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A short Knowledge Transfer Partnership (sKTP) project between Harman International and The Ecodesign Centre.
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Environmental Economics
Investigation into Eco-Design practices within Harman product development to reduce environmental impact and increase profit.
sKTP EcoDesign
eoin bailey DEC 2010
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Natural: Systems Thinking
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Industrial: Systems Thinking
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Contents
• EcoDesign• Project Brief• Harman Impact Understanding• Linier Systems• Think Logically• Ecodesign Tools
5
EcoDesign Introduction
Eco-Design
Is a strategic design management approach incorporating life cycle thinking of product development and services.
Ecodesign takes into account social, economic and environmental impacts in the production and consumption of products and services.
Ecodesign = good design
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• Green standardisation for global development - On the green wave
• Transparency of product impacts will become commonplace - EPD
• Opportunity for market leadership - Exploit GreenEdge Technology
• Set new standards in each division - Influence Policy
• Ecodesign promotes - Creativity, Innovation and active communication • Create commodity – Waste becomes valuable
Business Case
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• A shorter KTP (Knowledge Transfer Partnership) grant • Under the framework of the Wales Assembly Government,• Administered by UWIC• Facilitated by The EcoDesign Centre, Cardiff• A project champion• A multi-disciplinary Harman team
KTP
Project Approach
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• Initial investigation into the environmental impacts of Harman Speaker products throughout the life cycle.
• To facilitate implementation of Ecodesign principles into product development, with a view to:
Lower production costs. Improve product functionality and quality Eliminate waste to landfill Increase market share Improve environmental performance Compliance with legislation Increase potential for recycling Increase marketability of Brand profile
KTP Project Objectives
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• 4 Production Lines
• 6,000 Units Produced Per Line Per Day
• 227 Working Days Per Year
• 5,448,000 Speaker Produced Per Year
Internal Influences Harman Bridgend Impacts
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Internal Influences Customer Program
ProgramBMW Units
paHARMAN units per system
F10 THF 28,350 X16 373,600
F10 HF 72,370 X12 868,440
F11 THF 5,300 X14 72,200
F11 HF 10,600 X12 127,200
F12 THF 9,100 X12 109,200
F12 HF 3,900 X10 39,000
F13 THF 9,100 X14 127,400
F13 HF 3,900 X10 39,000
TOTAL 3,345,680
• Tweeters• Mid Range• Sub Woofer
Total
2,262,040798,400285,240
3,345,680
BMW F10 Platform
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Material Selection
• Low Carbon Steel• Mild Steel• Neodymium Iron Boron• Copper• Polyamide (Nylon)• Dried Paper Pulp• Rubber• Phenolic Resin (Formaldehyde)• Brass• Polyethylene• Polypropylene• Polycarbonate (Bisphenol)
Internal Influences Procurement
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Material Concerns
• Bisphenol A: (Monomer)• Polycarbonate (PC)• Polystyrene• PVC• Epoxy Resins• ABS
Health Concerns:• Endocrine disruptor• Foetal and neonatal development defects• Obesity• Neurological issues• Dopaminergic system defects• Thyroid function defects• Breast cancer• Prostate cancer• Reproductive systems defects• DNA methylation
Internal Influences Material Selection
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Procurement Decisions
Internal Influences Component Transport
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Component Tracking - Sub-Woofer • HARMAN Bridgend• Sea / Air Port Location• Supplier Location
Sea TravelLand travelAir Travel
Internal Influences Component Travel Plans
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• Over-Moulded components• Variety of materials• Adhesives used• Activators used• Unspecified adhesives• Over Specification• New product introduction
Internal Influences Production Process
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Fiscal year 2008 Tonnes - cost
Fiscal year 2009 Tonnes - cost
Using information from Envirowise the estimated cost of waste= Cost of Waste Management x 10
Total Waste Non Hazardous 472.5 £43,120Total Waste Hazardous 80.42 £48,150
£91,270
Total Waste Non Hazardous 315.9 £44,000Total Waste Hazardous 76.08 £47,500
£91,500
Internal Influences Waste Management
Fiscal year 2010 Tonnes - cost
Total Waste Non Hazardous 504.9 £………?Total Waste Hazardous 21.6 £………?
£………?
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• Customer Specification• Customer Design Tolerances• Government Directives: ELV, REACH.• Standards: ISO, TS• Industry Directives: IMDS compliance• International markets: Neo export
External Influences
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Current ELV Directive:• Deploy airbags.• Remove all liquids.• Remove wheels and tyres.• Crush all remaining vehicle parts.• Vehicle shredding.• Defragmentation.• 85% of the Vehicle weight Recycled
2015 ELV Directive:• 95% of the Vehicle Weight Recycled• Details not specified??
Automotive Value Chain
ELV
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Vehicle Material Content
End Of Life Vehicle Directive
ELV
Recycled Vehicle Material Content
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• Resource Depletion• Environmental and• Social degradation• Intensive energy use• VOC’s
• Energy Use• Waste• Pollution• CO2 emissons
• Energy Use• VOC’s
• Landfill• Inceneration• Ecotoxicity
• Waste• Pollution• CO2 Production
Raw Materials Production Distribution Product use End of life
Current product life
Cradle to Gate
Cradle to Grave
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Raw Materials
Use
End of Life
Distribution
Production
Full Life Cycle Systems Thinking:
Cradle to Cradle
Raw Materials
Production
Distribution
Product Use
End of Life
Life Cycle
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Raw Materials
Use
End of Life
Distribution
Production
Benefits of EcoDesign to a Product-Life-Cycle
Raw Materials
Production
Distribution
Product Use
End of Life
• Reduce Materials• Use of Technical Nutrients• Material Selection• Responsible development
• Eliminate Waste• Reduce Energy Use• Eliminate Pollution• Reduce CO2 Production• Design for Disassembly• Eliminate Hazardous Materials
• Eliminate VOC• Reduce Energy Use
• 0% Waste to Landfill• Recycle Waste• Technical Nutrients• Resource Recovery• ELV Directive
• Recycle Waste• Reduce Pollution• Reduce CO2 Production
Life Cycle
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• No over-moulded components• Material selection• Design for disassembly• Adhesive decision• Mechanical fix• Specify every item with suppliers• Review specs with customers• Communication
Suggested Paths
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Low Hanging Fruit
Supplier Specification
Waste Management Venders
Internal Communication
External Collaboration
Supplier Collaboration Customer
Specification
ELV DirectiveContinuedCommunication
EPD
LCA
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Financial• 0% Waste to Landfill = £0 Landfill Tax.• Material Recycling from Waste.• Resale of Recovered Material (Technical Nutrients).• Recovery of Rare earth Material.• Recovery of material from ELV products
Market• Green is the new black.• Be the market leader.
Brand Image• Truly sustainable brand image• GreenEdge Technology
Legislation• ELV Directive 2015• WEEE• REACH• RoHS
Standards• ISO:14001
EcoDesign Drivers
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Environmental Product Decloration – EPDISO: 14001ISO: 14006ISO: 14062
Market Movement
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EcoDesign Tools
• Communication• Collaboration• EcoDesign Workshop• Cradle to Cradle • Systems Thinking• LCA
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• Adhesive Suppliers – • Henkel.• 3M
• Plastic Suppliers –• Bayer Material Science
• Recycling Companies – • Axion.• MBA Polymers
• LCA Providers – • GaBi.• Sustainable Minds. • SAP Sustainability.• PTC Insight.• Wipro SMART• Granta design
• Waste Management Providers – • Broughshire. • Enviroquip.
• Neo Magnets Recyclers – • Birmingham Uni.
• Harman International – • Harman Professional• Harman Automotive Germany• Harman Corporate US
• Customer Collaboration• VW Sustainability• BMW DesignWorks, Sustainability
• ELV Experts – • Dr. Paul Nieuwenhuis, Cardiff Uni. • Nick Morley, Oakdene Hollins. • Jon Mayton, BIS. • Dr Shahin Rahimifard, Loughborough Uni.
• Government Departments – • WAF.• WRAP.• Carbon Trust.• Envirowise.• KTN
• Seminars, Workshops and Conferences – • EcoDesign Centre workshop, Harman• New Frontiers, Manchester • E:DN, Cardiff• BIC, Bridgend.• CARE Innovation Conference, Vienna• Ellen MacArthur Foundation 10+1, Bradford• LCA Sustainable Product Design, London
Collaboration
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5. EcoDesign Tools
Raw Materials Production Packaging &
Distribution
Use End of Life
Materials Waste ComponentsAdhesivesRubberPlasticMetalsCloths1000kg of Adhesive per yearPaperFoam1 Speaker = 3 mtr of Copper wire2.5m PC components4m Neo Magnets
SolderConsumablesCardboardUtilitiesSolventsVOC'sH2S04Waste ComponentsWaste Assemblies
CardboardPlasticFoamFuelVOC's
VOC's Electricity
LandfillMetal Recycling
Energy Shellpot / Metal wareMagnetPlatingExtractionMiningTransportPolymer Production
Injection MouldingAnodisingMagnet CleaningUtilitiesElectricityWaterTransport (forklift truck)GasAir Conditioning
Freight: sea, road, air75% Ship, 25% AirElectricity
400 - 2kwFuelOilGasElectricity
ElectricityFuelIncineration
Chemicals SolventsPhonolic ResinPolymer ProductionPlating processImpregnationReleasing Agents
AcidsAdhesive AcceleratorsOilWaterSolder (flux)SolventsNitrogenAdhesivesAnodisingHCLH2S04
TapeFuelPlastic Wrap (PP)FoamPaperAdhesive
VOC’s Chemical WasteEffluent WasteLeachingFire Retardants
Other Chemical ContaminationLeakage
EcoDesign Workshop Impact Considerations
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5. EcoDesign Tools
Materials Production Transport &
Packaging
Use End of Life
C
O
N
•Virgin Materials•Source away from Use•Time•Cost•Reach•Down Cycling•Crude Oil•Transport Far East•Carbon Footprint•Communication•Inventory•Non-Recyclable Materials•Packaging•Human Social Costs•Unethical working conditions•Unfairly Traded•Excessive use of natural resources•Warehouse & storage costs•Mining of Neodymium
•Fuel Costs•Gas & Electricity Costs•Waste via Scrap•Packaging Waste•Cost•No design for disassembly•VOC’s•Production Waste•Harm to workforce•Sulphuric acid•Insurance Costs•Unethical working conditions•Non returnable Packaging•Response time
•Energy•Cost•Trade route destructive to wildlife•Location of Manufacturing to end-user•Ship lots of air•Emissions•CO2 Footprint•Packaging energy in production•Oil residue in the Sea
• CO2• Toxins• VOC’s• Health impact end-user• Warranty• Durability
• VOC’s• Government Policy• Leaching• Methane Production• Shipping waste back to China• Waste removable Costs• Landfill Tax• Impact to ecosystems• Acidification• Waste• Eutrophication• Land Value goes down• Speakers go to Landfill• Methane Production
P
R
O
•Local Suppliers•Use of ELV materials•Induce good work practices at Suppliers•Packaging Technology improvements•Up Cycling•Repeat Recycling•Returnable Packaging
•Right first time•Employment•Reduced Packaging•0% Waste to Landfill•Design for Manufacture DfM•Workforce Eco Aware•Skills Base•Adhesive-less assembly•Eco-Factory
•Reusable packaging•Local suppliers•Efficient packaging•Right first time project management•Packaging Materials selection
• Green Edge Technology• Product Life Cycle• Product service systems• User Satisfaction sound quality & other factors• Warranty• Durability• Entertainment• Pleasure
•0% Waste to Landfill• Reuse of Materials• Design for Dis-assembly• ELV 2015• Government Policy
EcoDesign Workshop Impact Considerations
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1. Knowledge Transfer amongst the Team
2. Procurement Location Supply Chain
1. Material Selection2. Material Recyclability
1. Product Weight2. Product Disposal
1. Quality, Reliability, Durability
2. Quality, Reliability
1. Energy Use (Air Conditioning) Shop Floor
2. Brand Identity& Quality1. Direct Waste2. Design for Manufacture & De-materialisation
1. Materials Processing2. Product Efficiency in Use
1. Supplier Engagement2. Manufacturing Cost &
Waste
5. EcoDesign ToolsEcoDesign Target Areas: Groups 1&2
EcoDesign Workshop
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LCA
5. EcoDesign Tools
Corporate Sustainability Management
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Cradle to Cradle
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• Always look at the bigger picture• Collaborate with as many people as possible• Never be afraid to ask difficult questions• Promote Creativity• View challenges as avenues for creativity• View design as an evolution without an end date
To Finish
design