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April 11, 2006
Design for
EnvironmentJeff Dahmus & Alex Thiriez
Outline
1. DfE Practice
2. DfE Approaches
3. Green Labeling
Government
Computers
Electronics
Durable Goods
Buildings
Practice
Win-wins?
• Energy/material efficiency results in
lower utility/material costs.
• A good environmental profile keeps
employees, customers and
governments happy ☺☺☺☺
What to improve in a product?
• Look at the LCA to see which lifecycle stage (material production, manufacturing, use, end-of-life) has the greatest environmental impact.
• First focus your efforts on this stage. Then dedicate your time to the others.
• Gage your improvements with SLCAs or full LCAs
Source: http://www.moea.state.mn.us/publications/betterbydesign.pdf
DfE Toolkit:
1. Design to minimize material usage
2. Design for disassembly
3. Design for recycling and use of recycled
materials
4. Design for remanufacturing
5. Design to minimize hazardous materials
6. Design for energy efficiency
7. Design to meet regulations and
standards
One for each day of the week !!!
DfE Toolkit1. Design to minimize material usage
• Objective: Reducing material usage –
dematerialization - over the life of the product
(not only in the product, but also in
manufacturing, packaging…)
• Examples
– Reducing computer packaging (reduces material at
end-of-life).
– Avoiding paint use by instead using colored plastic
body panels (reduces material at manufacturing).
– Selling services, not goods (reduces material at end-
of-life, and overall)
Success Stories- Dematerialization
Interface carpets
Problem: carpet life is governed by high-wear areas (20% of the carpet gets 80% of the wear)
Solution: modular carpet tiles that can be changed individually; selling carpeting as a service, not a good.
Result: extends product life by a factor of 5.
Success Stories- Dematerialization
Xerox CorporationProblem: lack of
environmentally acceptable packaging
Solution: replace Styrofoam packaging with "corrupad" and molded pulp made from post-consumer recycled materials
Result: Improved customer satisfaction and savings of about $ 2 million a year.
DfE Toolkit2. Design for disassembly
• Objective: Make disassembly – either manual or
automated – simple, to allow for easier
component reuse, material recovery, and
hazardous material removal.
• Examples
– Using mechanical fasteners instead of glue
– Modularizing products
– Isolating hazardous materials
Joints suitable for Disassembly
“Design for environment surprisingly coincides very well with design for manufacturability”
- Development engineer at IBM
Source: http://www.moea.state.mn.us/publications/betterbydesign.pdf
Good to Bad Plastic-to-Plastic Joints
Disassembly Times
Use these tables to approximate the disassembly time for a product.
Example:
3. Design for Recycling and Use of Recycled
Materials
• Objective: Allow the use of recycled material
inputs and the recycling of products and
production byproducts at end-of-life.
• Examples
– Metal recovered from end-of-life automobiles is
recycled into new automobiles (as opposed to
aluminum cans which are not recycled into new
aluminum cans)
– Downcycling – recycling
engineering plastics into
park benches
DfE Toolkit
Cross-section of a Snack Bag
• Looks simple…easy to recycle?
Source: http://www.eng.uc.edu/~pbishop/69
• Insert Bras recyclability ratings
Design for Recycling Techniques:
• Eco-industrial park in Kalundborg, Denmark
• Waste = food
Downcycling - Recycled PVC goes into:
window frame coextrusion
Garden hoses
From: http://www.bpfwindowsgroup.com/downloads/files/Windows%20-
%20A%20Transparent%20Case%20for%20PVC.pdf
Carpet Undercoating
Shoe Soles
DfE Approaches4. Design for remanufacturing
• Objective: Allow component or product life to
be extended through remanufacturing.
• Examples
– Printer cartridges
– Kitchenaid mixers
DfE Approaches4. Design for remanufacturing
Marcotte Mining Machinery Services
5. Design to minimize hazardous materials
• Objective: Minimize hazardous materials in final
product and in production stages
• Examples
– Lead-free solder
– ROHS – Restriction Of the use of certain
Hazardous Substances in electrical and
electronic equipment– Lead
– Mercury
– Cadmium
– Hexavalent chromium
– Poly-brominated biphenyls (PBB)
– Polybrominated diphenyl ethers (PBDE)
DfE Approaches
5. Design to minimize hazardous materials
• Chemicals identified in the EPA’s Industrial
Toxics Project
DfE Approaches
•Benzene•Cadmium and compounds•Carbon tetrachloride•Chloroform•Chromium and compounds •Cyanides•Dichloromethane•Lead and components
•Mercury and compounds•Methyl ethyl ketone•Mercury isobutyl ketone•Nickel and compounds•Tetrachloroethylene•Toluene•Trichloroethane•Trichloroethylene•Xylenes
DfE Approaches5. Design to minimize hazardous materials
• the charm is 99% lead; the safety threshold for lead content in jewelry is 0.06%
Boston Globe, March 24, 2006
DfE Toolkit5. Design to minimize hazardous materials
DfE Toolkit5. Design to minimize hazardous materials
• uses sodium rhodizonate• turns pink or red with as littleas 1-2 micrograms of lead
• the darker the color, thehigher the lead content
DfE Approaches
• Objective: Produce energy efficient products to
reduce the impact of the use phase
• Examples
– (Some) Hybrid automobiles
– Energy Star appliances
6. Design for energy efficiency
DfE Approaches6. Design for energy efficiency
DfE Approaches6. Design for energy efficiency
DfE Approaches
• WEEE – Waste Electrical and Electronic
Equipment
• ROHS – Restriction Of the use of certain
Hazardous Substances in electrical and
electronic equipment
• End-of-Life Vehicle Recycling in the EU
• Corporate Average Fuel Economy Standards
• …
7. Design to meet regulations and standards
Eco-Labeling
Energy Star
EU Flower
Nordic Swan