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Dr. L. Ramakrishnan, FIEMA, C.Env.
Regional Environmental Coordinator Philips Lighting, Asia Pacific
2006.03.07
Green Manufacturing and Management
in Electronics Industry
CONFIDENTIAL 2Workshop on Green Manufacturing and Management, Pune Ref: Greenpeace
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CONFIDENTIAL 3Workshop on Green Manufacturing and Management, Pune
Environmental Issues of Products
The number of computers in India:
+/- 14,000,000 (growth: 25 % per year)
- Each one of these PCs is a TOXIC Trap
- Workers working in chip making facilities are likely to be
exposed to toxic chemicals that may lead to cancer, miscarriage,
birth defects etc.
- Many manufacturing sites of chips generate hazardous wastes
and contaminate ground water; for every 2 gm of chip about1260 gm of chemicals and materials are used
CONFIDENTIAL 4Workshop on Green Manufacturing and Management, Pune
Environmental Issues of Products
- EOL PCs contribute to the mounting
electronics waste EOL PCs find their way to
many Asian countries including India for
Recycling where workers are exposed to
toxins leading to damage to the central nervous
system, endocrine disruption, interference with
brain development and organ damage
- A typical computer monitor with a cathode raytube contains 2-4 Kg of Lead, as well as
phosphor, barium and Chromium (VI)
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CONFIDENTIAL 5Workshop on Green Manufacturing and Management, Pune
Environmental Issues of Products
- the chip resistors and semiconductors contain
Cadmium;
- Mother Boards and connectors contain Beryllium
- Printed Circuit Boards and Plastics casing
contain Brominated flame retardants (e.g.
PBBE)
(Source: Worldwatch Institute)
CONFIDENTIAL 6Workshop on Green Manufacturing and Management, Pune
Design
Transport
Use
EOL Product
Reuse, Repair, Remanufacture, Recycle
Manufacture
Landfill,Incinerate
Green Manufacturing & Management Supplier
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CONFIDENTIAL 7Workshop on Green Manufacturing and Management, Pune
Design for Environment:
Focal Areas:
Mass reduction Reduced consumption of resources
Reduction/elimination of hazardous substances (Cd, Pb, PBBE etc)
Reduction in consumption of energy (standby and in operation)
Recyclability (disassembly, monomaterials, pressfit, glue, welding)
Packaging Mass (elimination of PVC, PU, EPS)
Repairability and long life
Design
CONFIDENTIAL 8Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 9Workshop on Green Manufacturing and Management, Pune
CONFIDENTIAL 10Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 12Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 13Workshop on Green Manufacturing and Management, Pune
CONFIDENTIAL 14Workshop on Green Manufacturing and Management, Pune
SupplierGreen Purchasing:
Focal Areas:
Compliance Reduced Risk
Substances in process and in product
Eco-Efficiency Resource Consumption
Recirculation of Packages
Environmental Management System
(Supplier Sustainability Audits)
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CONFIDENTIAL 15Workshop on Green Manufacturing and Management, Pune
Green Manufacturing:
Focal Areas:
Energy Consumption
Water Consumption
Hazardous Substances
Waste Reduction (Hazardous and non-hazardous Waste)
Emission Reduction (Lead, solvents, decomposition products)
Mass Balance
Manufacture
CONFIDENTIAL 16Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 17Workshop on Green Manufacturing and Management, Pune
2006-2009
CONFIDENTIAL 18Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 20Workshop on Green Manufacturing and Management, Pune
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CONFIDENTIAL 21Workshop on Green Manufacturing and Management, Pune
760000
780000
800000
820000
840000
860000
880000
900000
920000
940000
2001 2002 2003 2004
Energy Consumption (GJ) Philips India
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
500000
2001 2002 2003 2004
Water Consumption (KL) Philips India
0
1000000
2000000
3000000
4000000
5000000
6000000
7000000
2001 2002 2003 2004
Waste Generation (KG) in Philips India
0
500
1000
1500
2000
2500
2001 2002 2003 2004
Mercury Emissions (KG) Philips India
0
1000
2000
3000
4000
5000
6000
7000
2001 2002 2003 2004
Cat II (EGE, Toluene, Xylene, Sb, Pb) Emissions (KG)
Philips India
0
100000
200000
300000
400000
500000
600000
2001 2002 2003 2004
Cat III (VOCs, SOx, NOx etc) Emissions (KG) Philips India
CONFIDENTIAL 22Workshop on Green Manufacturing and Management, Pune
TransportGreen Supply Chain (Logistics):
Focal Areas:
Compliance
Optimization
Handling of goods at transfer points
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CONFIDENTIAL 23Workshop on Green Manufacturing and Management, Pune
Use
Use:
Major Issue:
Energy Consumption
Maintenance
CONFIDENTIAL 24Workshop on Green Manufacturing and Management, Pune
End of Life Product:
E-Waste
Recycling, Repair & Reuse, Remanufacture
Incineration / Land-fill
EOL Product
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CONFIDENTIAL 25Workshop on Green Manufacturing and Management, Pune
In Essence
Green Manufacturing and Management is about
Designing products using Design For Environment Principles,
manufacturing them with eco-efficient processes,
delivering them to the customer with the least environmental
impact and
applying Cradle to Cradle or similar approaches for handling
EOL products.
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