DFE - A “How-to” Approach. A Generic Design Approach for Reducing Environmental Impact Basic phases are: Assessment of current design/state Improvement/redesign

Georgia Institute of TechnologySystems Realization Laboratory

DFE - A “How-to” ApproachDFE - A “How-to” Approach


A Generic Design Approach for Reducing Environmental ImpactA Generic Design Approach for Reducing Environmental Impact

Basic phases are:

• Assessment of current design/state

• Improvement/redesign (if needed)

• Implementation and documentation of new design/state

2 - Product and Process Improvement

3 - Implementation and Documentation

Assess existing design

Identify planned changes affecting environmental impact

Environmental impact within targets?

Yes

Obtain initial targets1 – Assessment and Planning

No

Reevaluate new design

Select design changes

Identify design alternatives

Identify and prioritize limiting factors

Obtain detailed information

Distribute information to suppliers/partners (if needed)

Improvements needed ?

Yes

No

Minor or major ?

Min

or

imp

rove

me

nts

ne

ed

ed

Ma

jor

im

pro

ve

me

nts

ne

ed

ed

Document environmental impact of new design

Provide feedback and education

Implement proposed design


Assessment and PlanningAssessment and Planning


IssuesIssues

• What needs to be assessed?– Whole life-cycle or a specific aspect (e.g.,

recyclability)?

• How are we going to assess it?– Is a method available?

• How accurate do we need to be?– Relative versus absolute assessment?

– Simple versus sophisticated tools?

• How do we verify our results?


Characteristics of Efficient and Effective Assessment MetricsCharacteristics of Efficient and Effective Assessment Metrics

• An efficient and effective assessment metric (and associated models) should ideally have the following characteristics:

– simple – it should be easy to use,

– easily obtainable – at a reasonable cost,

– precisely definable – it is clear as to how the metric can be evaluated,

– objective – two or more qualified observers should arrive at the same value for a metric,

– valid – the metric should measure (correctly) the property it is intended to measure,

– robust – relatively insensitive to changes in the domain of application, and

– enhancement of understanding and prediction – good metrics should facilitate the development of models that will assist us in predicting process and product parameters.


Life-Cycle Analysis/AssessmentLife-Cycle Analysis/Assessment

• Life cycle analysis/assessment (LCA) is a method in which the energy and raw material consumption, different types of emissions and other important factors related to a specific product are being measured, analyzed and summoned over the products entire life cycle from an environmental point of view.

• LCAs started in the early 1970s and are the most comprehensive approach to assessing environmental impact.

• In principle, LCAs could be used:– in the design process to determine which of several designs may leave a smaller

"footprint on the environment", or

– after the fact to identify environmentally preferred products in government procurement or eco-labeling programs.

• LCAs are extremely complex and time consuming.


Focused AssessmentsFocused Assessments

• Assessments focused on a specific aspect of a life-cycle are often easier to do.

• Examples:– Recyclability and disassemblability assessments (ranging from USCAR rating

procedure to Activity-Based Cost models for product demanufacture)

– Remanufacturability assessments (ranging from spreadsheet based assessments to plant simulations)

• Also, energy and material consumption and waste amounts are good indicators

– Energy consumption during use.

– Amount of waste during manufacture

• However, it is important to know which life-cycle aspect is most critical and WHY!


Product Example – Motorola Display/Keypad MicrophoneProduct Example – Motorola Display/Keypad Microphone

5

426

3

12

22

717

18

19

6 89

11

27

9

1615

14

12

13

20

21

25

24

23

10

ITEM NO. DESCRIPTION 1 SCREW 2 WASHER (2 req’d) 3 SCREW 4 LABEL 5 LEVER, PTT (part of item 6) 6 ASSEMBLY, Housing (includes item 5) 7 STRAIN RELIEF 8 CLAMP 9 SCREW (2 req’d) 10 CORD, Coil 11 HOUSING, Header 12 WIRE, Receptacle 13 WIRE, Receptacle 14 PRINTED CIRCUIT BOARD, PTT 15 CONTACT, Snap 16 SEAL, Dome 17 FRAME 18 MICROPHONE 19 BOOT, Microphone 20 WIRE, Receptacle 21 WIRE, Receptacle 22 PAD 23 ASSEMBLY, Display Cover 24 LABEL, Nameplate 25 O-RING 26 WASHER, Insulator 27 INSULATOR


Material Recyclability and Part Remanufacture CategoriesMaterial Recyclability and Part Remanufacture Categories

1 Part is remanufacturable – Example: starter, transmission

2 Recyclable – infrastructure and technology are clearly defined.– Part is completely recyclable, infrastructure clearly defined and functioning.

Example: Body sheet metal.

3 Technically Feasible, infrastructure not available.– Collection network not defined or organized, technology for material recycling

has been established. Example: Plastic interior trim.

4 Technically feasible, but further process or material development is required.

– Technology has not been commercialized. Example: Backlite glass.

5 Organic material for energy recovery, that cannot be recycled.– Known technology/capacity to produce energy with economic value. Example:

Tires, rubber in hoses.

6 Inorganic material with no known technology for recycling.– Recycling technology not known.

Category 3 is a prediction of materials that are technically feasible to recycle.

Category

+

-


Categories for Ease of Disassembly for Material Separation in a Component

Categories for Ease of Disassembly for Material Separation in a Component

1 Can be disassembled easily, manually.– Approximate disassembly time is one minute or less. Example: “A” pillar trim

cover

2 Can be disassembled with effort, manually. – Component may contain compatible coatings or adhesives.

– Approximate disassembly time is one to three minutes. Example: fan shroud.

3 Disassembled with effort, requires some mechanical separation or shredding to separate component materials and parts.

– Component may contain non-compatible coatings or adhesives.

– The process has been fully proven. Example: seat assembly, windshield glass.

4 Disassembled with effort, requires some mechanical separation or shredding to separate component materials and parts.

– Component may contain non-compatible coatings or adhesives.

– The process is currently under development. Example: instrument panel.

5 Cannot be disassembled. – No know technology for separation. Example: heated backlite glass.

+

-


USCAR DFR AssessmentUSCAR DFR Assessment

Disassembly activity Disassemblability Material recyclability CommentsNo. Name Quantity Type Access Tool Force Time Rating Material Mass Rating Rating Marked

CE/SP/SA [sec.] [1-5] [1-4] (1-6) [y/n]

1 Disconnect mic. from base 1 CE 4 - 4 1 1 - 0 - - NMicrophone Disassembly

2 Remove screws #1 phillips 2 CE 3 #1 PS 4 24 1 Stainless Steel 0.000600 4 2 N3 From No. 2 Washer 2 SP 4 - 4 1 1 Plastic PP 0.000010 2 3 N4 From No. 2 Washer 2 SP 4 - 4 1 1 Plastic PP 0.000010 2 3 N5 Remove keypad subassembly 1 SUB 4 Pliers 2 5 1 Mix 0.000000 1 4 N6 From No. 5 Gasket 1 SP 4 - 4 1.5 1 Rubber 0.001000 3 2 N7 From No. 5 Break H-S Tabs 8 CE 1 Knife 1 210 3 - 0.000000 - - N8 From No. 5 Keypad PCB/LCD 1 SUB 4 Pry 4 2 1 Mix 0.000000 1 4 Y9 From No. 8 Undo metal tabs 6 CE 3 Pliers 3 25 1 - 0.000000 - - N

10 From No. 8 Remove. Disp. Sub. 1 SUB 3 - 4 1 1 Mix 0.000000 1 4 Y11 From No. 10 LCD Cover 1 SP 4 - 4 1 1 Plastic HDPE 0.000750 2 3 Y12 From No. 10 LCD 1 SP 4 - 4 1 1 Mix 0.002500 1 4 Y13 From No. 10 Conductor 2 SP 4 - 4 1 1 Mix 0.000030 1 4 Y14 From No. 10 LCD Base 1 SP 4 - 4 1 1 Aluminum 0.001200 4 2 Y15 From No. 8 PCB 1 SP 4 - 4 1 1 Mix Cu, Au 0.010400 1 4 Y16 From No. 5 Keypad 1 SP 4 - 4 2 1 Rubber 0.006100 3 2 Y17 From No. 5 LCD Prot. Scrn. 1 SP 1 Pry out 1 5 1 Plastic HDPE 0.001000 2 3 N18 From No. 5 Foam 1 SP 2 Knife 4 1 1 Foam 0.000000 1 4 N19 From No. 5 Inserts 2 SP 1 Saw 1 30 1 Brass 0.001000 4 2 N20 From No. 5 Keypad base 1 SP 4 - 4 1 1 Plastic ABS 0.015000 3 2 Y21 12-pin connector housing 1 CE 2 pin 4 50 1 Plastic HDPE 0.000800 2 3 Y22 Microphone subassembly 1 SUB 3 Pliers 3 7.5 1 Mix 0.000000 1 4 Y23 From 22 Mic. & wires 1 SP 2 - 3 7 1 Mix Cu, Al 0.000940 1 4 Y24 From 22 Microphone boot 1 SP 4 - 4 1 1 Rubber 0.001250 3 2 N25 PTT Contact & wires 1 SUB 1 Pliers 3 5 1 Mix Cu, Au 0.001500 1 4 Y26 Screw - mic. cord/bracket 1 CE 4 #1 PS 3 10 1 Steel 0.000200 4 2 N27 Mic. cord bracket 1 SP 3 Pliers 2 8 1 Stainless Steel 0.000600 4 2 Y28 Microphone cord 1 SUB 2 - 2 25 1 Mix Cu, AU, Pl 0.089300 1 4 Y29 Mic. cord boot 1 SP 4 - 2 5 1 Rubber 0.001300 3 2 N30 Spacer 2 SP 4 - 3 3 1 Plastic PP 0.000010 2 3 N31 Screw - mic./PTT lever mount 1 CE 4 #1 PS 4 10 1 Steel 0.000200 4 2 N32 Microphone/PTT mount bracket 1 SP 3 Pliers 2 4 1 Plastic ABS 0.005000 1 4 Y33 Rubber pad 1 SP 3 - 3 2 1 Rubber 0.000900 3 2 N34 Motorola label 1 SP 2 - 3 5 1 PLastic HDPE 0.000100 2 3 N35 PTT lever 1 SP 1 Pliers 2 3 1 Plastic ABS 0.000800 2 3 Y36 PTT bezel 1 SP 2 Pliers 2 3 1 Plastic ABS 0.000500 2 3 Y37 PTT actuator 1 SP 2 - 4 1 1 Rubber 0.001500 3 2 Y38 Microphone Hanger 1 SP 4 Drill 1 60 2 Stainless Steel 0.030223 4 2 N39 Microphone base 1 SP 4 - 4 1 1 Plastic ABS 0.046777 2 3 Y

0.2215000.111830

Percent Recyclability by Weight50.4875619


Activity-Based Costing Disassembly AssessmentActivity-Based Costing Disassembly Assessment

• In any “detailed” assessment, uncertainty should be taken into account!

Other DepartmentsCosting Department

Process Department

Design Department

Equipment Information

Legal Information

Transportation Information

ABC Cost Model with Uncertainty

Shredder Information

Truck Information Fork lift Information

Assumptions

EPA Storage Requirements Recycling Revenue Reuse Revenue

Product Database

Tools

Recycling & Reuse Efficiencies

Action Chart for Each Product

Dismantling Information

Cell F415 Frequency Chart

[$/unit]

996 Trials Shown

.00

.00

.01

.02

.034

0

8.5

17

25.5

34

-9.50 -8.38 -7.25 -6.12 -5.00

Forecast: Dismantling Unit-profitability

Target Forecast: Dismantling Unit-profitability

A13 Volume [$/ft^3] -.66

No. 7 Time [sec] -.53

Microphone Pay-back Price [… -.41

A311 Direct Labor [$/h] -.17

Business days per week .16

Microphone Total Volume [ft^… .14


Fuel Consumption intensity [… .08

Super-Duty Impact Wrench .08

Reusables Volume [ft^3] -.08

Aluminum [$/kg] .07

No. 44 Keypad RcE -.07


-1 -0.5 0 0.5 1

Measured by Rank Correlation

Sensitivity Chart


Activity-Based Costing Shredding AssessmentActivity-Based Costing Shredding Assessment

• Shredding cost less than manual dismantling in this case, which is not surprising.

• Note the sensitivity of the cost with respect to the product pay-back price.

Target Forecast: Shredding Unit-profitability

Microphone Pay-back Price […-1.00

A51 Direct Labor [h/batch] -.07

A51 Tooling Time [h/batch] .06

No. 25 Time [sec.] .06

Microphone Total Volume [ft^… .06

Business days per week .05

Operation hours per day -.05

Plastic Shredder Price [$/un… .05

Maintenance cost [$/year] .05

A1e21 Direct Labor [h/batch] -.05

A612 Direct Labor [h/batch] -.05

Concrete [Yard^3] .05

Inspection Fee [$/year] .05

-1 -0.5 0 0.5 1

Measured by Rank Correlation

Sensitivity ChartCell F416 Frequency Chart

[$/unit]

1,994 Trials

.00

.00

.01

.02

.027

0

13.2

26.5

39.7

53

-2.00 -1.50 -1.00 -0.50 0.00

Forecast: Shredding Unit-profitability


Remanufacturability AssessmentRemanufacturability Assessment

• The data for this assessment comes from two spreadsheet based worksheets.

• Much of the information can be shared with recyclability, disassemblability, and even assemblability assessments, limiting the burden on the designer.

• Integration with CAD systems is relatively easy.

RESULTS WORKSHEET

Design Metric Data

Assy/Part Name # Parts 39NMN6150A Microphone # Ideal 11 Product:

# Refurbished 3Part Number # Replace 2 Model:

# Key Parts 9# Key Repl 2 MY:

Weight [kg] # Tests 30.2215 # Ideal Insp 10

Qty Cln Score 43 (=Total cleaning score)

1 TD 526 (=Total disassembly time)

Removal Time TA 623 (=Total reassembly time)

1 TT 200 (=Total testing time)

Level 1Metric Weighting Index Index

Replacement (Key) 0.778 0.778Disassembly 30.0% 0.031 RemanReassembly 70.0% 0.053 IndexTesting 80.0% 0.150 Category Weighting Index Level 2 0.091Inspection 20.0% 0.270 Interfacing 30.0% 0.044 IndexReplacement (Basic) 20.0% 1.000 Quality Assurance 5.0% 0.165 0.117Refurbishing 80.0% 0.923 Damage Correction40.0% 0.938Cleaning 0.256 Cleaning 25.0% 0.256

ATTACH REMANUFACTURABILITY ASSESSMENT WORKSHEETS 1 AND 2


Life-Cycle AssessmentLife-Cycle Assessment

• This assessment was done using the Eco-Indicator approach.

• The Eco-indicator values are listed in the Manual for Designers which can be downloaded for free from http://www.pre.nl/eco-ind.html (a web-site from Pre-Consultants in the Netherlands).

NMN6150A Microphone

Eco Indicator Units Quantities Eco Impact

Production

Steel 4.1 millipoints/kg 0.0004000 0.00164Stainless Steel 17 millipoints/kg 0.0314230 0.534191Aluminum 18 millipoints/kg 0.0012000 0.0216Plastic ABS 9.3 millipoints/kg 0.0680770 0.6331161Plastic PP 3.3 millipoints/kg 0.0000300 0.000099Plastic HDPE 2.9 millipoints/kg 0.0026500 0.007685Cu/Au/Al 60 millipoints/kg 0.1021400 6.1284Rubber 15 millipoints/kg 0.0120500 0.18075Foam 13 millipoints/kg 0.0000001 0.0000013Brass 75 millipoints/kg 0.0010000 0.075

Subtotals 0.2189701 7.5824824

Transport

Truck 0.34 per ton km 0.2189701 7.44498E-05ManufacturingInjection Molding 0.53 millipoints/kg 0.0707570 0.03750121Bending Steel 0.0021 millipoints/kg 0.0004000 0.00000084Machining 0.42 millipoints/kg 0.0324230 0.01361766Pressing/deep drawing 0.58 millipoints/kg 0.1033400 0.0599372Cutting 0.0015 millipoints/kg 0.0120501 1.80752E-05

Subtotals 0.2189701 0.111074985

Recycling

Steel and metals -2.9 millipoints/kg 0.1361630000 -0.3948727Plastics -0.46 millipoints/kg 0.0000300000 -0.0000138Engineering Plastics -2.75 millipoints/kg 0.0707270000 -0.19449925

Subtotals 0.2069200000 -0.58938575

Incineration

Rubber/Foam 1.8 millipoints/kg 0.0120501 0.02169018

Total Eco Indicator for NMN6150A Microphone

7.125936265


DFE Product and Process Improvement Guidelines

DFE Product and Process Improvement Guidelines


Reducing Environmental Impact through DFEReducing Environmental Impact through DFE

• True DFE tackles the entire product life-cycle.

• First, identify the most critical and limiting factors, based on the assessment(s) done.

• Involve suppliers and cooperative life-cycle partners (e.g., recyclers)

• Apply DFE guidelines and create/develop new design alternatives.

• Always check whether major or minor improvements are still needed after the design effort.

(see generic design approach flowchart)


Design Requirements (EPA Life-Cycle Design)Design Requirements (EPA Life-Cycle Design)

• An extensive list of issues to consider when developing environmental requirements is given on page 47 and 48 of the EPA Life-Cycle Design Guidance Manual, categorized in

– Materials issues (amount-intensiveness, character, impacts associated with extraction, processing and use)

– Energy issues (amount-intensiveness, source, character, impacts associated with extraction, processing and use)

– Residuals issues (type, characterization, environmental fate)

– Ecological factors (type of ecosystem impacts, ecological stressors, scale)

– Human health and safety issues (population at risk, toxicological characterization, nuisance effects, accidents).

• These issues should be taken in consideration in conjunction with

– performance,

– cost,

– cultural, and

– legal design requirements


Design StrategiesDesign Strategies

• The following strategies are identified in the US EPA Life-Cycle Design Guidance Manual (page 62):

– Product system life extension

– Material life extension

– Material selection

– Reduced material intensiveness

– Process management

– Efficient distribution

– Improved management practices


Product System Life ExtensionProduct System Life Extension

• Product life can be measured in– number of uses or duty cycles

– length of operation (i.e., operating hours, months, years, or miles)

– shelf life (e.g., for chemicals)

• Products become obsolete because of– technical obsolescence

– fashion obsolescence

– degrade performance or structural fatigue caused ny normal wear over repeated uses

– environmental or chemical degradation

– damage caused by accident or inappropriate use

• Srategies for life extension are– appropriately durable

– adaptable

– reliable

– serviceable (maintainable and repairable)

– remanufacturable


Material Life ExtensionMaterial Life Extension

• Material life extension can be achieved through recycling.

• Issues to consider are:– types of recycled material

» home scrap» pre-consumer» post-consumer

– recycling pathways» closed loop» open loop

– infrastructure» recycling programs and participation rate» collection and reprocessing capacity» quality of recovered material » economics and markets

– design considerations» ease of disassembly» material identification» simplification and parts consolidation» material selection and compatibility


Material Selection and Reduced Material IntensivenessMaterial Selection and Reduced Material Intensiveness

• The following material selection strategies allow for environmental improvements:

– substitution (water based coatings instead of volatile organic compounds)

– reformulation (e.g., unleaded gasoline is a reformulation of the leaded variety)

• Elimination is also an option.

• Reducing material intensiveness/amount typically also has economic advantages


Process ManagementProcess Management

• Although product and process design are coupled, process improvements can often be pursued outside product development.

• Key issues to focus on:– Process substitution

– Process energy efficiency

– Process material efficiency

– Process control (suppress the influence of external disturbances, ensure process stability, keep process performance within environmental constraint)

– Improved process layout (increases efficiency and reduces accidents)

– Inventory control and material handling

– Facilities planning

– Treatment and disposal


Efficient DistributionEfficient Distribution

• Focus on transportation and packaging.

• Transportation issues:– Choose an energy efficient mode

– Reduce air pollutant emission from transportation

– Maximize vehicle capacity where appropriate

– Backhaul materials

– Ensure proper containment of hazardous materials

– Choose routes carefully to reduce potential exposures from spills and explosions

• Packaging issues– Packaging reduction

» elimination

» reusable packaging (needs collection, inspection, repair,storage and handling)

» product modifications

» material reduction

– Material substitution

» recycled materials

» degradable materials


Improved Management PracticesImproved Management Practices

• Office management– Pursue to a “paperless” office and/or use recyclables

• Phase out high impact products

• Choose environmentally responsible suppliers

• Provide information– Labeling

» Identify ingredients

» Instructions and warnings

» General information

– Advertising

» environmental claims can be powerfull promotional tools, but should not be made unless they are specific, substantive, and supported by scientific evidence.


A DFE-Tool: Lifecycle Design Strategies WheelA DFE-Tool: Lifecycle Design Strategies Wheel

1 Selection of low-impact materials Non-hazardous materials Non-exhaustable materials Low energy content materials Recycled materials Recyclable materials

0 New Concept Development Dematerialisation Shared use of the product Integration of functions Functional optimization of product (components)

2 Reduction of material Reduction in weight Reduction in (transport) volume

+-

3 Optimization of production techniques Alternative production techniques Fewer production processes Low/clean energy consumption Low generation of waste Few/clean production consumables

4 Efficient distribution system Less/clean packaging Efficient transport mode Efficient logistics

5 Reduction of the environmental impact in the user stage Low energy consumption Clean energy source Few consumables needed during use Clean consumables during use No energy/auxiliary material use

6 Optimization of initial life-time Reliability and durability Esay maintenance and repair Modular product structure Classic design User taking care of product

7 Optimization of end-of-life system Reuse of product Remanufacturing/refurbishing Recycling of materials Clean incineration

Priorities for the new product

Existing product

Brezet, J. C. and al., e., 1994, PROMISE Handleiding voor Milieugerichte Produkt Ontwikkeling (PROMISE Manual for Environmentally Focused Product Development), SDU Uitgeverij, The Hague, The Netherlands.

Hemel, C. G. v. and Keldmann, T., 1996, "Applying DFX Experiences in Design for Environment," Design for X: Concurrent Engineering Imperatives, Chapmann & Hall, London, pp. 72-95.


Blank LiDS WheelBlank LiDS Wheel

1

Selection of low-impact materials

Non-hazardous materials

Non-exhaustable materials

Low energy content materials

Recycled materials

Recyclable materials

0

New Concept Development

Dematerialisation

Shared use of the product

Integration of functions

Functional optimization of product (components)

2

Reduction of material

Reduction in weight

Reduction in (transport) volume

3

Optimization of production techniques

Alternative production techniques

Fewer production processes

Low/clean energy consumption

Low generation of waste

Few/clean production consumables4

Efficient distribution system

Less/clean packaging

Efficient transport mode

Efficient logistics

5

Reduction of the environmental

impact in the user stage

Low energy consumption

Clean energy source

Few consumables needed during use

Clean consumables during use

No energy/auxiliary material use

6

Optimization of initial life-time

Reliability and durability

Easy maintenance and repair

Modular product structure

Classic design

User taking care of product

7

Optimization of end-of-life system

Reuse of product

Remanufacturing/refurbishing

Recycling of materials

Clean incineration


New Concept DevelopmentNew Concept Development

• Dematerialization– Less materials means less consumption, also of energy. Also saves money.

– Ultimate question: do we need the product at all?

• Shared use of product– Instead of many distributed “small” products, have a central shared one. For

example, laundromat instead of personal washers and dryers.

– Car sharing is another novel example.

– Increases product utilization and, hence, material efficiency

• Integration of functions– Combine things into one, reduce redundancy (e.g., combines washer/dryer uses

less material than two separate machines)

– For example, integrated telephone, fax, and answering machines or TV screen as computer monitor.

• Functional optimization of product and components– Make sure product has a peak performance and avoid superfluous issues.

– For example, a luxury feel may also be achieved by intelligent design rather than over-elaborate material use.


Selection of Low-Impact Materials and Reduction of Materials

Selection of Low-Impact Materials and Reduction of Materials

• Non-hazardous materials– Legislation, liability, disposal costs, etc. are all good reasons to avoid hazardous

materials

• Non-exhaustable/renewable materials– Non-renewable resources can be depleted and what then?

• Low-energy content materials– The less energy it costs to process a material, the better for the environment,

especially if non-renewable energy sources are used.

• Recycled and recyclable materials– Use of recycled and recyclable materials avoids ecological damages through mining

and depletion of non-renewable material sources.

– In general (but not always!), recycling is also more energy efficient than production of new material.

• Reduction in weight and (transport) volume– Weight reductions reduce energy needed to move the product.

– Volume can be a problem when space (e.g. for landfill) is scarce


Reduction of Material UsageReduction of Material Usage

• Reduction of weight– Weight reductions reduce energy needed to move the product.

– Aim for rigidity through construction techniques such as reinformcement ribs rather than over-dimensioning the product.

– Aim to express quality through good design rather than over-dimensioning the product.

• Reduction in (transport) volume– Volume can be a problem when space (e.g. for landfill) is scarce

– Aim at reducing the amount of space required for transport and storage by decreaseing the product’s size and total volume.

– Make the product foldable and/or suitable for nesting.

– Consider transporting the product in loose components that can be nested, leaving the final assembly up to a third party or even the end-user.


Optimization of Production TechniquesOptimization of Production Techniques

• Alternative production techniques– Choose production techniques that require fewer harmful auxiliary substantives

or additives (e.g., water-based instead of solvent-based painting)

– Select production techniques which generate low emission (e.g., bending instead of welding, joining instead of soldering, counter-sink/cascade rinsing techniques for electroplating)

– Choose processes which make the most efficient use of materials, e.g., powdercoating instead of spray painting

• Fewer production processes– Results in less energy consumption and potential waste

– Combine constituent functions in one component so that fewer processes are required

– Preferably use materials that do not require additional surface treatments

• Low/clean energy consumption– Motivate the production department and suppliers to make their processes more

energy efficient (e.g., process steam can be recycled for building heating purposes)

– Encourage them to use renewable energy sources, or at least fossil fuels with low impact (e.g., low sulphur coal, natural gas)


Optimization of Production Techniques (cont.)

Optimization of Production Techniques (cont.)

• Low generation of production waste– Design products to minimize material waste, especially in processes such as sawing,

turning, milling, pressing and punching.

» Net-shape manufacturing is less wasteful than material removal processes.

– Motivate the production department and suppliers to reduce waste and the percentage of rejects during production.

– Recycle product residues within the company.

• Fewer/cleaner production consumables– Reduce production consumables required by, e.g., ensuring that cutting waste is

restricted to specific areas and less facility cleaning is required.

– Consult with production department and suppliers how to increase the effiency of using the operational materials, e.g., by good housekeeping, in-house recycling.

– Examples:

» Water-based coating/painting technologies are better than solvent-based technologies.

» Dust collector instead of watersheet for arc metal spraying process

• Use commonly available pollution prevention guidelines and practices!


Efficient Distribution SystemEfficient Distribution System

• Less/cleaner/reusable packaging– Germany’s packaging law was the first to emphasize reduction in packaging

waste

– If all the packaging does is to give the product a certain appeal, then use an attractive but lean design to achieve the same effect

– For transport and bulk packaging, give consideration to reusable packaging in combination with a monetary deposit or return system

– Use appropriate materials for the kind of packaging, e.g., avoid PVC and aluminum in non-returnable packaging

– Use minimum volumes and weights of packaging

– Make sure the packaging is appropriate for the reduced volume, foldability, and nesting.

• Efficient transport mode– Try to avoid environmentally harmful forms of transport

– Transport by container ship or train is preferred over truck or airplane.

– Transport by air should be prevented where possible (Overnight aircraft delivery is not environmentally friendly)


Efficient Distribution System (cont.)Efficient Distribution System (cont.)

• Efficient logistics– Preferably work with local suppliers in order to avoid long distance

transport.

– Encourage the introduction of efficient forms of distribution and try to combine deliveries to maximize efficiency of transport media, e.g., the distribution of larger amounts of different goods simultaneously.

– Use standardized transport packaging and bulk packaging (Europallets and standard package module dimensions)

– Also think about reverse logistics


Reduction of Environmental Impact in the User StageReduction of Environmental Impact in the User Stage

• Low energy consumption– Certain eco-label certification schemes (e.g., Blue Angel label) emphasize low

energy consumption

– Corporate Average Fuel Economy (CAFE)

– Use the lowest energy consuming components available on the market

– Make use of a default power-down mode.

– Ensure that clocks, stand-by functions and similar devices can be switched off by the user

– If energy is used to move the product, make it as light as possible.

– If energy is used for heating substances, make sure the relevant component is well insulated.

• Clean energy source– Electronics running on solar energy (e.g., a calculator) are better than those

using electricity generated from oil.

– Choose the least harmful source of energy (depends on localition)

– Avoid non-rechargeable batteries.

– Encourage the use of clean energy sources.


Reduction of Environmental Impact in the User Stage (cont.)Reduction of Environmental Impact in the User Stage (cont.)

• Fewer consumables during use– Design the product to minimize use of auxiliary materials, e.g., use a permanent

filter in coffee makers instead of paper filters.

– Minimize leaks from machines which use high volumes of consumables by, e.g., installing a leak detector.

– Study the feasibility of reusing consumables, e.g., reusing water in the case of a dishwasher.

• Cleaner consumables– Internal combustion engines use and emit non-clean materials (oil, anti-freeze, etc.).

– Design a product to use the cleanest available consumables.

– Ensure that using the product does not result in hidden but harmful wastes.

• Reduce wastage of energy and other consumables– Product misuse should be avoided by clear instructions and design.

– Ensure that the user cannot waste (e.g., spill) auxiliary materials.

– Use calibration marks to provide information to user about optimal levels.

– Make the default state that which is most desirable from an environmental point of view, e.g., “double-sided copies”.


Optimization of Initial Life-Time

Optimization of Initial Life-Time

• Reliability and durability– If something breaks, it can become waste immediately.

– Develop a sound design and avoid weak links. Use methods such as Failure Mode and Effect Analysis to check the design.

• Easy maintenance and repair– Especially for energy and material intensive products this should be pursued.

– Design the product such that it needs little maintenance.

– Indicate on the product how it should be opened for cleaning or repair.

– Indicate on the product itself which parts must be cleaned or maintained, e.g., by color-coding lubricanting points.

– Indicate on the product which parts or sub-assemblies are to be inspected often due to rapid wear.

– Make the location of wear detectable so that repair or replacement can take place on time.

– Locate the parts which wear relatively quickly close to one another and within easy reach.

– Make the most vulnerable components easy to dismantle.


Optimization of Initial Life-Time (cont.)

Optimization of Initial Life-Time (cont.)

• Modular product structure– Design the product in modules so that it allows for upgrading of function and

performance (e.g., computers) andreplacement of technically or aesthetically outdated modules (e.g., furniture covers)

– Strive for open systems and platform designs.

• Classic design– Design the product so that it does not become uninteresting and unpleasing quicker

than its technical life.

– Aesthetically appealing and “time-less” designs are usually better maintained

– Porsche 911s and MGBs are being restored and well kept. A Yugo is not.

• User taking care of product– Design the product so that it more than meets the (possibly hidden) user

requirements for a long time.

– User typically does take care of capital intensive products (e.g., a car), but what about a relatively cheap product (e.g., a $10 alarm clock)?

– Give the user added value in terms of design and functionality so that the user will be reluctant to replace it

– Ensure that maintaining and repairing the product becomes a pleasure rather than duty (proper care and maintenance by user can significantly extend a product’s life.


Optimization of End of Life SystemOptimization of End of Life System

• Reuse of Products– Saves both material and energy

– Good examples: Kodak single-use camera, Xerox copier machines (leased)

– Give the product a classic design that makes it attractive for a second user.

– Ensure that the construction is sound and allows for reuse.

– See also optimization of initial life guidelines

• Remanufacturing/refurbishing– Most products cannot directly be reused without at least an inspection

– Remanufactured parts can in many cases be “better than new”

– Make sure a product can be repaired. See optimization of initial life guidelines

• Recycling of materials– Reduces demand for mining and landfill.

– Specific guidelines follow.

• Clean incineration– Provides energy source and reduces landfill demand

– Avoid toxic materials in product because they increase incineration costs and may have to be removed before incineration.


Trade-OffsTrade-Offs

• Note that two (or more) different environmentally conscious design strategies may adversely affect eachother.

– For example, light weighting and component integration typically affect remanufacturability in a negative manner.

• Also, an environmentally conscious strategy may have adverse effects on technical and/or economic performance specifications.

– For example, cleaner production processes may cost more.

• Win-win situations are preferred and should always be pursued.

• Also distinguish between high risk versus low risk strategies.

• Quantitative trade-off resolution is (still) extremely difficult.

Documents

DFE - A “How-to” Approach. A Generic Design Approach for Reducing Environmental Impact Basic phases are: Assessment of current design/state Improvement/redesign