials

Mass

Toxicity Product

Energy

Recycled Content

Disassembly Time

Cost of Disposal

Recyclability

v2288

v2288 improved

Total Score

0

10

20

30

40

50

60

70

80

90

v2288 v2288ECO


Slide 22

Bromine (Br) Reduction v.2288

• A Bromine (Br) and Antimony (Sb) free PWB was used

ê The Bromine content of the Entire Product was reduced 89%

ê The board to boardreduction of Bromine (Br) for the populated PWB was 89%

0.89

0.10

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

Br Br-free

Bromine(Br) %Product


Slide 23

Lead (Pb) Reduction v.2288

• Lead-Free solder was used on the PWB

• No attempt was made to obtain lead freecomponents

ê The Lead content of the Entire Productwas reduced 51%

ê The board to boardreduction of lead for the populated PWB was 52%

0.48

0.24

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

Pb Pb-free

Lead(Pb) %Product


Slide 24

Energy Efficient Charger v.2288

• New energy efficient charger reduces no-load energy loss (stand-by)

• Charger meets EU voluntary agreement of 2002

ê The no-load energy loss was reduced from 2 W to 0.66 W=> 66%reduction

2.00

0.66

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

Conv. Env.

Powerconsumption(W)


Slide 25

Environmentally Improved Mobile Phone Prototype: Recycled Plastic Housing

Processing plastic waste into specified regrind

Post Production Waste

Post Industrial Waste

Post Consumer Waste

Waste stream convergence

Processing of specified regrind into quality assured base recyclate

Production of quality assured recyclate (pellets) consisting of base recyclate and virgin material = “Recycled“ grades

Recycled Content HousingPC+ABS recyclate blend

• comparable to lower grade virgin resin properties

• slightly lower toughness for comparable heat resistance


Slide 26

Design Sense Awards 2001• Sponsored by the Design Museum, London

England• Over 80 submissions for the Award• Motorola Labs submitted the v.2288

Environmental Limited Edition: lead-free solder, bromine-free wiring board, housing of recycled plastic, energy-efficient charger

• Motorola v.2288 one of 12 finalist• Only finalist with an electronic product• Judges critique

'A big company has taken a sustainable 'A big company has taken a sustainable initiative initiative -- I hope to see this experiment I hope to see this experiment lead to mainstream products in the near lead to mainstream products in the near future. It would be wonderful if this phone future. It would be wonderful if this phone could represent a turning point in the could represent a turning point in the sustainable design of masssustainable design of mass--produced produced products such as mobile phones.'products such as mobile phones.'


Slide 27

Performance Specifications • Dimensions: 131mm x 50mm x 30mm

with High Performance Battery• Weight: 132g with Slim Battery• Power: 600mW (typical)• Frequency Range:

Tx 806 - 825 Mhz/Rx 851-870 Mhz• Channel Spacing: 25 kHz• Channel Access: TDMA

• Halogen Reduced, Bromine Free, Interconnect Technology.

• Lead Free Solder Assembly Technology.

Motorola iDEN® i85s

General Features Digital Cellular Phone Service • Speakerphone• Java™ 2 Micro Edition Capable• Voice Activation• Multi-Language Support• SIM Card Operation• Voice Recorder• Voice Activated Dialing• VibraCall® Alert

Digital Two-Way Radio / Message Service• One-touch Private & Group Call• Built-in Speaker• Voice & Message Mail Indicators

Data Capable• Software Download Capability• Internet Access Services• T9 Text Input for fast entry


Slide 28

• Summarized Environmental Drivers and Attributes of Environmentally Preferred Products

• Described current proactive activities at Motorola

“The Journey to a Sustainable World ” has just begun

Summary

Conclusion


Slide 29

http://www.mot.com/EHS/

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