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Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

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Page 1: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Product Life Cycle(s)Product Life Cycle(s)

Page 2: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Module ObjectiveModule Objective

Having read this, you should know the following:

1. Basic product life-cycle stages

2. Different terminology used by different organizations and stakeholders

3. Be able to draw a product life-cycle diagram

Page 3: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Our Linear Production SystemOur Linear Production System

MaterialProcessing

ProductManufacture Distribution

DisposalUse

Materials Extracted from Biosphere

Materials Mined from Lithosphere

Resources are mined, wastes are generated, products are disposed

Page 4: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Cyclical Production SystemCyclical Production System

aaa

MaterialProcessing

ProductManufacture Distribution

ProductTake-Back

ProductDemanufacture

MaterialDemanufacture

Disposal

Manufacture

Demanufacture

Energy recoverywith incineration

Clean fuelproduction viapyrolysis

1= Direct reuse2= Remanufacture of reusable components3= Reprocessing of recycled material4= Monomer/raw material generation

1234 Use

Materials ExtractedFrom Biosphere

Materials MinedFrom Lithosphere

Engineering decisions in design and manufacturing can have profound implications throughout the entire product life cycle, from raw materials production, through the use phase of the product and into it’s end of life treatment.

Page 5: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Stages of the Product Life Cycle (Office of Technology Assessment)Stages of the Product Life Cycle

(Office of Technology Assessment)

Environmental impacts occur at all stages of a product’s life cycle. Design can be employed to reduce these impacts by changing the amount and type of materials used in the product, by creating more efficient manufacturing operations, by reducing the energy and materials consumed during use, and by recovery of energy and materials during waste management. (OTA)

Page 6: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

A Product’s Life Cycle – From Cradle to Re-IncarnationA Product’s Life Cycle – From Cradle to Re-Incarnation

The term “demanufacture” is used to characterize the process opposite to manufacturing involved in recycling materials and products.

Disposal

MiningMaterial

processingProduct

manufactureDistribution

Product take-back

Material de-manufacture

Energy recovery with incineration

Use +

Service

Product demanufacture

Environment: air, sea, land 1234

Clean fuel production via pyrolysis

2 = Remanufacture of reusable components

3 = Reprocessing of recycled material

4 = Monomer / raw material regeneration

1 = Direct recycling / reuse

Manufacture

Demanufacture

Page 7: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

OEM

Assembly Plant(s)

Dealer Consumer

Vehicle Platform

Tier 1 Part Molder/Suppliers

Tier 2 Part Molder/Suppliers

Tier 2 Part Molder/Suppliers

Tier 3 Part Molder/Suppliers

Material Supplier

Material Supplier

partsmaterials vehicles

parts

parts

materials

material and parts specifications

Supplier Base

vehicles

Recycler(s)

Vehicle Dismantler

Auto Shredder

junked vehicles

scrap parts

scrap vehicles

reusable parts

Parts Re-manufacturer

cores

coresremanufact. parts

recyclable non-metallic materials

Millsmetals

Automobile Life-CycleAutomobile Life-Cycle

• Many modern products like automobiles are assembled by OEMs (Original Equipment Manufacturers) from components manufactured by numerous suppliers, creating a complicated network of interactions.

Page 8: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Examples of undesired releases and consumptionsExamples of undesired releases and consumptions

Product life cycle stage Some examples of harmful energy and matter

consumption and emissions

Manufacturing Energy inefficient manufacturing processes.

Manufacturing waste material.

Hazardous chemicals.

Waste heat.

Large energy consumption.

Deployment Packaging materials.

Transportation energy.

Operation and service Increased emissions and energy consumption due to loss

of peak performance.

Worn components which are replaced and discarded.

Retirement Energy for (garbage) collection.

Scrap products.The above names for life cycle stages are often used in Defense related industries and products.

Page 9: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Generic High Level Life-Cycle ActivitiesGeneric High Level Life-Cycle Activities

Materials Manufacture

Product Fabrication

Filling/ Packaging/ Distribution

Manufacturing

Raw Materials Acquisition

Use / Reuse / Maintenance

Recycle / Waste Management

Life-cycle StagesInputs Outputs

Atmospheric Emissions

Waterborne Wastes

Solid Wastes

Coproducts

Other Releases

Energy

Raw Materials

For a mechanical product. (Source: EPA)

Page 10: Georgia Institute of Technology Systems Realization Laboratory Product Life Cycle(s)

Georgia Institute of TechnologySystems Realization Laboratory

Some Aspects of an Environmentally Benign ProductSome Aspects of an Environmentally Benign Product

Product Life Cycle

UseProduction and Distribution

Post Use

low energy and material consumption few and environmentally benign emissions

long product life = easy to: inspect, maintain, repair, update

usefulness

low energy and material consumption use of environmentally benign (e.g. recycled) material few and environmentally benign (recyclable) emissions / waste

Recycling Disposal

Material Recycling Product Recycling (Reuse of the product or its parts)

degradability

Incineration

high reuse value disassemblability

high recycling value of the materials separability or compa- tibility of materials

no hazardous emissions

The terms “material” and “product” recycling are used in Germany and the German engineering standard VDI 2243 – “Designing Technical Products for Ease of Recycling”