10 11Lecture-DesignforEnvironment

Design For Environment
Centre for Product Design & Manufacturing

Copyright by Centre for Product Design and Manufacturing, Faculty of Engineering, University of Malaya
Trends of an unsustainable future

Waste generation -occupies landmass -produce greenhouse gasses -hazardous to ecosystem -now you have to pay for your garbage
Copyright Centre for Product Design and Manufacturing, Faculty of Engineering, University of Malaya. All Rights Reserved.
Accumulation of Electronics Waste
Ecological Changes
Ecological Changes -temperature rise -sea level rise -unpredictable weather -loss of land mass -disrupt ecosystem

Scarcities of resources

Oil Metal water
Economics losses $$$$$
Tightening Regulations
Weee Rohs- hazadous substances product compliance Packaging-Directive 94/62/EC ELV Batteries and Accumulators EuP REACH-Chemical safety
Cover almost all product
WEEE- Directive 2002/96/EC

cover product marking, take-back and recycling obligations Producers are people who:

import electrical and electronic equipment make and sell EEE under their own brand; or re-brand and sell EEE
Producer responsible for take-back and recycling
EuP Framework DIRECTIVE 2005/32/EC

The Eco design for Energy-Using Products Regulations 2007 SI 2037 in force from 11 August 2007- UK Cover most products requirements to be met before product placed on the market in the EU Harmonised standard will be adopted Required to maintain CE mark
End of Life for Vehicle-DIRECTIVE 2000/53/EC

measures to ensure that economic operators set up systems for the collection, treatment and recovery of endof life vehicles end-of life vehicles are discarded without endangering the environment, appropriate collection systems should be set up. Vehicles must incorporate end of life feature
Who is responsible for our sustainable future?
Source of un-sustainable future
Source of un-sustainable future

Rise in ownership -more
Product Life Cycle

Product Life cycle New lifestyle, technology, challenges brings new opportunity Ideas conceive and conceptualize Matured through refinement and manufacture Functionality deployment Maintenance and support extends life End of life From cradle to grave life cycle.
Eco product Life cycle

Cradle to cradle
Who are responsible in making the above possible????

Who is responsible for a sustainable future

we dont design things we just make stuff 80% of the cost of a product is set at the design stage 93% of production materials are never used in the final product 80% of products are discarded after a single use Design decisions will affect the manufacture, use and disposal phases of a product
Potential for improvement
Knowledge about product
Need to move from process efficiency and process regulation towards product efficiency and regulation
Idea
Specification
Concept Details
Prototype Production
Product Developer/Design engineers Responsibility Products to be Develop (IDEAS) must be conceive with the environment in mind
Products are born GREEN, continue to be GREEN when they are used and dies GREEN
What is sustainable development?

Sustainable Development: In 1987, the World Commission on Environment and Development defined Sustainable Development as: "...development that meets the needs of the present without compromising the ability of future generations to meet their own needs."
Benefits of DFE
Reduces environmental impact of products/processes. Optimizes raw material consumption and energy use. Improves waste management/pollution prevention systems. Encourages good design and drives innovation. Cuts costs. Meets user needs/wants by exceeding current expectations for price, performance and quality. Increases product marketability.
Strategic Benefits
Increased innovation new product, alternative design Greater ability to compete, add value, attract customers emerging market, image Become more cost-effective-compliance cost, better quality Reduce environmental impacts and liabilityinsurance, regulations, legal implications Gain a systems perspective-cross functional team
External Drivers
Internal Drivers
Electrolux
Electrolux, the Swedish global appliance manufacturer, has used using a combination of design and life cycle tools to improve energy and water efficiency in its product lines. It expanded its market share in professional refrigeration equipment from 5 per cent in 1997 to 14 percent in 1998 with its Explorer line, which was in the top range of energy-efficient appliances. Its Master System for apartment washing machines optimizes the use of electricity, water and detergents, reducing laundry costs to apartment buildings by 50 per cent.
IBM
IBM Sweden with the artist/designer, Jonas Torstensson, has designed glassware made from recycled cathode ray tubes (CRTs). The face of the CRT comprises two thirds of the weight of the glass and does not contain harmful lead. The result is that the majority of glass can be recycled into glassware. The other parts, containing toxic materials, can be recycled into CRTs at IBM Holland in the Netherlands. The results are cost-savings in recycled materials and greater awareness among marketing staff regarding the value of recycled materials.
DFE Strategies
Strategy 1: New Concept Development Strategy 2: Physical Optimization Strategy 3: Optimize Material Use Strategy 4: Optimize Production Techniques Strategy 5: Optimize Distribution System Strategy 6: Reduce Impact During Use Strategy 7: Optimize End-of-Life Systems
Strategy 1: New Concept Development

Examine the function(s) of a product in terms of both development assumptions and the needs of the end-user. This is an important strategy to undertake prior to product development. 1.1: Dematerialization replace physical product with non-physical product (lighter, smaller, digital) 1.2: Increase Shared Use share equipment 1.3: Provide a Service service rather than sales (repair)
Strategy 2: Physical Opitmization

Determine how a product can be best designed to increase its useable life span. 2.1: Integrate Product Functions 2.2: Optimize Functions 2.3: Increase Reliability and Durability 2.4: Easy Maintenance and Repair 2.5: Modular Product Structure 2.6: Strong User-product Relationship
Strategy 3: Optimize Material Use

Select the most environmentally appropriate materials, substances and surface treatments for a product. 3.1: Cleaner Materials 3.2: Renewable Materials-trees, plants 3.3: Lower Energy-content Materials energy to extract, process and refine 3.4: Recycled Materials 3.5: Recyclable Materials 3.6: Reduce Material Usage
Strategy 4: Optimize Production

Implement cleaner production practices through the continuous use of industrial processes and products that increase efficiency; prevent pollution to air, water and land; and minimize risk to human health and the environment. 4.1: Alternative Production Technique 4.2: Fewer Production Steps 4.3: Lower/Cleaner Energy Consumption 4.4: Less Production Waste-near net shape 4.5: Fewer/Cleaner Production Consumables solvents, degreasers, water, oil
Strategy 5: Optimize Distribution

Transport products from producer to distributor, retailer and user in the most efficient manner. 5.1: Less/Cleaner/Re-usable Packaging-containers, weight of packaging 5.2: Energy-efficient Transportation
price volume reliability time to delivery distance to customer environmental impact
5.3: Energy-efficient Logistics routing, large distribution, warehouse location, JIT
Strategy 6: Reduce Impact During Use

Design a product so that end-users will be able to make efficient use of product consumables such as energy, water and detergent, and secondary products such as batteries, refills and filters. 6.1: Lower Energy Consumption-auto swtch off, human powered, light material 6.2: Cleaner Energy Sources 6.3: Reduce Use of Consumables permanent filter, less leaks, reusing consumables 6.4: Cleaner Consumables and Auxiliary Products-reusable cartridge, beware of low quality oil/coolants, disposal issues 6.5: Reduce Energy and Other Consumable Waste-calibration, clear instructions, default most eco,
Strategy 7: Optimize End-of-Life Systems

Minimize the environmental impact of a product once it reaches the end of its useable life span through proper waste management and reclamation of components and materials. 7.1: Product Re-use- reconditions 7.2: Design for Disassembly-facilitate repair, facilitate component re-use, assist recycling 7.3: Product Re-manufacturing-remanufacture of product using old /refurbish parts 7.4: Material Recycling 7.5: Safer Incineration
Eco Innovation Implementation Strategy
applied within a single product life-cycle and focus on specific lifecycle stages, complete product life-cycle and cover all life-cycle stages beyond single product life-cycles.
Integration of Eco Design in Product Development

Green Issue
There are a lot of tools available catering for different aspect and used at different stages.
Road map for Eco product development

tools which assess/analyze different aspects of a products lifecycle (such as recylability and remanufacturability assessments), tools which allow an assessment/analysis of the entire products life-cycle (e.g., Life-Cycle Analyses and Costing) are needed, tools which facilitate trade-off analyses in pursuing various lifecycle aspects, i.e., decision support tools which include technical, economical, quality, and environmental concerns.
Eco Design Tools? Checklist and guidelines
Most basic tool Various type are available Easiest to implement especially with some training Provide some rough idea for exploration Too general and static Qualitative in nature Hinders trade-offs assessments Life cycle perspective maybe overlooked
Eco Design Tools? Checklist and guidelines

To reduce impact, use less material and energy and avoid toxic substances over the life cycle of a product using qualitative guidelines for assessment
End-of-Life Improveme 7 nt Reduce Use Stage Impact
New Concept Development Initial 2 Lifetime Improveme nt
Distribution 5 Improvement
3
4
Production Improvement
Material Improvemen t
When to Use?

not much (if any) hard data available (early in a design process) screening of major problem areas (assessment of concepts) to stimulate creation/innovation relates to TRIZ
Eco Design Tools? Eco-QFD
Based on the house of quality method Translate VOC into technical improvements In this case the VOC are environmental concern
Eco Design Tools? Eco-QFD
Eco Design Tools? E-FMEA/EEA

E-FMEA method identifies and evaluate potential environmental impacts in all lifecycle phases of the investigated product in a systematic way
Eco Design Tools? Eco-TRIZ
Based on the TRIZ theory But the problem focus is on environmental innovation
Eco Design Tools? MET Tables
MET Matrix help the design team look at all environmental aspects throughout a product's life. The rows correspond to the five different product life-cycle stages and the columns concentrate on three important environmental issues; the material used, the energy used and waste, including toxic emissions
Eco Design Tools? : Boothroyd Dewhurst
DFMA+DFE
Compares the economics of DfDisassembly against environmental impact (based on MET)

Eco Design Tools? Eco-Indicators Eco99

Indicators numbers that express total environmental load of a product or process Indicators based on dimensionless ecoindicator points (mili-point) Indicator point are derive from some form of LCA Indicator value for

Material Production process Transport Energy generation Disposal scenarios
Accumulates indicator point through out product life cycle

Eco Design Tools? Eco-Indicators Eco99
Eco Design Tools? LCA
A lot of software available Build LCI then do LCA Database varies according to countries Detail understanding of environmental impact Require longer duration to complete
More tools is needed

Some tool are too basic may not cover the whole life cycle Some are too qualitative which makes trade-off difficult Some are to complex and tedious Time consuming in the fast pace of product development Some requires too many information that may not be available Add extra burden to design engineers Requires experts to decipher Some are detach to the mainstream engineering application
Conclusion
Design Engineer/Product Developer is a key source in developing GREEN Products Many tools are available at different level/stages of product development process Any tool used will be helpful in making products greener from the simple to the complex But there are still a lot of room to improve DFE tools so that product can be made GREENER without extra burden

10 11Lecture-DesignforEnvironment

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Design For Environment

Centre for Product Design & Manufacturing

Trends of an unsustainable future

Accumulation of Electronics Waste

Trends of an unsustainable future

Oil Metal water

Trends of an unsustainable future

Economics losses $$$$$

Cover almost all product

WEEE- Directive 2002/96/EC

Producer responsible for take-back and recycling

EuP Framework DIRECTIVE 2005/32/EC

End of Life for Vehicle-DIRECTIVE 2000/53/EC

Who is responsible for our sustainable future?

Source of un-sustainable future

Source of un-sustainable future

Product Life Cycle

Eco product Life cycle

Who are responsible in making the above possible????

Who is responsible for a sustainable future

Potential for improvement

Knowledge about product

What is sustainable development?

Strategy 1: New Concept Development

Strategy 2: Physical Opitmization

Strategy 3: Optimize Material Use

Strategy 4: Optimize Production

Strategy 5: Optimize Distribution

5.3: Energy-efficient Logistics routing, large distribution, warehouse location, JIT

Strategy 6: Reduce Impact During Use

Strategy 7: Optimize End-of-Life Systems

Eco Innovation Implementation Strategy

Integration of Eco Design in Product Development

Road map for Eco product development

Eco Design Tools? Checklist and guidelines

Eco Design Tools? Checklist and guidelines

New Concept Development Initial 2 Lifetime Improveme nt

Eco Design Tools? Eco-QFD

Eco Design Tools? Eco-QFD

Eco Design Tools? E-FMEA/EEA

Eco Design Tools? Eco-TRIZ

Eco Design Tools? MET Tables

Eco Design Tools? : Boothroyd Dewhurst

Compares the economics of DfDisassembly against environmental impact (based on MET)

Eco Design Tools? Eco-Indicators Eco99

Material Production process Transport Energy generation Disposal scenarios

Accumulates indicator point through out product life cycle

Eco Design Tools? Eco-Indicators Eco99

Eco Design Tools? LCA

More tools is needed

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