系统化的限用物质管理 - FDRA

TÜV SÜD Greater China Slide 1

Systematic Restricted Substances Management 系统化的限用物质管理

Devin Zhan / 詹达琦 TÜV SÜD China Jun. 2015

Content 目录


1 General Information 概览

2 Motivations 动机

3 RS Management System 限用物质管理系统

4 Benefits of the System 系统可带来的好处

5 Q&A 问答

RAPEX Recall Cases Statistics RAPEX召回案例统计


•  Period / 周期: 2014

•  Clothing, textiles and fashion items 服装、纺织品及时尚品类

•  Total: 596 cases / 共596例

•  RAPEX –  Established under GPSD 2001/95/EC –  EU rapid alert system for dangerous consumer products – with the exception of food,

pharmaceutical and medical devices 欧洲非食品类消费产品快速警报系统

Country of Origin 来源国家


6 1 1 1 3

334

1 1 4 4 9 30

2 15 1 1 1 6 5 1 1 3 1 1 9 8 2

52

3 1

84

5 0

50

100

150

200

250

300

350

400

Bang

lades

h Be

lgium

Bu

lgaria

Br

azil

Camb

odia

China

Ec

uado

r Ey

gpt

Germ

any

Gree

ce

Hong

Kon

g Ind

ia Ind

ones

ia Ita

ly Ja

pan

Malay

sia

Mada

gasc

ar

Pakis

tan

Polan

d Re

publi

c of M

oldov

a Re

publi

c of K

orea

Sp

ain

Swed

en

Switz

erlan

d Ta

iwan

Th

ailan

d Th

e Neth

erlan

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Turke

y Un

ited K

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m Un

ited S

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Un

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etnam

2014 - Country of Origin

Country of Origin 来源国家


334; 56%

262; 44%

⽐比例

China

Notifying Country 发布国家


90 84

3 1 1 12

18

72

32

149

8 8 2

10 2

60

37

3 4 0

20

40

60

80

100

120

140

160

2014 - Notifying Country

RAPEX Recall Cases Statistics RAPEX召回案例统计


•  Physical hazards / 物理危害：426例 –  Injuries / 伤害 –  Strangulation / 勒颈 –  Burn / 烧伤

•  Chemical hazards / 化学危害：170例 –  Cr (VI) / 六价铬：95 –  AZO / 偶氮染料：21 –  SCCP / 短链氯化石蜡：13 –  Phthalates / 邻苯二甲酸酯：2 –  DMFu / 富马酸二甲酯：2 –  PAHs / 多环芳香烃：1 –  Formaldehyde / 甲醛：1 –  PCP /五氯苯酚：1 –  Nickel Release / 镍释放：14 –  Lead and Cadmium / 铅镉：9+11

Summary 小结


•  No. of RAPEX recall case in 2104 is 596 2014年RAPEX召回案例596起

•  Most products made in China “黑名单”中大部分案例的产品来自中国

•  Recall factors include physical hazards and chemical hazards 召回因素有物理危害类、化学危害类

•  Related chemicals include CrVI, AZO dye, SCCP, PCP, etc. 化学危害包括六价铬、AZO、SCCP、PCP等

Content 目录






5 Q&A 问答

Motivations to Establish a RS Management System 建立限用物质管理系统的动机


•  Increasing complexity and ever changing international and national regulations, as well as the sharp awareness of the general public under the keen actions of NGOs. 国际标准和法规持续更新，且越来越复杂。同时在非政府组织的推动下，公众的绿色健康环保的意识越来越强

–  E.g. !  REACh, RoHS 1&2, EU Food Grade Testing Guidelines, EU New Toys Directives !  US CPSIA, US Cal Prop 65, US Washington 66, US FDA !  German LFGB, French Decrees, Italian Decrees, !  GCC of the Gulf region !  national testing standards of BRIC !  ZDHC !  …



•  Super-linear amplification of rework cost along the supply chain from the upstream to the downstream. 若出现返工，则费用在供应链中，从上游到下游，呈现超线性扩大趋势

•  Not affordable in terms of time, sample amount, and money for the article producers, retailers, and brand owners in the market, especially when talking about fashion, trendy business. 对生产商、零售商以及品牌商，测试所需的时间、样品量、费用都越来越难以承担，特别是时尚、流行类产品。



•  Conventional TIC (Testing-Inspection-Certification) approach is not (cost-) effectively managing the issue of chemical testing. It offers few mechanisms to minimize testing and most importantly, to eliminate and replace hazardous chemicals right from the up stream of the chain. 传统的TIC（测试-检验-认证）模式，对于化学测试管理，并不是很有效，特别是费用方面。这种模式不能提供减少测试的机理，特别是，不能在供应链的上游就将有害物质消除或者取代。

Future Goals (reference to ZDHC 2020) 未来目标


•  In 2011, a group of major apparel and footwear brands and retailers made a shared commitment to help lead the industry towards zero discharge of hazardous chemicals by 2020 2020年前，实现所有产品生命周期中的有害化学品的零排放

•  Elimination or substitution of hazardous chemicals in consumer products and their manufacturing. 在消费品及其生产过程中，将有害物质消除或取代

" RSL: Restricted Substances List 限用物质清单

" MRSL: Manufacturing Restricted Substances List 生产过程限用物质清单

Content 目录






5 Q&A 问答

The Restricted Substances Management System 限用物质管理系统


A schematic of a highly simplified supply chain of footwear production 简化的鞋子生产过程 Raw materials

•  Chemicals: dyes, plastics, polymers, glues, pigments, auxiliaries, catalysts, detergents, etc 化学品：染料、塑料、胶水、颜料、辅助剂、催化剂等

•  Yarns 纱线 •  Metals 金属 •  Wet blues 湿蓝皮

Components

•  PU on non-woven fabric PU人造革 •  Dyed polyester, cotton, canvas upper 染色纱线、帆布帮面 •  Trims 装饰配件 •  Plastic outsoles 塑料大底 •  Tanned leather 已鞣制的皮革

Final products

•  Sandals 凉鞋 •  Sport shoes 运动鞋 •  Ladies high heels 高跟鞋 •  Men classics 男士皮鞋



Target 目标 1.  Consolidate all the production info along the supply chain (BOM, BOS).

收集供应链上的产品信息，如BOM、BOS

2.  Ensure tracibility along the supply chain from raw materials to final products – a relational database. 带有数据库，可从原材料到成品进行追踪

3.  Compile up-to-date requirements of regulations on chemicals by materials, by usages, and by regions/countries. 带有最新的有害物质法规要求，根据材料、用途、区域、国家进行细分



4.  Store the MSDS, TDS of chemicals with risk assessments, precautionary actions, and phase out plans for hazardous chemicals. 带有化学品的MSDS、TDS等，以及预防措施、淘汰计划等

5.  Formulate test plans to monitor the reduction and elimiation of restricted substances. 可制定计划，可监督有害物质的减少使用及消除使用



6.  Consolidate the available technologies and processes, hence the uses of chemicals, along the supply chain to evaluate declarations of suppliers. 综合使用的技术及工艺，以及化学品的使用情况，评估供应商的声明

7.  Compile testing statistics to evaluate the performance of suppliers - KPI. 根据测试的数据进行统计，对供应商进行评估（KPI）



管理系统生产信息

法规信息

化学品信息产业经验及技术

管理计划

数据统计及供应商评估

Requirements on the system 期望功能


•  Full traceability along the supply chain 供应链追溯性

Components of production (serial # 20140828-001 to 500) Supplier Lot # 1. Royal Blue suede leather (toe cap & heel cap) A A20140828L1 2. Silver Grey leather (upper patch) A A20140828L9 3. Royal Blue polyester fabric with printing (upper) B B-PE-RB-L10 4. Royal Blue PU with White fabric backing (eyestay) B B-PU-RB-L20 5. White fabric shoelace (upper) C C-SL-W-#102 6. Lemon PU with White fabric backing (heel upper) B B-PU-L-L09 7. White polyester fabric (lining & sock lining with printing) B B-PE-W-L201 8. White EVA (sock cushion) D D-EVA-W-#090 9. White EVA foam (outsole) D D-EVA-W-#090 10. Dark Brown rubber (outsole piece) D D-TPR-DB-#34



•  Up-to-date regulatory requirements on test plans 根据最新要求制定测试计划

Test Required Components Remarks

24 Banned AZO-Dyes

002+003-LE 005 007 004

DIN EN 14362-1:2012 Textile and Synthetics DIN EN 14362-3 , Textiles, PES- pAAB

DIN EN ISO 17234-1 Leather DIN EN ISO 17234-2 Leather- pAAB

Total Cadmium 005+007 009+010+011 EN 1122

Nickel release N/A

Chrom VI after aging 002-LE 003-LE

BVL B 82 02-11: 10.2008, Aging condition: 24 h, Temperature: 80 ± 3° C, Humidity: max. 5 %

Chlorinated Phenols-PCP 002+003-LE DIN EN ISO 17070

Formaldehyde 002+003-LE 004+006+008 005+007

DIN EN ISO 14184 Part 1 Textile, Synthetic DIN EN ISO 17226 Leather

DIN EN 717-3 Wood/Paperboard

Organotin Compounds 005+007 008 009+010+011

ONR CEN ISO/TS 16179



•  Able to suggest possible hazardous/restricted substance used according to the industrial practices. 能够根据产业经验判断可能存在的限用物质

For example 例如： Toe / heel counter reinforced by non-woven Fabrics glued together by solvent base adhesive: 经无纺布粘合增强的鞋头衬或鞋包跟，使用了溶剂型胶黏剂 Restricted substance: formaldehyde 限用物质：甲醛



•  Able to change the acceptance limits automatically in the test plans according to a) importing countries and b) latest updates 能根据目标国家及其最新更新，自动设定测试限值

•  For example 例如： –  AZO

!  EU - REACH：30 mg/kg !  China - GB 18401: 20 mg/kg

–  PAHs !  Old: BaP < 1 mg/kg; sum < 10 mg/kg !  New: each < 1 mg/kg (general); each < 0.5 mg/kg (toys)



•  Able to reduce testing under pre-defined conditions such as same lot of components has been tested in another models again being used in the current product of concern. 可以自动识别，如果该批次样品已经测试过，则可以避免重复测试

Components of production (serial # 20140828-001 to 500) Supplier Lot # 1. Royal Blue suede leather (toe cap & heel cap) A A20140828L1 2. Silver Grey leather (upper patch) A A20140828L9 3. Royal Blue polyester fabric with printing (upper) B B-PE-RB-L10 4. Royal Blue PU with White fabric backing (eyestay) B B-PU-RB-L20 5. White fabric shoelace (upper) C C-SL-W-#102 6. Lemon PU with White fabric backing (heel upper) B B-PU-L-L09 7. White polyester fabric (lining & sock lining with printing) B B-PE-W-L201 8. White EVA (sock cushion) D D-EVA-W-#090 9. White EVA foam (outsole) D D-EVA-W-#090 10. Dark Brown rubber (outsole piece) D D-TPR-DB-#34



•  Able to plan to phase out hazardous chemicals with substitutes and improved technologies/processes by continuously collecting info into the database 可以制定计划，淘汰限用物质

For example 例如: Toe / heel counter reinforced by non-woven fabrics glued together by water base adhesive: 鞋头衬、鞋包跟，使用无纺布增强时，应使用水基型胶黏剂 Phase out substance: solvent base glues by yyyy-mm-dd 淘汰计划：溶剂型胶黏剂淘汰时间（某年某月某日）



•  Keeping the testing statistics and perform supplier pool mgmt 持续的测试数据统计，并对供应商进行评估

Supplier Lots # Parameters No. of fails Percentage of fails (%)

A A20140828L1 , L4, L6 ... Set 1 3 3 A A20140828L9, L22, L80 … Set 1 5 6 B B-PE-RB-L10, L34, L56 … Set 2 2 12 B B-PU-RB-L20, L76, L104, … Set 2 6 1 C C-SL-W-#102, #234, #109… Set 3 0 0 B B-PU-L-L09, L88, L90, … Set 4 11 33 B B-PE-W-L201, L202, … Set 4 2 25 D D-EVA-W-#090, #101, … Set 5 35 10 D D-EVA-W-#090, # 334, … Set 5 4 4 D D-TPR-DB-#34, #232, … Set 11 4 12

Content 目录






5 Q&A 问答

Benefits of the System 系统可带来的好处


•  Reduce duplicate testing 减少重复测试

–  Different importing countries 不同国家

–  Different brands / buyer 不同品牌、买家

Testing Cost



•  Reduce duplicate testing 减少重复测试



Testing Time



•  One test, multiple reports 一次测试，多份报告



–  Different specification (baby, adult) 不同规格（儿童产品、大人产品）



•  Reduce unnecessary test 减少不必要的测试

–  What chemicals really need to check after reprocessing? 加工处理后，哪些项目需重新检测？

!  Resin particles 树脂颗粒 + additives 添加剂-> plastic part 塑料部件 Resin particles 树脂颗粒（Pb：Pass） Additives 添加剂（Pb：Pass） plastic part塑料部件（Pb：Pass）



•  Reduce test frequency with risk assessment based on statistics 根据统计，经风险评估，减少测试频率

–  Test item 测试项目

–  Limit 限值

–  Material 材质

–  Supplier 供应商

–  …



•  Network effect 网络式效应

–  Longer operation, more information collected 运作时间越长，信息越丰富

–  More suppliers join, more information collected, and less overall testing cost 参与的供应商越多，信息越丰富，测试总体成本越低



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系统化的限用物质管理 - FDRA