IRAP DfE Guide Introduction
dfe overview dfe benefits DfE Guide Overview int/ext drivers Design for Environment (DfE) is the systematic integration of environmental product cycle considerations into product and process design. Because it offers new sustainable dev. perspectives with a product and business focus, DfE can be a powerful tool to make your company more competitive and more innovative, as well as more environmentally responsible. dfe strategies getting started But to small- and medium-sized enterprises (SME), DfE often appears to be too time-consuming and too expensive to implement. The aim of this Guide download is to make it easier for an SME to get started with some practical DfE acknowl. applications. As an SME, you will have a solid framework to build an internal team to implement DfE and make the best use of external advisors.
DfE provides an organized structure into which companies can integrate most features of sustainable development, e.g., eco-efficiency, pollution prevention and clean production.
This Guide takes advantage of the inclusive nature of DfE to provide you with wide variety of useful references and resource information that is linked to the main text. This system of linkages allows you to:
● Retrieve useful information easily. ● Access information in the way you prefer, e.g., by industry sector or by DfE strategy.
Currently, there are only a few hundred references in the Guide. You can have a role in making the Guide more useful site by identifying others that could be included. Please feel free to e-mail us at ### with your suggestions.
DfE Benefits How DfE stimulates innovation, lowers costs, increases competitiveness, and reduces liability.
DfE Internal and External Drivers What motivates companies to undertake a DfE project or program.
DfE and the Product Life Cycle Environmental evaluations/improvements are related to a product's life span.
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DfE and Sustainable Development DfE in the context of other environmental initiatives.
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dfe overview Contact dfe strategies getting started For general public and media inquiries on the programs, services and download publications of The Industrial Research Assistance Program: please contact the IRAP Communication Team at the Industrial Research Assistance acknowl. Program (IRAP) Communication office in Ottawa to discuss the specific nature of your interest.
The Industrial Research Assistance Program Building M55, Montreal Road Ottawa, Ontario K1A OR6
E-Mail: Public Inquiries E-mail Phone: (613) 993-5326 Fax: (613) 952-1086 Website: http://www.nrc.ca/irap
For information, questions concerning technical details or collaboration opportunities on DfE program, please contact Jim Rollefson.
For information on IRAP, or to reach an Industrial Technology Advisor (ITA), please call our toll-free number which will direct you to the the IRAP regional office nearest to you: 1-877-994-4727
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Stratégie de conception écologique, c'est l'intégration systématique des considérations environnementales dans la conception des produits et des processus
Survol de la Stratégie de conception écologique La Stratégie de conception écologique est une approche environnementale axée sur le produit.
● Les avantages de la Stratégie de conception écologique ● Les pilotes internes et externes de la Stratégie de conception écologique ● La Stratégie de conception écologique et le cycle de vie des produits ● La Stratégie de conception écologique et le développement durable
Stratégies de la Stratégie de conception écologique 34 stratégies rentables et des soustratégies avec conseils et exemples.
● Survol des stratégies ● Stratégie 1 : élaboration d'un nouveau concept ● Stratégie 2 : optimisation physique ● Stratégie 3 : optimisation de l'utilisation du matériel ● Stratégie 4 : optimisation des techniques de production ● Stratégie 5 : optimisation du système de distribution ● Stratégie 6 : réduction des impacts lors de l'utilisation ● Stratégie 7 : optimisation des systèmes de fin de vie
Comment démarrer-Cinq étapes vers la Stratégie de conception écologique un plan d'action étapiste.
● Étape 1 : élaboration d'un énoncé de projet ● Étape 2 : analyse du profil environnemental du produit ● Étape 3 : analyse des incitateurs internes et externes ● Étape 4 : analyse des options d'amélioration ● Étape 5 : étude de faisabilité des options ● Feuilles de travail à télécharger
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dfe overview DfE Guide Overview dfe benefits int/ext drivers Design for Environment (DfE) is the systematic integration of environmental product cycle considerations into product and process design. Because it offers new perspectives with a product and business focus, DfE can be a powerful tool sustainable dev. to make your company more competitive and more innovative, as well as more environmentally responsible. dfe strategies But to small- and medium-sized enterprises (SME), DfE often appears to be getting started too time-consuming and too expensive to implement. The aim of this Guide download is to make it easier for an SME to get started with some practical DfE applications. As an SME, you will have a solid framework to build an internal acknowl. team to implement DfE and make the best use of external advisors.
DfE provides an organized structure into which companies can integrate most features of sustainable development, e.g., eco-efficiency, pollution prevention and clean production.
This Guide takes advantage of the inclusive nature of DfE to provide you with wide variety of useful references and resource information that is linked to the main text. This system of linkages allows you to:
● Retrieve useful information easily. ● Access information in the way you prefer, e.g., by industry sector or by DfE strategy.
Currently, there are only a few hundred references in the Guide. You can have a role in making the Guide more useful site by identifying others that could be included. Please feel free to e-mail us at ### with your suggestions.
DfE Benefits How DfE stimulates innovation, lowers costs, increases competitiveness, and reduces liability.
DfE Internal and External Drivers What motivates companies to undertake a DfE project or program.
DfE and the Product Life Cycle Environmental evaluations/improvements are related to a product's life span.
DfE and Sustainable Development DfE in the context of other
http://www.nrc.ca/dfe/ehome/overview/overview.html (1 de 2) [08/01/2002 05:11:01 p.m.] IRAP DfE Guide Introduction
environmental initiatives.
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dfe overview dfe benefits DfE Benefits int/ext drivers DfE offers businesses opportunity to enhance environmental performance, product cycle while simultaneously improving their bottom line. Companies that apply DfE sustainable dev. find that it:
● Reduces environmental impact of products/processes. dfe strategies ● Optimizes raw material consumption and energy use. ● getting started Improves waste management/pollution prevention systems. ● Encourages good design and drives innovation. download ● Cuts costs. acknowl. ● Meets user needs/wants by exceeding current expectations for price, performance and quality. ● Increases product marketability.
DfE can also provide a means for establishing a long-term strategic vision of a company's future products and operations. In general, DfE is an enabling force to shape more sustainable patterns of production and consumption. (DfE and Sustainable Development)
● Increased innovation ● Greater ability to compete, add value, attract customers ● Become more cost-effective ● Reduce environmental impacts and liability ● Gain a systems perspective
Increased innovation. By incorporating DfE into product design/development, companies gain a fresh perspective on established practices, resulting in new ideas and solutions. For example:
● New product/service concepts. ● Alternate production techniques. ● Increased employee participation. ● Greater creativity.
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Greater ability to compete, add value, attract customers. There is a growing global demand for environmental quality in products and services. Incorporating DfE into product design can help companies:
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● Meet emerging market demands. ● Differentiate their products in the marketplace. ● Improve their image and win customer attention. ● Attract investment.
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Become more cost-effective. DfE targets opportunities for cost-reduction at all stages of a product's life and ensures the greatest reduction in environmental effects/releases per dollar invested. The results are:
● Reduced production costs. ● Increased product quality. ● Elimination of compliance costs. ● Increased return on environmental investments.
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Reduce environmental impacts and liability. By decreasing a product's impact on the environment, DfE helps companies:
● Ensure compliance with environmental regulations. ● Reduce uncertainty with respect to future environmental requirements. ● Improve access to insurance and financing. ● Achieve better community relations. ● Contribute to a better local, regional and global environment.
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Gain a systems perspective. DfE, which focuses on a product's life cycle, helps companies create corporate links between product design, supply chain management and sales/marketing, thereby providing:
● An overall, systemic view of company operations. ● A mechanism for cross-functional teams to continuously improve products.
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Interface Flooring Systems (IFS), a leading global supplier of floor coverings, fabrics, chemicals and interior architectural components, has been using product redesign and material formulation to eliminate targetted toxic elements and compounds in its production processes. These processes:
● eliminated costs of toxic substances. ● improved product quality and performance. ● reduced unsaleable materials from 5.4 to 0.4 per cent since elimination of toxic substances was a factor in improving product quality.
IFS saved over $90 million USD from 1995 to 1999 as a result of its in-house, zero-waste initiative.
Source: Lorinda R. Rowledge, et al. Mapping the Journey: Case Studies in Strategy and Action towards Sustainable Development. Greenleaf Publishers, UK, 1999.
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.
Source: Electrolux, Environmental Report, 1998.
Henkel, a global company specializing in applied chemistry, manufactures products such as surface treatments, adhesives, cosmetics/toiletries and detergents/household cleaners. In order to gain a better understanding of client needs which would lead to improved products, long-term contracts and supplier security, Henkel has a new business strategy of providing services rather than products--for example, offering surface treatment and degreasing services to its automotive clients. Service-based sales have increased by up to 200 per cent in the first year.
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Source: Lorinda R. Rowledge, et al. Mapping the Journey: Case Studies in Strategy and Action towards Sustainable Development. Greenleaf Publishers, UK, 1999.
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.
Source: Inga Belmane. AEco-innovation: cathode ray tube recycling at IBM Sweden.@ Journal of Sustainable Product Design, Issue 9, April 1999. Centre for Sustainable Product Design, Surrey, UK.
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http://www.nrc.ca/dfe/ehome/overview/benefits/benefits.html (4 de 4) [08/01/2002 05:11:08 p.m.] DfE Internal and External Drivers
dfe overview DfE Internal and External Drivers dfe benefits int/ext drivers Motivation to implement DfE can come from two different directions. product cycle ● sustainable dev. Within the company itself--internal drivers. ● From the immediate surroundings--external drivers.
dfe strategies getting started download Internal Drivers acknowl.
Need for increased product quality. A high level of environmental quality will raise product quality in terms of functionality, reliability in operation, durability and repairability.
Image improvement. Communicating a product's environmental quality to users through an environmental "seal of quality," such as the Environmental Choice Label or a good report in consumer tests, can improve a company's image significantly.
Need to reduce costs. Companies can combine DfE strategies with financial benefits by:
● Purchasing fewer materials for each of its products. ● Using energy and auxiliary materials more efficiently during production. ● Generating less waste and lowering disposal costs. ● Disposing of hazardous waste.
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Need to stimulate innovation. DfE can lead to radical changes at the product system level--the combination of product, market and technology. Such innovations can provide entry into new markets.
Employee motivation. Morale generally increases when employees are empowered to help reduce the environmental impact of the company's products and processes. DfE can also boost employee motivation by improving occupational health and safety.
A sense of responsibility. A growing awareness that business must play an important role in working towards sustainable development can provide a strong incentive for implementing DfE.
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External Drivers
Government Policies. Product-oriented environmental policy is growing rapidly in northern Europe, the United States and Japan. Some examples and trends:
● Legislation on "extended producer responsibility" and "take-back obligation." Germany has introduced a take-back obligation for goods such as television sets, computers and cars. The U.S. Environmental Protection Agency requires discharge disclosures for certain types of generators.
● Introduction of eco-labelling programs for products or product groups.
● Requirement to provide environmental information on products and processes, requiring business to pursue more pro-active environmental communication policies.
● Development of industrial subsidy programs to stimulate DfE activities and encourage companies to carry out research into potential http://www.nrc.ca/dfe/ehome/overview/drivers/drivers.html (2 de 4) [08/01/2002 05:11:16 p.m.] DfE Internal and External Drivers
environmental improvements.
● Termination of subsides on energy-intensive production methods and energy/raw material consumption.
Market demand/competition. The needs/wants of suppliers, distributors and end-users are powerful drivers for environmental improvement. Some examples and trends:
● Requirements by some companies--generally large corporations--for environmental-safeguarding declarations from suppliers. Some companies are systematically looking at their entire supply chain and imposing the new environmental standards or other measures of environmental performance.
● Boycotts or other actions by consumer organizations/environmental groups. For example, Greenpeace successfully pressured industry to develop GreenFreeze, an ecologically efficient refrigerant made of propane and butane that can replace environmentally harmful chlorofluorocarbons (CFCs).
● Environmental requirements incorporated into consumer product testing. If a product fails to get a high score on these requirements, it will no longer qualify for the title of "best buy" or "good choice," no matter what other excellent features it may possess. Good environmental ratings can increase market share.
● Increased implementation of "responsible care programs" in many industries, resulting in more companies with experience in cleaner production. In cases where intense competition exists for a particular product, companies with a good environmental profile can have an "edge."
Trade/industrial organizations. These organizations often encourage member companies to take action on environmental improvement and/or may impose penalties on companies that do not take required action.
As well, standardization organizations are expanding all existing norms and standards to include environmental issues. The ISO 14 000 series will become the international standard for certifying environmental management systems. It is expected that product-related aspects, such as the obligation to collect and publish environmental data, will be incorporated in this standard.
Waste charges. Waste-processing charges such as land-fill and incineration costs are likely to increase, based on the principle of "polluter pays." The prevention of waste and emissions, re-use and recycling will consequently become more economic.
Environmental requirements for design awards. Several respected design competitions have now stipulated that contestants must provide specific environmental information on their products.
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the Hannover Messe, which has a five-year plan to obtain environmental information on aspects such as packaging, materials used, re-usability and warranties. Other international design competitions now pro-active with regard to the environment are:
● IDEA award in the United States. ● G-Mark award in Japan. ● Form Finlandia award by Nestle. ● Excellent Swedish Form by the Swedish Design Council. ● Brown Competition in Germany. ● ION award in the Netherlands.
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http://www.nrc.ca/dfe/ehome/overview/drivers/drivers.html (4 de 4) [08/01/2002 05:11:16 p.m.] DfE and the Product Life Cycle
dfe overview DfE and the Product Life Cycle dfe benefits int/ext drivers With the global market is undergoing continuous and rapid change, your product cycle company's ability to innovate and be flexible will be crucial to its profitability. sustainable dev. The DfE Strategies can play a significant role in product innovation by:
dfe strategies ● Providing new criteria for evaluating design such as choices for getting started materials, production techniques, finishing technologies, and packaging methods. The new criteria can often lead to innovative download product or service solutions. acknowl. ● Considering the entire product life cycle--a process which can stimulate partnerships with suppliers/distributors/recyclers, open up new market areas, and increase product quality.
Products impact the environment at all stages of the product life cycle. Key environmental factors include:
● energy supply ● raw materials acquisition ● component/product manufacturing ● transportation and distribution ● product use ● end-of-life product disposal
DfE allows you to systematically evaluate a product and set continuous improvement goals for the entire product life cycle. This life cycle generally has five phases:
● design ● production ● distribution ● product use ● end-of-life
While most companies don't control the whole product life cycle, their design decisions do have an impact on upstream and downstream impacts, from choice of materials to product service and end-of-life options.
The life cycle of a manufactured product
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For manufactured products such as an office chair or a magazine, the life cycle will include all five phases. For other products such as computer software, or for services such as metal coatings, the product life cycle may be more or less complex.
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dfe overview DfE and Sustainable Development dfe benefits int/ext drivers DfE is designed to help companies adopt environmental practices that will product cycle lead to a more sustainable and healthier society. Therefore, DfE both supports, and works within, the context of other environmental initiatives. sustainable dev.
● Sustainable Development dfe strategies ● Industrial Ecology ● getting started Pollution Prevention (PP) ● Environmental Management Systems (EMS) download ● Occupational Health and Safety (OH&S) acknowl.
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."
One of the basic assumptions underlying Sustainable Development is that environmental considerations must be entrenched in economic decision- making. Sustainable Development initiatives are increasingly widespread among individuals, communities, industry and governments around the world.
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Industrial Ecology: This term encompasses the practices of scientists, engineers and manufacturers to achieve more sustainable industrial production and consumption for local, regional and international economies by:
● Examining the environmental costs of industrial production/consumption patterns. ● Addressing the effects of invisible and persistent toxic chemicals on the earth's ecological systems.
The basic components of the industrial ecology model
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"In a sustainable society, durability and recycling will replace planned obsolescence as the economy's organizing principle, and virgin materials will be seen not as a primary source of material but as a supplement to the existing stock."
Source: Lester R. Brown and Pamela Shaw. Six Steps to a Sustainable Society, Worldwatch Paper No. 48. Worldwatch Institute, Washington, 1982.
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Pollution Prevention (PP): PP focuses on process and product improvements in order to avoid environmental problems before they occur. It is economically and environmentally superior to traditional "end-of-pipe" controls or clean-up strategies.
DfE dovetails with PP by focusing on product and process involved specifically in manufacturing. While many DfE strategies incorporate PP, DfE goes beyond PP practices by also examining product functionality and services.
PP during the manufacturing process saves costs with regard to:
● Disposal. ● Raw materials/consumables. ● Ventilation equipment. ● Maintenance-ducts, motors, balancing. ● Operations-internal "balancing." ● Pollution prevention equipment. ● Health-workers, protective equipment, training. ● Regulatory compliance-approval from government.
A number of measures can be taken to prevent pollution during manufacturing:
1. Control pollution at the source ● substitute materials ● change form of material to reduce emissions 2. Enclose the process ● prevent release, accomplished with sealed vessels and piping 3. Suppress emissions http://www.nrc.ca/dfe/ehome/overview/sd/sd.html (2 de 6) [08/01/2002 05:11:43 p.m.] DfE and Sustainable Development
● water sprays--dusty processes or liquids ● gaseous--gas blanket 4. Change the process entirely ● degreasing--from chlorine-based to high-pressure steam ● soldering--from traditional acid etching/fluxes/lead to different base materials, VOC-free fluxes, lead-free solder
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Environmental Management Systems (EMS): EMS such as ISO 14001 are organizational approaches to facility environmental evaluation and management. Except in cases of legal compliance, an EMS does not set or demand specific levels of performance in relation to product or process design.
The core requirement for EMS is that an organization have a reasonable amount of information on the environmental effects of its products and processes and, in turn, seek continuous improvement. Pollution prevention (PP) is typically part of EMS.
DfE is complementary to EMS. It augments the organizational approach by including product-oriented environmental evaluations and improvements. Manufacturers using DfE strategies take into account the environmental aspects of a product's use and end of life, and apply this information during its design, production and distribution.
Hierarchy and realm of application for PP, DfE and EMS
Note: It is estimated that $1 spent on prevention saves $10 otherwise spent at end-of-pipe or $100 expended on environmental remediation.
EMS benefits are:
● Cost savings from greater efficiency in processes, waste reduction, materials and energy use. ● Increased ability to meet customer/supplier requirements. ● Greater competitive advantage. ● Regulatory compliance and reduced liability. ● Improved community relations. ● Greater company appeal for investors.
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● Increased employee pride and morale.
EMS and product design EMS key elements When product design is included Commitment from top Senior management responsible for management for improved environmental effects of products environmental performance Policy statement outlining Refers to products/services commitment Includes aspects of product life cycle that company controls:
Summary and supporting data of ● suppliers environmental effects of current ● product design and planned projects ● product use ● end-of-life phase
Includes product-related environmental Summary of regulations regulations Objectives, targets and programs Include product design where relevant for continuous improvement Clearly defined environmental Includes roles and responsibilities related to responsibilities for managers product design/development Awareness training in Training for managers/designers environmental issues Performance monitoring Monitoring of design process procedures Reviews of environmental performance by senior Includes product aspects management
Source: Product design and ISO 14001: A guide for environmental managers and product designers, by Martin Charter and Tom Clark, Centre for Sustainable Design, Surrey, UK, 1999.
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Occupational Health and Safety (OH&S): The DfE strategies provide support for programs related to worker safety during production, and worker health in terms of material selection and use. DfE helps reduce:
● Need for in-plant emission controls. ● Worker contact with physical or chemical hazards. ● Need for protective equipment.
Improving health and safety performance will:
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● Reduce lost time due to injury and illness. ● Reduce insurance fees and liabilities. ● Improve employee morale. ● Increase productivity.
Linking the DfE Strategies to OH&S Program Elements OH&S DfE Strategy Elements Strategy 2: Physical Optimization Ergonomics 2.1 Integrate Product Functions Material handling 2.4 Easy Maintenance and Repair Safety 2.5 Modular Product Structure Strategy 3: Optimize Material Use Material substitution 3.1 Cleaner Materials Hazards materials 3.6 Reduce Material Usage Process substitution Strategy 4: Optimize Production Chemical substitution 4.1 Alternate Production Techniques Industrial housekeeping 4.2 Fewer Production Steps Hazardous materials 4.4 Less Production Waste Safety equipment 4.5 Fewer/Cleaner Production Consumables Ergonomics Strategy 5: Optimize Distribution Material substitution 5.1 Less/Cleaner/Re-usable Packaging Material handling/storage 5.3 Energy-efficient Logistics Benefits $ Reduced need for in-plant emission controls $ Reduced assembly time/use of tools and machinery $ Reduced worker exposure to physical hazards $ Reduced need for safety/protective equipment $ Reduced handling of product components, materials, chemicals and hazardous substances $ Reduced industrial housekeeping $ Reduced production time
Source: Canadian Centre for Occupational Health and Safety, Hamilton, Ontario.
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Daimler-Chrysler Corporation wanted to meet regulatory requirements in various world markets, save costs for liability, training, medical testing and administration, and take advantage of opportunities for recycling. To achieve these goals, the company implemented a Life Cycle Management (LCM) program as a business tool to identify and incorporate environmental, health and occupational safety and recycling (EHS&R) into product development.
This program:
● ensures that EHS&R is an integral part of company decision-making. ● targets regulated substances for elimination, reformulation and/or reduction. ● ensures the use of materials with recycled content. ● encourages vehicle design for end-of-life ease of recovery and/or re-use.
After having conducted over 30 LCM analysis projects from 1994-1998, Daimler-Chrysler saved or avoided costs totalling $22 million and reduced waste by over 400 tons. As well, the elimination/reduction of several regulated substances have lowered risks to worker health and the environment.
Source: The Extended Enterprise: Life Cycle Cost Management of Environment, Health, Safety and Recycling/End-of-Life as a Business Decision Process, by William E. Franklin, SAE Technical Paper 982165, Total Life Cycle Conference, Graz, Austria, 1998.
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dfe overview
DfE Strategies dfe strategies Overview of the Strategies overview An introduction to the strategies, the Strategy Wheel and what you should 1 new concept consider when choosing a strategy for a DfE project. 2 physical opt. 3 materials 4 production Strategy 1: New Concept Development Examine the function(s) of a product in terms of both development 5 distribution assumptions and the needs of the end-user. This is an important strategy to 6 use undertake prior to product development. 7 end-of-life 1.1: Dematerialization
1.2: Increase Shared Use getting started 1.3: Provide a Service download acknowl. 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 3.3: Lower Energy-content Materials 3.4: Recycled Materials 3.5: Recyclable Materials 3.6: Reduce Material Usage
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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 4.5: Fewer/Cleaner Production Consumables
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 5.2: Energy-efficient Transportation 5.3: Energy-efficient Logistics
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 6.2: Cleaner Energy Sources 6.3: Reduce Use of Consumables 6.4: Cleaner Consumables and Auxiliary Products 6.5: Reduce Energy and Other Consumable Waste
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 7.2: Design for Disassembly 7.3: Product Re-manufacturing 7.4: Material Recycling 7.5: Safer Incineration
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra.html (3 de 3) [08/01/2002 05:12:07 p.m.] IRAP DfE Guide Introduction
dfe overview Getting Started--Five Steps to DfE dfe strategies Your company is involved in change such as developing a new product or getting started seeking ways to improve a product. 1: design brief Seize an opportunity. This change is your chance to: 2: env. profile
3: drivers ● Integrate DfE into your design/development process. 4: options ● Use DfE to achieve your goals of creativity and cost-cutting. ● Apply DfE to turn the environment into an opportunity for innovation. 5: feasibility worksheets Use the DfE strategies. As you review these strategies, consider business questions related to resources, technological feasibility and marketing potential. Consider how the answers can be integrated with DfE. download
acknowl. Form a team. Because DfE considers the full product life cycle, input is needed from different parts of the organization. In effect, DfE promotes a holistic look at your business operations, but with a focus on a specific product. Take advantage of this to enhance teamwork in your organization. Form a project team to address issues related to:
● design ● engineering ● production ● quality assurance ● marketing
Get focused. Perhaps your company has options in product/component development that would fit well with DfE strategies, but you are unsure which would be best. The DfE Matrix can help you set priorities.
Start in ways that suit you. It's not necessary to apply DfE to everything at once--you can start in a small way and apply DfE in increments to meet your needs. For example:
● You may find it beneficial to focus on environmental improvements that have a short implementation time. If there is considerable internal or external pressure to improve the environmental performance of your company's products, implementing DfE quickly can improve employee morale and have market benefits. In such cases, you might focus on packaging which generally allows for rapid improvement.
● When working on products with a longer development time such as consumer durables, you may find it more cost-effective to apply DfE on a component-by-component, or sub-assembly-by-sub-assembly,
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basis. This allows your company to benefit from incremental product improvement while developing DfE experience.
Get organized. With teamwork comes organization. Below are a number of steps that may facilitate your analysis and decision-making process.
Step 1: Create a Design Brief -- helps set the framework for the others. All the steps suggested are suggestions only. Feel free to adapt the steps to meet your company's needs.
Step 1: Create a Design Brief
Step 2: Analyze Product's Environmental Profile
Step 3: Analyze Internal/External Drivers
Step 4: Analyze Improvement Options
Step 5: Study Option Feasibility
Worksheets for Downloading
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dfe overview Download Documents dfe strategies getting started The following sections of this Guide are downloadable in Microsoft Word 97.
● download DfE_Documents.zip
Please note: acknowl. 1. The illustrations have been included but other design elements have been eliminated to speed up the download.
2. Each section will be in a seperate file. You can begin at "first page.doc" and use the internal hypertext links to navigate among the sections. (This will work as long as all the files are maintained within the same directory.)
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http://www.nrc.ca/dfe/ehome/downloads/downloads.html [08/01/2002 05:12:36 p.m.] Acknowledgements
dfe overview Acknowledgements dfe strategies getting started Much of the content for this site is based directly on the United Nations download Environmental Program's PROMISE Manual. http://www.unep.org/
The initial adaptation of the content for the Web site was provided by Five acknowl. Winds International and Associate Ralf Nielsen of Nielsen Design Consulting. http://www.fivewinds.com
The editing was provided by Claire Harrison of CANDO Career Solutions. http://candocareersolutions.com
The information retrieval system software was provided by Advanced Services of the Canada Institute of Scientific and Technical Information, National Research Council Canada. http://www.nrc.ca/cisti/
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http://www.nrc.ca/dfe/ehome/acknowledgements/acknowledgements.html [08/01/2002 05:12:53 p.m.] National Research Council Canada/Conseil national de recherches Canada
This site is best viewed with Il est préférable de consulter ce site Netscape 4.0 and Internet Explorer avec Netscape 4.0 et Internet 4.0 at 800x600 pixels. The site is Explorer 4.0 sur un écran de JavaScript enabled. 800x600 pixels. Ce site comporte des fonctions JavaScript.
http://www.nrc.ca/ [08/01/2002 05:13:20 p.m.] disclaimer
dfe overview Disclaimer dfe strategies getting started The National Research Council of Canada shall not be liable for any damages download or losses of any type arising from the use or content of this site. acknowl. The information in the database has been provided by external sources. Although every effort has been made to ensure the accuracy, currency and reliability of the content, the National Research Council of Canada accepts no legal liability in that regard.
The National Research Council of Canada has no control over the availability of remote sites, and is not responsible for the information found at those sites. The inclusion of a site in the database does not constitute an endorsement or recommendation by the National Research Council of Canada. The contents of this site shall not be used for advertising or product endorsement purposes. The National Research Council of Canada reserves the right to remove, modify, or add to the content of this site.
Users concerned about the qualityof information on the content of remote sites listed here should read Considerations Regarding DfE Resources.
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http://www.nrc.ca/dfe/ehome/disclaim/disclaim.html [08/01/2002 05:13:38 p.m.] IRAP Design for Environment Guide Homepage
Design for Environment (DfE) is the systematic integration of environmental considerations into product and process design.
DfE Overview DfE is a product-focused environmental approach.
● DfE Benefits ● DfE Internal and External Drivers ● DfE and the Product Life Cycle ● DfE and Sustainable Development
DfE Strategies 34 cost-effective strategies and sub-strategies including tips and examples.
● Overview of the 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
Getting Started--Five Steps to DfE A step-by-step action plan.
● Step 1: Create a Design Brief ● Step 2: Analyze Product's Environmental Profile ● Step 3: Analyze Internal/External Drivers ● Step 4: Analyze Improvement Options ● Step 5: Study Option Feasibility ● Worksheets for Downloading
Download Documents Sections of the Web site in downloadable format.
Directory of DFE Web Resources
Disclaimer
Acknowledgements
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http://www.nrc.ca/dfe/ehome/ehome.html (2 de 2) [08/01/2002 05:14:16 p.m.] Overview of the Strategies
dfe overview Overview of the Strategies dfe strategies The DfE Strategy Wheel provides a basic framework that you can use overview systematically to review the entire life cycle of a product. It is a tool that can: 1 new concept ● stimulate the creative design process. 2 physical opt. ● assist in visualizing current environmental performance. 3 materials ● highlight opportunities for improvement. 4 production Optimizing your product's performance will require a balance of functional, 5 distribution economic and environmental elements. The Strategy Wheel begins with new 6 use product concepts, and covers design, materials selection, production, distribution, and the use and end of a product's life. 7 end-of-life
The Design for Environment Strategy Wheel getting started download acknowl.
Although the strategies are numbered consecutively based on a product's life cycle, you will find the sequence for implementing the strategies is not the same for every product. In other words, there is no one way to use of the strategies that is "right"; the sequencing depends on the needs of your organization and the product's production.
Choosing a Starting Strategy
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The table below, which compares sequencing approaches for a photocopier, a telephone and a packaging product, demonstrate how each specific product requires a different starting strategy. For example:
● In the case of the photocopier, the reduction in the energy consumption (6: Reduce Impact During Use) should be implemented early in the development process because this has a great effect on the function of the machine. However, solutions for improving recycleability (7: Optimize End-of-Life Systems) can wait until the photocopier's detail design is being filled in.
● In the case of a package, the choice of materials ( 3: Optimize Material Use) is so significant to further development that decisions must be undertaken at the earliest stage in product development.
Sequencing of DfE Strategies during the Design of Different Products Copier Telephone Packaging
Idea for New 7. Feasibility study 1. Consider 1. Optimize the Product on reuse of integration with other product so packaging components. media modes. is no longer required. Result: design brief 6. Structural 7. Feasibility study 7. Feasibility study decrease of paper on recycling. on recycling. consumption.
Conceptual 6. New principles for 6. Development of 3. Development of Design lower energy use. zero-Watt principles minimal packaging. to reduce energy Low-impact use. materials. Result: several 3. Development of concepts photo conductor with clean materials. 2. Optimize 2. Optimize functions functions. Increase - shipping and reliability / durability. display. 2. Facilitate maintenance and repair.
Preliminary 7. Design for reuse of 7. Optimizing 3. Selection of Design components. electronics for cleaner production recycling. techniques. Reduction of Result: 6. Design for use of materials usage. preliminary recycled paper. design Optimization of energy use. 4. Cleaner printing processes.
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Detail Design 7. Design for 7. Design for 7. Design for disassembly. recycling. recycling. Result: product and production 3. Minimal 4. Selection of 3. Reduction of specification packaging. cleaner production materials usage. and documents Recyclable and clean techniques. materials. 3. Reduction in amount of materials. Clean and recyclable materials.
Applying Strategies to One Part of the Product's Life Span
You may also find that you can apply more than one strategy to one part of a product's life span. For example, you can apply the full range of DfE strategies to a product's design process alone. The strategies take designers through a sequence of progressively demanding challenges, from the relatively simple to the highly complex. Design teams are well aware that it's usually far more difficult to achieve a viable "new concept" than a "reduction of materials."
The table below provides one sample scenario of how the different strategies could be applied during four main phases of a product's design process. Note that their logical order of use is based on design needs.
Sample Scenario: DfE Strategies and A Product's Design Process Phase Activity DfE Strategies
Idea for a New Analyze, plan, 1. New Concept Development Product develop scope
Conceptual Conceive, create, Apply strategies that affect the entire product Design explore concept: 2. Physical Optimization 7. Optimize End-of-Life Systems
Preliminary Evaluate, select, Apply strategies that affect physical structures: Design develop 4. Optimize Production 5. Optimize Distribution 6. Reduce Impact During Use
Final Design Define, delineate, Apply a strategy that affects components and communicate materials: 3. Optimize Material Use
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http://www.nrc.ca/dfe/ehome/dfestra/dfestraintro/dfestraintro.html (4 de 4) [08/01/2002 05:15:36 p.m.] DfE Strategy 1: New Concept Development
dfe overview DfE Strategy 1: New Concept Development dfe strategies This strategy can lead to revolutionary changes in reducing the environmental overview impact of products and services. It focuses on:
● basic assumptions regarding the function of a product. 1 new concept ● determining the end-users' needs. 1.1 dematerial- ● how the specific product will meet end-users' needs. ization If you wish to apply Strategy 1, you should do so prior to product 1.2 shared use development. Its application may lead you to discovering alternate way to 1.3 provide a service fulfil the needs of users.
2 physical opt. 3 materials 1.1: Dematerialization 4 production 5 distribution 1.2: Increase Shared Use 6 use 7 end-of-life
1.3: Provide a Service getting started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra1/dfestra1.html [08/01/2002 05:16:27 p.m.] Dematerialization
dfe overview 1.1: Dematerialization dfe strategies Dematerialization is the replacement of a physical product with a non-physical overview product or service, thereby 1) reducing a company's production, demand and use of physical products; and 2) the end-user's dependence on physical products. In implementing this strategy, you will realize cost-savings in 1 new concept materials, energy, transportation, consumables and the need to manage the eventual disposal and/or recycling of a physical product. 1.1 dematerial- ization Dematerialization may involve: 1.2 shared use
1.3 provide a service ❍ Making the product smaller and lighter. ❍ Replacing a material product with an immaterial substitute, e.g., mail replaced by E-mail. 2 physical opt. ❍ Reducing the use of material or infrastructure-intensive systems, e.g., 3 materials telecommuting vs. use of automobile for work purposes. 4 production Your designers should conduct an in-depth analysis of end-users' needs to 5 distribution identify the true value or service that a product provides before exploring new 6 use product concepts which may involve immaterial solutions. This strategy often leads to an exploration into 1.2: Increase Shared Use and 1.3: Provide a 7 end-of-life Service as alternative ways to add value for users.
getting started Companies, over a period of time, often make evolutionary changes to their download products within a long-term strategy of dematerialization. acknowl.
Pro Con ● reduced production of ● changes customers' goods perception of the ● savings in energy, product materials, labour ● often provides energy- ● often provides flexible, intensive solutions multifunctional, ● few studies measuring productive solutions environmental improvements
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● E-mail and the Internet are improved communication methods that reduce paper, post and faxes.
● An answering service can substitute for an answering machine, leaving the user with no physical equipment.
● On-line catalogues by retailers, libraries and government departments facilitate public access to goods and services while reducing the dependence on physical filing and storage systems.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra1/dfestra1_1/dfestra1_1.html (2 de 2) [08/01/2002 05:17:12 p.m.] Increase Shared Use
dfe overview 1.2: Increase Shared Use dfe strategies When several people make joint use of a product without actually owning it, overview the product is used more efficiently. Good examples of products that can be shared include equipment such as photocopiers, laundry equipment, hardware and construction tools. 1 new concept 1.1 dematerial- Shared use from the users' perspective: When an organization decides to ization implement "shared use" of a product, it is no longer considered the property of an individual user. Rather, it becomes the property of the organization 1.2 shared use which provides all users with the product. The organization must then 1.3 provide a service manage a limited number of products which are "shared" among users. This often involves developing a new organizational structure.
2 physical opt. Shared use from the suppliers' perspective: Companies who supply 3 materials products that will be "shared" often supply services as well the product, e.g., technical support. (1.3: Provide a Service) As a result, users pay per unit of 4 production service offered by the product rather than for ownership of the product. 5 distribution 6 use The benefits of applying this strategy are: 7 end-of-life ❍ More efficient use of products. ❍ Reduced material (1.1: Dematerialization), energy and transportation getting started costs due to the production and distribution of fewer products. download ❍ Increased ability for manufacturers to track the use and life span of their products. acknowl. ❍ Facilitation of disposal and/or recycling of the product.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra1/dfestra1_2/dfestra1_2.html [08/01/2002 05:17:37 p.m.] Provide a Service
dfe overview 1.3: Provide a Service dfe strategies Companies often find that they can increase profits and add value to their overview product when they focus on selling a service related to the product, rather than selling the product itself. This strategy complements 1.1: Dematerialization and 1.2: Increase Shared Use. 1 new concept 1.1 dematerial- When a company provides a service related to a product, it assumes ization responsibility for maintenance, repair, disposal and/or recycling of the product during its use and end-of-life phases. The system operates on a pay- 1.2 shared use per-unit-of-service basis. 1.3 provide a service When applying this strategy, you: 2 physical opt. ● Will have to undertake an in-depth analysis of users' needs. You are 3 materials likely to find that users are more interested in the value a product 4 production provides than in its physical presence. Providing a service also reduces the user's need to manage the product during its use. 5 distribution ● May have to re-organize your product development and production 6 use from being sales-oriented to being service-oriented. 7 end-of-life ● Will find that you have increased contact with your customers.
The benefits of this strategy are: getting started
download ● A constant stream of information about users' needs and concerns. ● acknowl. The opportunity to respond rapidly to changes in the marketplace. ● More control over product distribution, maintenance, disposal and recycling. ● The opportunity to generate revenue during the product's use and end-of-life phases.
A service model offers companies an opportunity to generate revenue during a product's use and end-of-life phases
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In 1996, Nortel stopped buying component-cleaning chemicals for some of its electronics manufacturing. Rather, it hired the supplier to provide the cleaning service directly in Nortel's production facility. Since the supplier was the "expert" in using its own products, it was able to lessen the amount of chemicals required, thereby lowering Nortel's cost, improving health and safety in the facility, and reducing hazardous waste disposal requirements. Nortel agreed to share the savings realized from this arrangement with the supplier. The supplier now makes more profit despite selling fewer chemicals.
Rental services provide a single piece of equipment, which is often complex or expensive, to multiple users. A well-organized rental service company can maximize the utility and life span of a single unit before the product is no longer usable and, simultaneously, realize a good income from customer use. Good examples of products that are used by rental companies are photocopiers, laundry equipment, hardware and construction tools.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra1/dfestra1_3/dfestra1_3.html (2 de 2) [08/01/2002 05:18:00 p.m.] DfE Strategy 2: Physical Optimization
dfe overview DfE Strategy 2: Physical Optimization dfe strategies This strategy, which is both qualitative and quantitative in nature, covers overview aspects of a product's form, aesthetics and materials as well as the human responses to the product. In some cases, the application of this strategy can 1 new concept lead to significant, if not revolutionary, improvements in environmental aspects of a product. 2 physical opt. The activities in this strategy, while complementing 3: Optimize Material Use 2.1 integrate functions and 4: Optimize Production Techniques, are typically undertaken during the 2.2 optimize functions Conceptual and Preliminary phases of the design process. To follow this 2.3 reliability strategy, you will need an in-depth understanding of the product's position in the market with respect to environmental concerns and a thorough knowledge 2.4 maintenance of user needs. 2.5 modularity 2.6 user relationship This strategy focuses on 1) enhancing a product's function and life span with the added benefit of improving its environmental profile, and 2) designing its physical characteristics, features or components with the aim of increasing 3 materials value for the end-user. The strategy is geared to: 4 production ● Optimizing the product's function. 5 distribution ● Extending the technical life span, i.e., the time during which a product 6 use functions well. ● 7 end-of-life Extending the aesthetic life span, i.e., the time during which a user finds the product attractive.
getting started Designers who balance and optimize the technical and aesthetic life-span download requirements for a product can reduce the energy and materials dedicated to these requirements. In some cases, this may mean designing for a short life acknowl. span; in others, for a longer life span.
● A company may prefer that a product have a shorter life span if, as is the case with engine technology and emissions controls, newer and less energy-intensive alternatives are under development, and the company is confident customers will upgrade or purchase the more efficient products.
● A company will offer a product with a long life span when it is important to the overall economics or use of that product. For example, new high-performance, sealed-glazing window units offer superior energy efficiency and lead to more comfortable indoor living. However, such units are initially higher in cost, and users must be confident they will benefit from a purchase for many years. Therefore, it becomes a priority for the manufacturer to design a system with a long life span and, preferably, back that up with a good guarantee.
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In the early 1990s, a consumer journal rated Sony Europe's TV well below competitors on Environmental Performance. Sony realized that to achieve market leadership, it would have to focus on environmental issues. As one manager put it: "If we fail with the environmental features, we can never reach the Best Buy qualification."
The redesigned TV eliminated hazardous materials, being halogen-free and not using antimony trioxide and PVC. It also had 52 per cent fewer plastics and less total material overall. As well, Sony ensured that the TV could be disassembled quickly, as it now had only nine screws. The result was that its recyclability increased to 99 per cent.
A major plus for Sony was that the TV now costs 30 per cent less to produce and is assembled much faster.
2.1: Integrate Product Functions
2.2: Optimize Product Functions
2.3: Increase Reliability and Durability
2.4: Facilitate Easy Maintenance and Repair
2.5: Modular Product Structure
2.6: Strong User-product Relationship
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2.html (2 de 2) [08/01/2002 05:18:32 p.m.] Integrate Product Functions
dfe overview 2.1: Integrate Product Functions dfe strategies Material and space can be saved when you integrate several functions or overview products into a single product by taking advantage of common components such as power supplies, keypads, structural chassis and displays. 1 new concept
Pro Con 2 physical opt. ● provides customers with ● product increases in complexity 2.1 integrate functions attractive product alternatives ● adds design challenges with ● opens up new markets regard to volume/size, ease of 2.2 optimize functions assembly and ease of use 2.3 reliability 2.4 maintenance
2.5 modularity Manufacturers who produce combination TV-VCR units have 2.6 user relationship found a niche market with people who live in small spaces or require ease of portability.
3 materials 4 production By combining the alternator with the starter motor in new cars, 5 distribution some automobile manufacturers have eliminated the need for 6 use two devices and are contributing to energy efficiency through vehicle "lightweighting." 7 end-of-life
getting started Manufacturers are now combining a printer, fax, scanner and download copier into a single multi-purpose machine. Common acknowl. components such as the printing mechanism, power supply and scanning assembly perform several different functions.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_1/dfestra2_1.html [08/01/2002 05:19:02 p.m.] Optimize Product Functions
dfe overview 2.2: Optimize Product Functions dfe strategies When analyzing a product's primary and secondary functions, designers may overview discover that some components are superfluous. For example, secondary functions such as the quality or status expressed by a product can often be 1 new concept achieved in an improved and less polluting way.
2 physical opt. Stage 1: Ask questions that lead to a better understanding of end-users' purchase decisions and what they consider important in a product. 2.1 integrate functions
2.2 optimize functions ● What are the product's primary functions for users? 2.3 reliability ● What are its secondary functions? ● Are the functions utilitarian or aesthetic in nature? 2.4 maintenance
2.5 modularity Stage 2: Analyze and synthesize the costs of manufacture, materials, 2.6 user relationship processes, assembly, labour and overhead. In this respect, the strategy is similar to value engineering, a branch of industrial engineering that provides a systematic method for studying a product in order to meet its optimum cost. 3 materials 4 production Stage 3: Format the data into an analysis matrix (as shown below)--a technique used by value engineers. In the table: 5 distribution 6 use ● Primary and secondary functions are listed in priority by column. 7 end-of-life ● Individual parts are listed by row. ● Part cost is positioned where function and parts meet in the matrix. getting started This matrix allows designers and engineers to establish the value of each download function and identify the minimal cost required to produce a part in order to acknowl. satisfy the function.
Example of an analysis matrix used in value engineering Primary and Secondary Product Functions
f1.1 f1.2 f1.3 f2.1 f2.2 f3.1 f3.2 Total part cost Prod uct p1.1 Parts by p1.2 Sub - p1.3 Asse mbly p2.1 p2.2
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_2/dfestra2_2.html (2 de 2) [08/01/2002 05:19:12 p.m.] Increase Reliability and Durability
dfe overview 2.3: Increase Reliability and Durability dfe strategies This strategy is not a new one, but is emphasized here because of its overview importance. Designing a product to perform its task in a reliable, consistent manner ensures that it will have a long life span. 1 new concept Reliability and durability are aspects of a product's design that are 2 physical opt. interrelated. To achieve reliability, you must analyze the product's working components that are subject to wear and seek ways to make them more 2.1 integrate functions durable. 2.2 optimize functions 2.3 reliability Durability refers to the ability of the product to withstand the expected demands in the end-users' environments. Housings, controls, connectors and 2.4 maintenance interfaces must be designed in such a way as to withstand continued abuse. 2.5 modularity Designing for durability implies that both technical and aesthetic aspects of the product be taken into consideration. 2.6 user relationship
Product designers and developers can use special methods such as Failure 3 materials Mode and Effect Analysis to improve the reliability and durability of the 4 production products they produce. 5 distribution 6 use 7 end-of-life Textured surface finishes on injection-moulded parts. Benefits include:
getting started ■ Extending the aesthetic life download span of the product. ■ Protecting against acknowl. abrasion. ■ Providing a gripping surface and indicating touch areas. ■ Hiding sink-and-flow marks and blemishes.
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Design for impact resistance in injection moulding.
● Increase impact resistance by spreading the impact load over a large area of a part or product.
● Look for a balance between introducing rigidifying features, e.g., ribs, and the ability of the part to absorb an impact through flexing.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_3/dfestra2_3.html (2 de 2) [08/01/2002 05:19:26 p.m.] Facilitate Easy Maintenance and Repair
dfe overview 2.4: Facilitate Easy Maintenance and Repair dfe strategies Ensuring that a product will be cleaned, maintained and repaired on time will overview increase its usability and life span. 1 new concept User maintenance: Providing easy-to-follow instructions on regular maintenance and simple repairs can reduce the costs associated with 2 physical opt. transport of products for repairs and maintenance. A product's ease of maintenance and repair is often dependent upon its reliability/durability and 2.1 integrate functions the positive attitude of the user to the product. (2.3: Reliability and Durability 2.2 optimize functions and 2.6: Strong User-product Relationship). 2.3 reliability 2.4 maintenance Manufacturer maintenance: When a product is too complex for user maintenance, you should consider: 2.5 modularity
2.6 user relationship ● how the product can be transported to a repair facility. ● The skills and tools required by service personnel. ● The ease or difficulty of disassembling of the product. 3 materials ● Developing a modular structure for the product. (2.5: Modular Product 4 production Structure) 5 distribution 6 use
7 end-of-life Follow these strategies for facilitating repair and maintenance: getting started ■ Indicate clearly on the product how it should be opened download for cleaning or repair (for example, where to apply acknowl. leverage with a screwdriver to open snap connections).
■ Indicate on the product which parts must be cleaned or maintained in a specific way (for example, by colour- coded lubricating points).
■ Indicate on the product any parts or subassemblies that must be inspected often, due to rapid wear.
■ Make the location of wear on the product detectable so that repair or replacement can take place on time.
■ Locate the parts that wear relatively quickly close to one another and within easy reach so that replacements can be easily fitted.
■ Make the most vulnerable components easy to
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dismantle for repair or replacement.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_4/dfestra2_4.html (2 de 2) [08/01/2002 05:19:41 p.m.] Modular Product Structure
dfe overview 2.5: Modular Product Structure dfe strategies A modular structure makes it possible to revitalize a product from a technical overview or aesthetic point of view, enabling the product to keep pace with the changing needs of the end-user. 1 new concept As well, a modular structure allows the benefits of a new technology to be 2 physical opt. incorporated into an older product. As a result, a modular product may undergo several upgrades in components over its life span, reducing the need 2.1 integrate functions for new products to be purchased on a more frequent basis. 2.2 optimize functions 2.3 reliability Designers and product engineers can design product that enable: 2.4 maintenance ● Upgrades at a later date, e.g., plugging in larger memory units in 2.5 modularity computers. 2.6 user relationship ● Renewal of technically or aesthetically outdated elements, e.g., making furniture with replaceable covers that can be removed and cleaned. 3 materials ● Facilitation of repair and maintenance by grouping high-wear 4 production components together into sub-assemblies. (2.4: Facilitate Easy Maintenance and Repair) 5 distribution 6 use 7 end-of-life Can a standard be established? A modular product structure requires the design of a product system or a connection getting started standard between components. If you're considering such an download approach, you should attempt to estimate the technical life span of the underlying system or standard. Questions to ask: acknowl.
● Can the standard be internal to my products? ● Will competitors in the market agree to an industry standard?
However, products undergoing rapid evolution may not be suitable for such an approach.
The 35 mm single lens reflex camera is an excellent example of a modular product structure. Within a particular company's product line, camera bodies, lenses, bellows, flash attachments and filters can be replaced and are often backwards compatible with components manufactured several years, or even decades, before.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_5/dfestra2_5.html (2 de 2) [08/01/2002 05:19:55 p.m.] Strong User-product Relationship
dfe overview 2.6: Strong User-product Relationship dfe strategies Industrial design, or product design, is a process which matches, in a creative overview way, the technologies of production with end-user needs. Good design transcends changes in the technologies of production. On a societal level, 1 new concept however, ideas of good design are dependent on the culture of the time. The challenge for many companies and designers is to create products which users will find attractive to purchase, use and maintain. 2 physical opt.
2.1 integrate function The objective of this strategy is to avoid design that may cause the user to 2.2 optimize function replace the product as soon as the design becomes unfashionable. The psychological life span is the time in which products are perceived and used 2.3 reliability as worthy objects. Products should have the material ability, i.e., technical and 2.4 maintenance aesthetic life span, as well as the immaterial opportunity to age in a dignified 2.5 modularity way. 2.6 user relationship Most products need maintenance and repair to remain attractive and functional. (2.4: Facilitate Easy Maintenance and Repair) Users are only 3 materials willing to spend time on such activities if they care about a product. You can aim to produce a strong user-product relationship by: 4 production 5 distribution ● Creating a design that more than meets the (possibly hidden) 6 use requirements of the user for a long time. ● Designing surface finishes that improve gracefully with age. 7 end-of-life ● Ensuring that maintenance and repair will be pleasurable rather than tedious. ● getting started Ensuring that maintenance can be conducted safely with minimal tools. download ● Providing added value in terms of design and functionality so that the acknowl. user will be reluctant to replace the product.
The Thonet Model No.14 chair has been in production since 1859 with the 50th million model sold circa 1930. The chair is comprised of six bent wood components, 10 screws and two nuts. The Model No.14 chair is an excellent example of a product that has transcended advances in technology and cultural change, and still remains in fashion.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra2/dfestra2_6/dfestra2_6.html (2 de 2) [08/01/2002 05:20:07 p.m.] DfE Strategy 3: Optimize Material Use
dfe overview DfE Strategy 3: Optimize Material Use dfe strategies Use of environmentally hazardous materials involves costs for health and overview safety, handling and waste disposal. This strategy focuses on selecting the most environmentally appropriate materials, substances and surface 1 new concept treatments for product manufacture. 2 physical opt. When applying this strategy, you will find that it depends largely on product characteristics and life cycle, and that there can be many trade-offs when 3 materials making decisions regarding materials selection. Here are some factors to 3.1 cleaner materials consider: 3.2 renewable materials ● Whether materials can be recycled. 3.3 lower embodied ● The priority of material recycleability for short-lived products as energy materials compared to long-lived products. 3.4 recycled materials 3.5 recyclable ● Whether products that consume energy during their use-phase can be materials "lightweighted" to reduce energy demand. 3.6 reduce material ● If products that disperse or wear out need to be recycled as compared usage to products that can be easily collected at their end-of-life-phase.
4 production ● If you have a system where product disposal is important, how will 5 distribution material chemistry impact the environment and human health through traditional disposal methods. 6 use 7 end-of-life Life Cycle Assessment(LCA) is a method that provides companies with useful tools for determining how to make decisions based on these factors and trade- offs. ISO 14040 is the international standard for LCA, which evaluates the getting started environmental- and resources-loading associated with products. download acknowl. Kuntz Electroplating Inc., an Ontario company, designed a Cyanide Hydrolysis System(CHS) to destroy their hazardous chemicals in an environmentally safe and cost-effective manner. As a result, Kuntz has significantly reduced the use of sodium hypochlorite, caustic soda, hydrochloric acid and chlorine. The new system also reduces the amount of required labour. CHS has saved Kuntz $150,000 annually.
3.1: Cleaner Materials
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3.2: Renewable Materials
3.3: Lower "Embodied Energy" Materials
3.4: Recycled Materials
3.5: Recyclable Materials
3.6: Reduce Material Usage
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dfe overview 3.1: Cleaner Materials dfe strategies Some materials or additives are best avoided because they cause hazardous overview emissions during production, when they are incinerated, or if they are used as landfill. Examples are: 1 new concept
2 physical opt. ● colourants ● heat or UV stabilizers ● fire retardants 3 materials ● degreasers 3.1 cleaner materials ● softening agents ● fillers 3.2 renewable ● foaming agents materials ● antioxidants 3.3 lower embodied energy materials Some colourants and fire-retardants are especially hazardous and, in many 3.4 recycled materials countries, are restricted by law. 3.5 recyclable materials 3.6 reduce material Alert: toxic materials. Many substances that contribute to usage ozone layer depletion are now forbidden or restricted such as methyl bromide, halons, CFCs and HCFCs. Many large corporations are practising materials de-selection by developing 4 production their own lists of substances banned from internal use such as 5 distribution mercury, lead, VOCs and PVC. This practice is a growing trend and has a direct impact on suppliers. 6 use 7 end-of-life
getting Started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_1/dfestra3_1.html [08/01/2002 05:21:08 p.m.] Renewable Materials
dfe overview 3.2: Renewable Materials dfe strategies Renewable materials are substances derived from a living tree, plant, animal overview or ecosystem which has the ability to regenerate itself. 1 new concept The use of renewable materials can represent a good environmental and 2 physical opt. societal choice since these materials:
● 3 materials Will not be depleted if managed properly as a renewable resource. ● May have reduced net emissions of CO2 across their life cycle as 3.1 cleaner materials compared to materials derived from fossil fuels. 3.2 renewable ● Result in biodegradable waste. materials ● Can be grown and used locally--a situation that promotes employment. 3.3 lower embodied energy materials However, when considering the use of a renewable material, you should 3.4 recycled materials assess its full environmental impact. For instance, the plastic sack may be a 3.5 recyclable better environmental choice than one made of paper. In a life-cycle analysis, a materials factor that becomes important is the superior ratio of strength to weight of plastics that leads to lower energy requirements and costs for transport. 3.6 reduce material usage If you are interested in using more renewable materials in your product, check your suppliers' product labels to see if you can find out: 4 production ● The quality and consistency of organic materials that are sourced from 5 distribution renewable stocks. 6 use ● If the materials have been harvested and the stocks managed in an 7 end-of-life environmentally preferable manner.
getting Started Products like oriented strand board (OSB) are enabling builders download to make better use of the renewable resource of wood than they acknowl. have in the past. Waste is virtually eliminated in the OSB production phase with 90 per cent of the wood incorporated directly and 10 per cent used as an energy source. The wood strands are combined with a resin binder and put under intense pressure and heat to form structural panels. The phenol- formaldehyde resins lead to extremely low levels of off-gassing. Indoor air quality problems that have been associated with wood products using urea-formaldehyde binders are thus avoided.
Other combinations of resin, wood fibre and maize fillers have been used in injection-moulding processes for products such as door handles, latches and decorative details. Researchers are now conducting studies to explore better ways of using lignin, a
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natural binding agent in trees.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_2/dfestra3_2.html (2 de 2) [08/01/2002 05:21:17 p.m.] Lower "Embodied Energy" Materials
dfe overview 3.3: Lower "Embodied Energy" Materials dfe strategies The embodied energy of a material refers to the energy used to extract, overview process and refine it before use in product manufacture. Therefore, a correlation exists between the number and type of processing steps and the 1 new concept embodied energy of materials. For example, the fewer and simpler the 2 physical opt. extraction, processing and refining steps involved in a material's production, the lower its embodied energy. The embodied energy of a material is often reflected in its price. 3 materials 3.1 cleaner materials In some cases, the most technically appropriate material will lower energy costs over the life cycle of a product. For example, composite materials 3.2 renewable involving carbon fibres or ceramic compounds may have a relatively high materials embodied energy, but when they are used appropriately, they can save 3.3 lower embodied energy in a product's use-phase due to their advanced physical properties, energy materials e.g., strength, stiffness, heat or wear resistance. 3.4 recycled materials On the other hand, materials with less embodied energy may often be 3.5 recyclable substituted without a loss in product performance, if you optimize the use of materials the material with respect to the product's reliability/durability and 3.6 reduce material technical/aesthetic functions. ( 2: Physical Optimization) usage
4 production 5 distribution 6 use 7 end-of-life
getting started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_3/dfestra3_3.html [08/01/2002 05:21:27 p.m.] Recycled Materials
dfe overview 3.4: Recycled Materials dfe strategies This strategy focuses on production use of recycled materials, i.e., those used overview in products before. If suitable, companies can use and re-use these materials in order to maximize invested resources. 1 new concept 2 physical opt. Recycling provides cost-benefits, can enhance product production, and is an excellent environmental choice. 3 materials ● By implementing product take-back programs, companies have a cost- 3.1 cleaner materials effective source of materials and/or parts. 3.2 renewable ● Using recycled materials can lower the embodied energy needed to materials produce a product by avoiding the energy costs associated with extraction. (3.3: Lower "Embodied Energy" Materials) 3.3 lower embodied ● Unique features of recycled materials such as variations in colour and energy materials texture can be advantageous when used appropriately in product 3.4 recycled materials production. This can include using recycled paper, steel, aluminum, other metals and plastics. 3.5 recyclable materials There are two sources for recycled materials. 3.6 reduce material usage 1. Industrial off-specification material generated from an industrial process, and not used. 4 production 2. Post-consumer material recovered after use from an industrial or 5 distribution domestic setting. This material is typically collected, sorted and 6 use cleaned, but may still be contaminated by foreign material. 7 end-of-life Currently, many recycled materials come from industrial sources and have minimal impurities and only slightly inferior properties to the originals. getting started Nevertheless, if you decide to use recycled materials, you should: download ● Specify the required performance properties of the recycled material to acknowl. control the physical characteristics. ● Establish a quality assurance requirement with your supplier regarding recycled material. ● Be aware that the cost of recycled materials depends on their source, percentage of virgin material content, level of contamination and physical characteristics.
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Some guidelines for designing with recycled plastics.
1. Specify thicker walls or features that enhance rigidity in a design where increased strength must compensate for reduced strength in material.
2. Select applications where colour is not critical when recycled plastics come with a variety of colourants. Additional colourants may mask the original colour of the material.
3. Select processes that have a wide "operating window," i.e., the production parameters do not have to be tightly specified for successful manufacturing. Of the processes generally in use today, the most forgiving would be compression moulding, injection moulding, and extrusion. Other processes could be used if the behaviour of the material is comparable to that of suitable grades of new plastics.
4. Apply specialized processing methods that allow significant quantities of recycled plastics to be used successfully.
● Co-extrusion--this process, which can be used in sheet, film and blow-moulding operations, makes a multi- layered product that can have a middle layer of recycled plastics sandwiched between layers of new plastic.
● Sandwich Injection Moulding--this is a similar technique to co-extrusion in which recycled plastics are injected as the bulky core of thick-walled plastic products and new plastic is used only for the outer skin.
● Foamed Extrusion and Foamed Injection Moulding-- these techniques use gases to form bubbles in plastics that reduce the weight of thick-walled products and produce a textured skin on the surface. They provide good rigidity through enlarged thickness.
● Extrusion and Injection Moulding of Mixed Plastics-- these processes provide good potential for the use of recycled material because they eliminate the need for sorting or cleaning prior to processing. However, the products may have limited strength due to the incompatibility of different plastics and the contaminants. These processes usually use polyethylene as a "binder" for the other plastics and contaminants, thereby tending to limit a product's physical characteristics to those of polyethylene, i.e., generally low in rigidity and strength, and prone to display "creep" behaviour. As well, the colour is usually http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_4/dfestra3_4.html (2 de 3) [08/01/2002 05:21:42 p.m.] Recycled Materials
dark due to the variety of incorporated colourants.
Adapted from Design for Plastics Recycling, Centre for Design at RMIT, Australia and the Plastics Industry Association, April 1991.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_4/dfestra3_4.html (3 de 3) [08/01/2002 05:21:42 p.m.] Recyclable Materials
dfe overview 3.5: Recyclable Materials dfe strategies Recyclable materials are those that can be easily recycled, depending on the overview type of material and the available recycling infrastructure. Reducing the amount of waste your company sends to landfill can produce significant cost- 1 new concept savings. Or, your waste materials could be a source of income. 2 physical opt. If you wish to use recyclable materials, you need to: 3 materials ● Know which materials are recyclable. 3.1 cleaner materials ● Find out if collection systems are in place or anticipated. 3.2 renewable ● Ensure the material will produce high-quality material when recycled. materials Product design can make a significant contribution to recyclability. Here are 3.3 lower embodied some criteria to follow: energy materials 3.4 recycled materials ● Select just one type of material for the product as a whole or for each 3.5 recyclable sub-assembly. materials ● If selecting one type of material is not practical, select plastics in mutually compatible groups, i.e., SAN, ABS, PC, PMMA; PC, PET; or 3.6 reduce material PVC, SAN, PMMA. usage ● Don't cross-contaminate metals, e.g., mixing steel components with copper; aluminum with copper or iron; or copper with mercury or beryllium. 4 production ● To aid recycling, avoid materials which are difficult to separate such as 5 distribution compound materials, laminates, fillers, fire-retardants and fibreglass reinforcements. 6 use ● Choose recyclable materials for which a market already exists. 7 end-of-life ● Avoid polluting elements such as stickers that interfere with recycling, or glues and small components that are not removable. getting started download Fir Tree Farm in Nova Scotia prepares packaged vegetables for acknowl. "ready meals." This produces a large amount of organic and packaging waste. By separating and recycling all cardboard, as well as selling organic waste as pig and cattle feed, Fir Tree Farm now saves over $3,000 each month in landfill fees.
Canadian General-Tower Limited (CGT), a vinyl manufacturer in Ontario, is using recyclable materials in two ways--one, as a source of income, and two, as a source of savings. In 1996, CGT sold more than 950,000 kg of pool vinyl to a local company, Norwich Plastics. In the same year, CGT reprocessed 1.8 million kg back into their own vinyl production, saving thousands of dollars and benefitting the environment.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_5/dfestra3_5.html (2 de 2) [08/01/2002 05:21:58 p.m.] Reduce Material Usage
dfe overview 3.6: Reduce Material Usage dfe strategies This strategy focuses on optimizing the volume and weight of materials so overview less energy is used during production, transport and storage. This strategy can improve the productivity of your material resources and save on raw 1 new concept material consumption and transportation costs. 2 physical opt. Products are often deliberately designed to be heavy or large in order to project a quality image. However, a quality image can be achieved through 3 materials other techniques, i.e., creating a lean but strong design. While products 3.1 cleaner materials cannot be made so light that their technical life is affected, you many find that, in many cases, a reduction in the weight or volume of materials is possible. 3.2 renewable materials Reduction of weight: Using less material is a simple, direct means to 3.3 lower embodied decrease environmental impact, i.e., fewer resources extracted, less waste energy materials and lower environmental-loadings during transportation. If you are interested 3.4 recycled materials in reducing material usage, you should closely scrutinize appropriate materials and design, e.g., reinforcing ribs instead of using thick-walled 3.5 recyclable components. Weight reduction can significantly lower material use and costs. materials 3.6 reduce material Reduction in (transport) volume: When a product and its packaging are usage reduced in size and volume, more products can be shipped more efficiently in a given transport mode. Consider foldable or stackable designs and final product assembly at the retail location or by the end-user. 4 production 5 distribution
6 use S.C. Johnson Wax has saved over $5 million by "lightweighting" 7 end-of-life its candle and aerosol products. It reduced the weight of its Glade candles by six per cent, decreasing material use by
1,536 tons and increasing shipping efficiency without a getting started reduction in the life or quality of the candles. As well, it reduced download the amount of material used in its aerosol products, cutting plastic use by 1,200 tons and packing material by 600 tons. acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra3/dfestra3_6/dfestra3_6.html [08/01/2002 05:23:49 p.m.] DfE Strategy 4: Optimize Production Techniques
dfe overview DfE Strategy 4: Optimize Production Techniques dfe strategies This strategy include approaches to production that involve practices for overview "cleaner" production, i.e., the continuous use of industrial processes and products to increase efficiency, prevent pollution to all media (air, water and 1 new concept land), and to generally minimize risk to human health and the environment. 2 physical opt. 3 materials To accomplish cleaner production, you need to adopt a goal to make your processes as environmentally benign as possible. Production techniques should: 4 production 4.1 production ● Minimize the use of ancillary materials and energy. techniques ● Avoid hazardous compounds. ● Provide high efficiency production with low material losses. 4.2 production steps ● Generate as little waste as possible. 4.3 energy consumption Process improvements are an effective strategy to reduce pollution and can 4.4 production waste provide many cost-benefits by: 4.5 consumables ● Improving efficiency and reducing costly production downtime. ● Increasing regulatory compliance and reducing fines. 5 distribution Improving production processes is a key component of Environmental 6 use Management Systems like ISO 14001 which, although a voluntary program, 7 end-of-life requires organizations to make specific commitments to preventing pollution.
This strategy can be applied both to the production processes of the parent getting started company and its suppliers. In fact, many companies now insist that suppliers download have an Environmental Management System (EMS) registered to the ISO acknowl. 14001 standard.
4.1: Alternative Production Techniques
4.2: Fewer Production Steps
4.3: Lower/Cleaner Energy Consumption
4.4: Less Production Waste
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4.5: Fewer/Cleaner Production Consumables
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dfe overview 4.1: Alternative Production Techniques dfe strategies Implementing an Environmental Management System (EMS) provides an overview effective way to examine an existing production system and pinpoint areas where changes could be made to bring about positive environmental benefits, 1 new concept compliance with environmental regulations and cost-savings.(Environmental 2 physical opt. Management System) 3 materials Alternative, cleaner production techniques can help you realize the benefits of process optimization, quality control, energy conservation and preventive 4 production management. It can also lower energy and costs associated with: 4.1 production techniques ● raw materials ● energy 4.2 production steps ● labour 4.3 energy ● treatment and disposal consumption ● insurance and liability 4.4 production waste 4.5 consumables Jenks & Cattell Engineering Limited, a small enterprise in England, manufactures pressings and welded assemblies for 5 distribution the automotive industry. During an environmental review of 6 use company processes in 1993, Jenks & Cattell managers decided to replace the solvent degreasing agent 1,1,1-trichloro- 7 end-of-life ethane, thereby significantly reducing the environmental impact as well as their costs by more than $20,000 per year. Jenks & getting Started Cattell went on to implement EMS and use the principles of cleaner production. The company saved more than $150,000 download annually by using material resources more effectively and acknowl. reducing energy use, solvent emissions and neighbourhood noise.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra4/dfestra4_1/dfestra4_1.html [08/01/2002 05:24:44 p.m.] Fewer Production Steps
dfe overview 4.2: Fewer Production Steps dfe strategies Each step of a production process increases financial costs and may also overview increase the environmental impact. The optimization of product production with respect to steps, techniques and processes should be undertaken by a 1 new concept team of product designers, industrial and mechanical engineers, and 2 physical opt. production personnel. The team should analyze the following: 3 materials ● The possibility of satisfying several product functions through one component or part. 4 production ● Allowing multiple production steps to be performed on a single part or component simultaneously. 4.1 production ● Allowing single production steps to be performed on multiple parts or techniques components simultaneously. 4.2 production steps ● Reducing the movement/transport distances of parts and components within the production facility. 4.3 energy ● Using materials that do not require additional surface treatment or consumption finishing for performance or aesthetics. 4.4 production waste 4.5 consumables
5 distribution 6 use 7 end-of-life
getting Started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra4/dfestra4_2/dfestra4_2.html [08/01/2002 05:24:51 p.m.] Lower/Cleaner Energy Consumption
dfe overview 4.3: Lower/Cleaner Energy Consumption dfe strategies This strategy focuses on making production processes more energy efficient. overview 1 new concept Your company can implement rewards-and-recognition policies to motivate employees to generate energy-saving ideas. Have them explore how to: 2 physical opt
3 materials ● Use cleaner energy sources such as natural gas, wind, hydro or solar energy, in order to replace existing sources that are more polluting or inefficient. 4 production ● Introduce a co-generation system that uses production by-products, 4.1 production e.g., steam or heat, to provide heating, cooling or compressed air. techniques ● Examine carefully the heating/ventilation/energy needs and set up systems and controls tailored to those needs. 4.2 production steps ● Increase efficiency of compressed air systems. 4.3 energy ● Optimize the facility's space requirements. consumption 4.4 production waste 4.5 consumables
5 distribution 6 use 7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra4/dfestra4_3/dfestra4_3.html [08/01/2002 05:25:03 p.m.] Less Production Waste
dfe overview 4.4: Less Production Waste dfe Strategies In applying this strategy, you would be optimizing production processes with overview respect to the output of waste and emissions. This optimization increases the efficiency of material use and decreases the amount of material sent to a 1 new concept landfill by reducing the "non-product output" per unit of production. To achieve 2 physical opt. this goal, consider: 3 materials ● Selecting shapes that eliminate processes such as sawing, turning, milling, pressing and punching in order to reduce waste. 4 production ● Motivating production teams and suppliers to reduce waste and cut the percentage of rejects. 4.1 production ● Looking for opportunities to recycle production residues in-house--a techniques process that saves resources and money. Relatively simple changes 4.2 production steps with little cost-output can save your company thousands of dollars a year. 4.3 energy consumption 4.4 production waste 4.5 consumables Entek International Ltd., a company based in Oregon and the UK, produces microporous polyethylene battery separator materials. Entek purchased a machine for $250,000 to 5 distribution granulate its plastic waste, which could then be re-used in the company's manufacturing process. As a result, Entek is saving 6 use over $100,000 each month--more than $1 million per year--in 7 end-of-life reduced landfill, labour and raw material costs. Their granulator paid for itself in three months.
getting Started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra4/dfestra4_4/dfestra4_4.html [08/01/2002 05:25:14 p.m.] Fewer/Cleaner Production Consumables
dfe overview 4.5: Fewer/Cleaner Production Consumables dfe strategies This strategy focuses on reducing the production consumables or ancillary overview materials required for product production and/or using "cleaner" ones. 1 new concept When applying this strategy, have your designers and production and 2 physical opt. industrial engineers conduct an analysis of consumables in the production 3 materials process. The use of water, solvents, degreasers, oil/lubricants, abrasives, solders and cutting tools can be correlated with per unit production.
4 production Designers should specify materials/parts/components that are also cleaner 4.1 production and non-hazardous. For example, identifying and using solvents, lubricants techniques or degreasers with low volatile organic compounds (VOCs) can reduce the use of ventilation systems and/or pollution prevention equipment. 4.2 production steps 4.3 energy Together with reducing waste during production and establishing in-house consumption recycling programs, the re-design of parts/components is an effective 4.4 production waste means of reducing the use of production consumables. 4.5 consumables The major benefits of using fewer/cleaner production consumables are reductions in: 5 distribution ● Production costs. 6 use ● Material storage/handling requirements and costs. 7 end-of-life ● Costs involved in the disposal of hazardous consumable waste. ● Raw materials/consumables. ● Need/use of ventilation equipment and costs of maintenance. getting Started ● Equipment, e.g., ducts, motors, balancing. download ● Operating costs. ● Need for pollution prevention equipment. acknowl. ● Health and safety costs, e.g., worker training and protective equipment. ● Costs of regulatory compliance.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra4/dfestra4_5/dfestra4_5.html [08/01/2002 05:25:22 p.m.] DfE Strategy 5: Optimize Distribution Systems
dfe overview DfE Strategy 5: Optimize Distribution Systems dfe strategies Application of this strategy ensures that products are transported from the overview producer to the distributor, retailer and end-user in the most efficient manner possible. The factors involved in optimization include: 1 new concept
2 physical opt. ● packaging 3 materials ● mode of transport ● mode of storage/handling 4 production ● logistics
5 distribution If you decide to apply this strategy, you should consider product development separately from packaging development since packages have their own life 5.1 packaging cycles and associated environmental impacts. 5.2 transport mode 5.3 logistics You can also apply other DfE Strategies to packaging development and use. (3: Optimize Material Use, 4: Optimize Production, 7: Optimize End-of-Life
Systems) 6 use 7 end-of-life
5.1: Less/Cleaner/Re-usable Packaging getting started download acknowl. 5.2: Energy-efficient Transport Mode
5.3: Energy-efficient Logistics
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra5/dfestra5.html [08/01/2002 05:25:32 p.m.] Less/Cleaner/Re-usable Packaging
dfe overview 5.1: Less/Cleaner/Re-usable Packaging dfe strategies This strategy focuses on reducing packaging for marketing and transport overview purposes, resulting in less waste, less energy for transport, less emissions and greater savings. By reducing the amount and weight of packaging, your 1 new concept company can save on landfill and resources. 2 physical opt. 3 materials Here are some ideas for applying this strategy. 4 production ● If your packaging provides aesthetic appeal to your product, use an attractive but lean design to achieve the same effect. 5 distribution ● For transport and bulk packaging, consider re-usable materials in combination with a return system between yourself and the retailer 5.1 packaging and, if possible, between the retailer and end-user. Consider a 5.2 transport mode package deposit/refund to encourage use of this system. ● Use appropriate materials, e.g., recyclable materials for non- 5.3 logistics returnable packaging, and more durable materials for returnable packaging. 6 use ● Reduce volume, e.g., providing foldability and nesting of products by using a modular structure. (2: Physical Optimization) 7 end-of-life ● Encourage your suppliers to also reduce their packaging waste.
getting started download In the early 1990s, Nissan had its suppliers become acknowl. accountable for their own packaging waste. By 1996, over 97 per cent of 9,750 parts arriving at one of the company's plants came in re-usable containers. This not only saved Nissan and its suppliers money, but also eliminated waste entirely instead of redirecting it into recycling.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra5/dfestra5_1/dfestra5_1.html [08/01/2002 05:25:41 p.m.] Energy-efficient Transport Mode
dfe overview 5.2: Energy-efficient Transport Mode dfe strategies The environmental impact of product transport comes primarily from energy overview consumed and air pollutant emissions. A consideration of this impact is important in a full-company program of environmental responsibility. As well, 1 new concept choosing energy-efficient transport can directly affect your bottom line as it will 2 physical opt. make your company more resilient to energy price fluctuations. 3 materials When deciding how to ship your products, consider many factors such as: 4 production
● price 5 distribution ● volume ● reliability 5.1 packaging ● time to delivery 5.2 transport mode ● distance to customer ● environmental impact 5.3 logistics
Have your designers, shipper/receivers and sales personnel compare the 6 use various modes of transport, i.e., foot, bicycle, courier, truck, rail, sea, air, with 7 end-of-life the above factors to determine the most appropriate mode of product transport.
getting started Also investigate your suppliers' modes of transport for materials and download components. Your costs can be reduced if energy-efficient modes are used throughout the supply, production and distribution chain. acknowl.
Fuel-efficient fleet operations.
❍ Install fuel-efficient computerized diesel engines to lower maintenance and operating costs. ❍ Specify fuel-efficient vehicles. ❍ Perform regular maintenance to reduce emissions. ❍ Convert your fleet to alternative fuels such as propane, natural gas or bi-fuel, e.g., gasoline/natural gas. ❍ Install on-board computers to help reduce fuel wastage by controlling idling speed and setting upper-speed limits. ❍ Install an on-site vehicle refueling service to reduce fuel costs and enhance fleet efficiency.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra5/dfestra5_2/dfestra5_2.html (2 de 2) [08/01/2002 05:25:55 p.m.] Energy-efficient Logistics
dfe overview 5.3: Energy-efficient Logistics dfe strategies Efficient routing of transportation and distribution can significantly reduce the overview environmental impact of a company's logistics system. You might consider the following: 1 new concept
2 physical opt. ● Motivate your sales personnel to work with local suppliers to avoid 3 materials longer product-transport distances. ● Motivate your sales personnel to introduce efficient forms of 4 production distribution, e.g., the simultaneous distribution of larger amounts of different goods. ● Use standardized transport and bulk packaging, e.g. industry-standard 5 distribution pallets, boxes or bags. 5.1 packaging ● Use route-optimization software to reduce product-transport distances. ● 5.2 transport mode If you are a just-in-time supplier, provide re-useable/returnable containers designed for your products. 5.3 logistics ● Reduce warehouse distance--from storage to loading--for high- turnaround products. 6 use 7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra5/dfestra5_3/dfestra5_3.html [08/01/2002 05:26:09 p.m.] DfE Strategy 6: Reduce Impact During Use
dfe overview DfE Strategy 6: Reduce Impact During Use dfe strategies Many products consume considerable energy, water and/or other overview consumables during their life span. Resources consumed in maintenance and repair can add to the environmental impact. This strategy focuses on product 1 new concept design to reduce environmental impact during product use. 2 physical opt. 3 materials 4 production 6.1: Lower Energy Consumption 5 distribution
6 product use 6.2: Cleaner Energy Sources 6.1 energy consumption 6.2 cleaner energy 6.3: Reduce Use of Consumables 6.3 reduce consumables 6.4 cleaner 6.4: Cleaner Consumables and Auxiliary Products consumables 6.5 reduce waste 6.5: Reduce Energy and Other Consumable Waste 7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6.html [08/01/2002 05:26:17 p.m.] Lower Energy Consumption
dfe overview 6.1: Lower Energy Consumption dfe strategies The goal of this strategy is to achieve energy efficiency and/or the use of overview more environmentally responsible energy sources during product use. 1 new concept It's important! Environmental analyses of durable products such as 2 physical opt. refrigerators and washing machines show that the largest environmental 3 materials impacts can come during the use-phase of a product's life cycle. As a result, the operational costs over the product's lifetime can often exceed the initial 4 production purchase price. When users are made aware of the importance of these costs 5 distribution through programs like EnerGuide, then energy efficiency becomes a strong marketing feature. 6 product use Energy efficiency can also lead to reduced fossil fuel consumption, thereby 6.1 energy lowering emissions of greenhouse gases and chemical contributors to acid consumption rain. 6.2 cleaner energy 6.3 reduce consumables Design strategies for energy-reducing products. 6.4 cleaner consumables ● Use the lowest energy-consuming components 6.5 reduce waste available. ● Design a default power-down mode and promote this function. 7 end-of-life ● Ensure that users can switch off clocks, stand-by functions and other non-required devices. ● Choose light-weight materials and designs if energy is getting started required to move the product. ● download If energy is used for heating or cooling, 1) ensure that appropriate components are well insulated, and 2) acknowl. consider if user-needs can still be met without such energy use. ● Consider the possibility for human-powered alternative designs. ● Consider possibilities for passive solar heating and rechargeable batteries.
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The Baylis FreePlay Wind Up Radio was intended initially for people in developing countries where affordable energy is scarce or non-existent. It was designed for recyclability; its materials have a low impact on the environment; and its production minimizes manufacturing waste. But the radio has also found many other applications for remote-location activities such as logging, boating and hiking. The radio uses strip steel springs as the primary energy storage device to drive a direct current generator. The spring maintains its performance characteristics over many years with a lifetime in excess of 10,000 cycles.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6_1/dfestra6_1.html (2 de 2) [08/01/2002 05:26:35 p.m.] Cleaner Energy Sources
dfe overview 6.2: Cleaner Energy Sources dfe strategies The use of clean energy sources can greatly reduce harmful emissions at the overview energy-generation stage, especially for energy-intensive products. This strategy, aimed at increasing the use of cleaner energy sources, should be 1 new concept applied in conjunction with 6.1: Lower Energy Consumption. 2 physical opt. 3 materials It may be that your source of energy for product manufacture is predetermined by context and market. However, if you do have a choice of a 4 production cleaner energy source such as electricity or natural gas, you should consider 5 distribution the following:
● Design products to use the least harmful source of energy. 6 product use ● Design high-efficiency alternatives when the least harmful source of 6.1 energy energy is not available in the target market or available at the consumption preferred manufacturing location. (6.1: Lower Energy Consumption) 6.2 cleaner energy ● For large industrial products or machinery, encourage the use of cleaner energy such as low-sulfur energy sources, i.e., natural gas 6.3 reduce and low-sulfur coal, fermentation, wind energy, hydro-electric power, consumables solar energy and on-site co-generation from waste heat or steam. 6.4 cleaner consumables 6.5 reduce waste
7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6_2/dfestra6_2.html [08/01/2002 05:26:50 p.m.] Reduce Use of Consumables
dfe overview 6.3: Reduce Use of Consumables dfe strategies This strategy focuses on applications of design that will lead to lower, or more overview efficient, use of consumables such as water, oil, filters, cleaners/detergents and food/organic materials during a product's life span. 1 new concept 2 physical opt. Reducing the need for, and use of, consumables can increase maintenance 3 materials intervals for the product, reduce operating costs, and improve user satisfaction. This strategy should be applied along with 2: Physical 4 production Optimization. 5 distribution
6 product use Design for less. 6.1 energy consumption ● Design the product to minimize the use of auxiliary 6.2 cleaner energy materials, e.g., use a permanent filter in coffee makers 6.3 reduce instead of paper filters, and use the correct shape of consumables filter to ensure optimal use of coffee. ● Minimize possible leaks from machines that use high 6.4 cleaner volumes of consumables by, for example, installing a consumables leak detector. 6.5 reduce waste ● Study the feasibility of re-using consumables, e.g., newer dishwashers re-circulate some wash water to reduce total water usage. 7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6_3/dfestra6_3.html [08/01/2002 05:26:59 p.m.] Cleaner Consumables and Auxiliary Products
dfe overview 6.4: Cleaner Consumables and Auxiliary Products dfe strategies If a consumable/auxiliary product is to become "cleaner," it should be overview regarded as an individual product with its own life cycle. DfE strategies can then be applied separately for each consumable/auxiliary product, particularly 1 new concept in regard to: 2 physical opt. 3 materials ● material (3: Optimize Material Use) ● production (4: Optimize Production) 4 production ● use (6.3: Reduce Use of Consumables) 5 distribution ● end-of-life phase (7: Optimize End-of-Life Systems)
6 product use Designers and suppliers should collect information on the environmental impact of possible consumables/auxiliaries in order to make informed 6.1 energy decisions. Specifying cleaner use can have the following benefits: consumption
6.2 cleaner energy ● Increased product safety. 6.3 reduce ● Reduced handling of hazardous/dangerous materials. consumables ● Reduced disposal costs of hazardous/dangerous materials. ● Greater environmental appeal to users, resulting in more sales. 6.4 cleaner ● Development of stronger customer relationships. consumables 6.5 reduce waste Some factors to consider when applying this strategy:
● Implementing a collection/recycling/re-manufacturing system to 7 end-of-life eliminate disposal of filters, cartridges and dispensers in landfill or incineration facilities. ● getting started Being aware of the possibility of harmful wastes being produced as a result of using inferior consumables, e.g., low quality oil or coolants in download engines can affect performance, emissions and efficiency. acknowl.
Black & Decker Canada has an ongoing pilot program in Ontario to provide a recycling system for its rechargeable appliances and reduce the impact of contamination from its NiCd batteries. The program gives users a rebate towards their next purchase when they bring unwanted appliances back to their dealer for re-use. They also receive the rebate if they bring their appliance back to have batteries replaced. The program diverted over 127 tonnes of waste from landfill in its first year of operation alone.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6_4/dfestra6_4.html (2 de 2) [08/01/2002 05:27:10 p.m.] Reduce Energy and Other Consumable Waste
dfe overview 6.5: Reduce Energy and Other Consumable Waste dfe strategies There is often a gap between the manufacturer's intended use and overview maintenance of a product and what actually happens when it's in the hands of end-users. This gap can result in waste. 1 new concept 2 physical opt. This strategy focuses on designs that foster proper product use. 3 materials 4 production ● Design for easy-to-understand use and Provide clear instructions. ● Design so that users cannot waste auxiliary materials, e.g., funnel- 5 distribution shaped filling inlets, and spring return or auto-off power switches. ● Place calibration marks so that users know exactly how much auxiliary/consumable material, e.g., detergent or lubricant oil, is 6 product use required. 6.1 energy ● Make the default position or state-of-the-product the one that is most consumption desirable environmentally, e.g., power-down or stand-by modes. 6.2 cleaner energy Related strategies are 2: Physical Optimization and 6.1: Lower Energy 6.3 reduce Consumption. consumables 6.4 cleaner consumables 6.5 reduce waste
7 end-of-life
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra6/dfestra6_5/dfestra6_5.html [08/01/2002 05:27:17 p.m.] DfE Strategy 7: Optimize End-of-Life Systems
dfe overview DfE Strategy 7: Optimize End-of-Life Systems dfe strategies This strategy is aimed at re-using valuable product parts/components and overview ensuring proper waste management at the end of a product's useful life. Optimized end-of-life systems can reduce environmental impacts through 1 new concept reinvestment of the original materials and energy used in manufacturing. 2 physical opt. 3 materials Companies should consider various end-of-life scenarios. The questions, listed here in order of most favourable to least favourable in terms of 4 production environmental impact, can help you determine how to optimize the end of a 5 distribution product's life. 6 product use ● Can the product/components/parts be reused?
● Can parts/components be remanufactured and then re-used? 7 end-of-life ● Can parts be used for material recycling? ● Can parts be safely incinerated? 7.1 re-use ● Should parts be disposed of in landfill? 7.2 disassembly 7.3 re-manufacturing 7.4 recycling 7.1: Re-use of Product 7.5 safer incineration
getting started 7.2: Design for Disassembly download acknowl. 7.3: Product Re-manufacturing
7.4: Material Recycling
7.5: Safer Incineration
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra7/dfestra7.html [08/01/2002 05:27:41 p.m.] Re-use of Product
dfe overview 7.1: Re-use of Product dfe strategies This strategy focuses on re-use of the whole product, either for the same overview application or a new one. The more the product retains its original form, the more environmental merit is achieved, provided that take-back programs ( 1 new concept 7.3: Product Re-manufacturing) and recycling systems (7.4: Material 2 physical opt. Recycling) are developed simultaneously. 3 materials 4 production The benefits of this strategy include: 5 distribution ● Greater environmental appeal for end-users. 6 product use ● Increase in sales. ● Cost-savings. 7 end-of-life The possibilities for re-use are dependent upon the following: 7.1 re-use
7.2 disassembly ● The product's technical, aesthetic and psychological life span. ● 7.3 re-manufacturing A secondary market willing to accept used products. ● A repair and maintenance infrastructure. 7.4 recycling 7.5 safer incineration When applying this strategy, products should be designed:
● With appropriate technical and aesthetic life spans in mind. getting started ● To be pleasing/useful for successive users in order to maximize life download spans. acknowl. ● To use quality components and reliable technology that will not become prematurely obsolete and will, therefore, contribute to maintaining value. ● To contribute to ease of cleaning, maintenance and upgrading.
Milliken, a North American carpet tile manufacturer, has a program which rejuvenates or "re-conditions" old carpet tiles. This program, called Ennovations, results in a carpet tile that lasts longer and can be resurfaced and re-used numerous times, as compared to the average carpet tile. As a result, Milliken has built stronger consumer relations and saved millions of dollars in new materials and landfill fees.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra7/dfestra7_1/dfestra7_1.html (2 de 2) [08/01/2002 05:27:54 p.m.] Design for Disassembly
dfe overview 7.2: Design for Disassembly dfe strategies To optimize a product's end-of-life system, you should consider designing for overview disassembly. This type of design is also closely related to making a product more serviceable for users (2.2: Optimize Functions) and aiding in 1 new concept maintenance and repair (2.4: Easy Maintenance and Repair). 2 physical opt. 3 materials Designing for disassembly can have the following benefits: 4 production ● Facilitate maintenance and repair, thereby reducing costs. 5 distribution ● Facilitate part/component re-use, thereby recovering materials and 6 product use reducing costs. ● Assist material recycling, thereby avoiding disposal and handling of waste. 7 end-of-life ● Assist product testing and failure-mode/end-of-life analysis. 7.1 re-use ● Facilitate product take-back and extended producer responsibility, thereby reducing liability and assisting in regulatory compliance. 7.2 disassembly
7.3 re-manufacturing Factors, such as the life span of parts/components, their standardization, 7.4 recycling maintenance requirements, and instructions for servicing and re-assembly, play a major role in designing for disassembly. In general, designers should 7.5 safer incineration attempt to:
getting started ● Use detachable joints such as snap, screw or bayonet instead of welded, glued or soldered connections. download ● Use standardized joints so that the product can be dismantled with a acknowl. few universal tools, e.g., one type and size of screw. ● Position joints so that the product does not need to be turned or moved for dismantling. ● Indicate on the product how it should be opened non-destructively, e.g., where and how to apply leverage with a screwdriver to open snap connections. ● Put parts that are likely to wear out at the same time in close proximity so they can be easily replaced simultaneously. ● Indicate on the product which parts must be cleaned or maintained in a specific way, e.g., colour-coded lubricating points.
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A product/component disassembly checklist.
Evaluate the ease of disassembly. Consider assigning a weighting and scoring system to the list.
● What are the bonding and fastening methods of parts and components? ❍ insert moulding ❍ cohesion ❍ adhesion ❍ mechanical fastening ❍ friction fitting ● What are the additional operations required for disassembly? ❍ fracturing ❍ drilling ❍ ungluing ❍ heating ❍ lubricating ● What are the tools required for disassembly? ❍ special tool ❍ simple tool ❍ by hand ● What is the tool motion required for disassembly? ❍ complex ❍ turning ❍ straight line ● What is the level of difficulty for disassembly? ❍ technician needed ❍ assistant needed ❍ deformation required ❍ hold-down required ❍ heavy ❍ small ❍ resistant ❍ difficult access ❍ difficult to grasp ❍ difficult to view ● What are the hazards during disassembly? ❍ chemical ❍ electrical ❍ sharp edges/corners ● Where are the instructions for disassembly? ❍ provided integrally ❍ provided separately
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra7/dfestra7_2/dfestra7_2.html (3 de 3) [08/01/2002 05:28:15 p.m.] Product Re-manufacturing
dfe overview 7.3: Product Re-manufacturing dfe strategies Many products end up in landfill sites even though they still contain valuable overview components. Often these components can be re-used, either for the original purpose or for a new one. This strategy focuses on re- 1 new concept manufacturing/refurbishing in the context of restoring and repairing sub- 2 physical opt. assemblies. 3 materials Re-manufacturing can benefit your company by: 4 production
5 distribution ● Recovering materials and the costs embodied in products. 6 product use ● Providing a reliable, cost-effective supply of parts/components for inclusion into new product production or service operations.
● Saving the costs of new manufacturing/purchasing. 7 end-of-life 7.1 re-use Re-manufacturing/refurbishing is related to 7.2: Designing for Disassembly 7.2 disassembly and 2.5: Modular Product Structure. 7.3 re-manufacturing 7.4 recycling 7.5 safer incineration Re-manufacturing/refurbishing considerations.
● Design for disassembly, i.e., from product to sub- getting started assemblies, to ensure easy accessibility for inspection, download cleaning, repair and replacement of vulnerable/sensitive sub-assemblies or parts. acknowl. ● Design a modular product structure so that each module can be detached and re-manufactured in the most suitable way. ● Design parts/components to facilitate ease of cleaning/repair and retrofitting prior to re-use. ● Indicate parts/components that must be lubricated or maintained in a specific way through colour coding or integral labels. ● Consider the tooling requirements for re-manufacturing in the physical design of parts/components. ● Consider transportation and packaging requirements for re-manufactured parts/components.
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Since countries such as Germany, England, Australia and Taiwan are preparing product take-back regulations, many companies have already undertaken take-back programs.
● Xerox re-uses up to 75 per cent of components and recycles up to 98 per cent of materials from take-back products. Those components that meet criteria for new components are used again in the Xerox Eco-Series Copiers. The take-back program saved $50 million in its first year of operation.
● As of 1997, IBM has saved over $70 million through machine parts re-use and over $7 million through use of recycled commodities.
● Hewlett Packard created a worldwide Equipment Management and Remarketing Division to re- manufacture used products including PCs, printers and scanners. As a result, the company has saved millions of dollars in parts manufacturing, has improved its image as environmentally sensitive, and has gained a greater competitive "edge" in the global marketplace.
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dfe overview 7.4: Material Recycling dfe strategies This strategy focuses on making products that can be easily disassembled overview and using materials suitable for recycling. 1 new concept The benefits of recycling: 2 physical opt.
3 materials ● Requires little time. 4 production ● Requires only a small financial investment. ● Attracts users and increases sales. 5 distribution ● Is easy to promote within and outside the company. 6 product use The levels of recycling, in order of the greatest environmental benefit to the least, are: 7 end-of-life
7.1 re-use ● Primary recycling--back to the original application. 7.2 disassembly ● Secondary recycling--to a lower-grade application. ● Tertiary recycling--decomposition into raw materials. 7.3 re-manufacturing
7.4 recycling This strategy is related to 7.2: Design for Disassembly which helps facilitate 7.5 safer incineration material recycling.
getting started download Facilitate recycling. acknowl. ● Try to recover and use recyclable materials for which a market already exists. ● If toxic materials have to be used in the product, they should be concentrated in adjacent areas so they can be easily detached. ● If non-destructive disassembly is not possible, ensure that the different materials can be easily separated into groups of mutually compatible materials. This is important, for instance, in efficient metal recovery and recycling.
In the design of the product, consider:
● Integrating as many functions in one part as possible. ● Minimizing the types of materials used in the whole product. If this is not possible, consider the compatibility of materials, e.g., glass/ceramics, plastics, various metals. ● Using recyclable materials such as thermoplastics rather than composite materials such as laminates,
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fillers, fire retardants and fibreglass reinforcements. ● Avoiding use of polluting elements such as stickers that interfere with the recycling process. ● Marking any parts made of synthetic materials with a standardized material code.
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dfe overview 7.5: Safer Incineration dfe strategies When product, component or material re-use and recycling are not possible, overview incineration--preferably with energy recovery--is an end-of-life option. 1 new concept You can design for safer incineration by avoiding the use of materials that can 2 physical opt. lead to toxic emissions if the product were to be incinerated without adequate 3 materials environmental controls. 4 production When the use of heavy metals or other potentially toxic materials is 5 distribution unavoidable, you should design the product for easy disassembly and 6 product use promote programs to recover the hazardous materials separately. For example, household products using chargeable batteries should be designed and labelled so that end-users can remove the batteries easily and send them 7 end-of-life for separate recycling. 7.1 re-use 7.2 disassembly 7.3 re-manufacturing 7.4 recycling 7.5 safer incineration
getting started download acknowl.
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http://www.nrc.ca/dfe/ehome/dfestra/dfestra7/dfestra7_5/dfestra7_5.html [08/01/2002 05:28:51 p.m.] How to integrate DfE into product development
dfe overview Step 1: Create a Design Brief dfe strategies The design brief topics, provided here as examples, offer a systematic getting started approach for a DfE project of some magnitude. However, the topics are suggestions only. Use those that make the best sense for your company and 1: design brief project. 2: env. profile 3: drivers A design brief can include: 4: options ● General analysis of the existing product, as in traditional design briefs. 5: feasibility ● Reasons for the selection of the specific product or component for worksheets DfE. ● Particular DfE strategies chosen as a focus.
● A statement about the project team's latitude, i.e., how radically the download existing product concept can be changed. ● Indication of the environmental and financial objectives. acknowl. ● How the project is to be managed. ● How the results will be documented and measured. ● Final composition of the project team, plus any outside experts, and a description of members' responsibilities. ● Project plan and time frames. ● Project budget and its allocation to subsequent activities.
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dfe overview Step 2: Analyze the Product's Environmental Profile dfe strategies A good understanding of the product's main environmental impacts during its getting started total life cycle is an essential first step. Your project team should decide the exact scope of the environmental profile by considering, not only the physical 1: design brief product, but also the whole system required for the product's proper 2: env. profile functioning. 3: drivers ● Qualitative analysis versus. quantitative analysis 4: options ● The MET Matrix 5: feasibility ● The DfE Checklist worksheets
download Qualitative analysis versus quantitative analysis: The project team needs acknowl. to decide how to analyze the environmental profile of the existing product. Several methods, qualitative and quantitative, are available to do this.
This section describes two qualitative tools: the MET Matrix and the DfE Checklist. For best results, they should be used in conjunction with each other.
While a qualitative analysis does involve data, it is not as detailed as a quantitative approach. Often, just establishing the environmental impact of a component or sub-assembly of the product will suffice.
However, if your team plans to deviate from the qualitative approach recommended in this section, you may find advantages to allocating more time and money on an extensive quantitative life cycle analysis.
For example, the project team may undertake a quantitative approach when they have minimal understanding of the environmental impact of the product. When the DfE project is over, you will gain valuable information by comparing the environmental profile of the improved product to that of the former product. This data may also be important for companies who have an existing Environmental Management System in place, and for companies upstream or downstream in the supply chain.
If your project team decides to analyze the environmental product profile in greater detail, it can make use of computer tools developed for this purpose, e.g., Life-Cycle Assessment software. The team may also consider hiring a consultant experienced in Life-Cycle Analysis.
Another solution is to combine qualitative and quantitative approaches if this would better meet your company's needs. In this case, the MET Matrix and DfE Checklist, discussed below, can be combined with a quantitative life-cycle
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assessment.
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The MET Matrix (Material cycle, Energy use and Toxic emissions)
The MET Matrix is a qualitative tool for performing a functional analysis of a product's environmental profile. Its vertical axis is used for stages of the product life cycle, while the horizontal axis allows for input on the environmental effects per life-cycle stage. The environmental effects are grouped into three main areas:
1. Material cycle (input/output) 2. Energy use (input/output) 3. Toxic emissions (output)
The product life cycle is divided into five stages:
1. Production and supply of materials and components. 2. In-house production. 3. Distribution--this is presented only once, although it represents all distribution stages in the product life. 4. Use, including operation and servicing. 5. End-of-life system, including recovery and disposal.
To use the MET Matrix, the project team should undertake three activities:
a) Define the product system boundaries: Your team defines what exactly belongs to the product system being studied versus what does not. It should focus not only on the physical product, but also the auxiliary products/consumables necessary during the product's total life span.
b) Perform a needs analysis: After defining the product, the team must address two central questions: 1) how does the product fulfil the needs it is meant to satisfy? and 2) can a product system be developed that fulfils the same needs in a radically more effective and efficient way? For a more detailed description of the needs analysis, see the discussion on "Needs Analysis" in the DfE Checklist later in this section.
c) Perform a functional product analysis: The team should then set up a MET Matrix using the MET Matrix Worksheet in order to focus on the physical product and its separate components
The functional analysis begins by describing:
● The product's functionality. ● Listing weak and strong parts/components. ● Measuring or projecting the product's life span. ● The product's energy consumption.
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During this process, the team should:
● Disassemble the product ● Measure the weights of the assemblies and components. ● List the type and amount of materials and components. ● Identify connections between materials and components.
To perform the functional product analysis systematically, the team should:
● Fill out the matrix for the main product, ensuring that auxiliary products/consumables are taken into account. ● Study a specific sub-assembly or component in a separate matrix if this item itself turns out to be a serious environmental problem. ● Examine all the cells of the matrix and highlight those where there are environmental bottlenecks. ● If possible, use measured data in the matrix to prevent working with vague statements.
Material Cycle: This column is for information on environmental problems concerning the input/output of materials. It should include data about:
● Non-renewable materials. ● Materials that create emissions during production, e.g., copper, lead and zinc. ● Incompatible materials. ● Inefficient use or lack of re-use of materials/components in all five stages of the product life cycle.
Energy Use: This column is for information regarding energy consumption. Your team should:
● List inputs of materials with an extremely high-energy content in the first cell. ● Include energy consumption for the product itself as well as for transport, operating, maintenance and recovery. ● Include exhaust gases produced as a result of energy use.
Toxic Emissions: This last column is for the identification of toxic emissions to land, water and air. To avoid excluding any environmental impacts, the team should use the DfE Checklist as described below.
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The DfE Checklist
DfE Checklist Worksheet provides support for a qualitative environmental analysis by:
● Listing all the relevant questions that need to be asked when http://www.nrc.ca/dfe/ehome/gettingStarted/step2/step2.html (3 de 4) [08/01/2002 05:29:20 p.m.] How to integrate DfE into product development
establishing environmental impacts during the product's life cycle. ● Indicating improvement options for areas where environmental problems are identified.
The Checklist starts with a needs analysis--a series of questions concerning the functioning of the product as a whole. This section of the Checklist answers the overarching question: to what extent does the product fulfil its main and auxiliary functions? This answer is necessary before the team can focus on the environmental impacts in each life-cycle stage.
The set of questions regarding the functioning of the product as a whole is followed by five sets of questions that correspond to the five stages of the product's life cycle.
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STEP 2 WORKSHEETS FOR DOWNLOADING
MET Matrix Worksheet.rtf (2kb)
DfE Checklist Worksheet.rtf (4kb)
NOTE: Rich Text Format (.rtf) worksheets can be viewed and printed by most word processing programs.
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dfe overview Step 3: Analyze Internal/External Drivers dfe strategies Internal drivers: Your team should fill in the Internal Drivers for DfE getting started Worksheet. A more detailed discussion of these drivers can be found in Internal and External Drivers of DfE. 1: design brief 2: env. profile Internal drivers include the need to: 3: drivers
4: options ● Satisfy managers' sense of responsibility. 5: feasibility ● Increase quality. ● Improve the product and company image. worksheets ● Reduce costs. ● Produce innovations and increase employee motivation. download Related issues are: acknowl.
● Availability of knowledge of environmental legislation. ● Presence of a quality assurance system. ● Presence of an Environmental Management System. ● Company willingness to make investments. ● Company desire to innovate. ● Motivation of employees to help clean up the environment.
External drivers: Your team should fill in the External Drivers for DfE Worksheet. A detailed discussion of these drivers can be found in DfE Internal and External Drivers.
External drivers include:
● Existing or expected legislation. ● Requirements made by industrial customers or end-users. ● Industry attitude and activities of competitors--a particularly important aspect of this driver involves comparing your product with similar products from competitors through benchmarking.
STEP 3 WORKSHEETS FOR DOWNLOADING
Internal Drivers Worksheet.rtf (2kb)
External Drivers Worksheet.rtf (6kb)
NOTE: Rich Text Format (.rtf) worksheets can be viewed and printed by most word processing programs.
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dfe overview Step 4: Analyze Improvement Options dfe strategies The project team should list improvement options on the DfE Improvement getting started Options Worksheet, grouping them according to a classification based on the seven DfE Strategies. The Improvement Options Worksheet can also be 1: design brief reformatted to include the DfE Sub-Stratgies. (DfE STRATEGIES) 2: env. profile 3: drivers After listing the improvement options, the team can then use the DfE Strategy 4: options Wheel Worksheet to visualize the main areas for product improvement. 5: feasibility The team should plot the existing product's worksheets The DfE Strategy Wheel: environmental profile, using the results of the MET Matrix Worksheet and DfE Checklist Worksheet. (Step 2: Analyze Product's Environmental Profile) download acknowl. ● Assign a rating, from 0 (poor) to 5 (excellent), according to the seven DfE Strategies. ● Plot seven points on the Wheel along the corresponding axis. ● Connect all seven plotted points.
The area generated is a visual representation of the product's environmental profile.
Plot a second Wheel using the results from the DfE Improvement Options Worksheet. The difference in area between the two plotted surfaces is a graphical representation of the level of "ambition" for the DfE project.
Strategy Wheel with current and targeted environmental ratings
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At this stage, the DfE Strategy Wheel is used primarily as a general framework. However, the Wheel has other uses:
● An idea-generating tool to help identify more options for product improvement. ● A tool for communicating the issues to other employees, suppliers and end-users later in the product design/development process.
Short-term, long-term goals. The Strategy Wheel can also help you communicate short- and long-term goals.
For example, a power-tool manufacturer decides to apply the DfE strategies to the design/product development of its cordless screwdriver. The current environmental profile for this product is a "poor-to-fair" rating for all seven DfE Strategies.
The team identifies two goals for the short term.
1. Significantly improve performance in product use by specifying a more efficient motor (Strategy 6: Reduce Impact During Use). The benefits are 1) decreased number of times batteries have to be recharged; and 2) reduced cost of ownership for the end-user.
2. Reduce injection-moulding waste by redirecting plastic re-grind for use in a less critical application product (Strategy 4: Optimize Production Techniques).
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The project team illustrates these short-term priorities on the DfE Strategy Wheel by plotting the screwdriver's existing profile and short-term priorities.
Cordless Screwdriver: Short-term Goals
The team also identifies a long-term DfE goal-a product take-back system for the screwdriver and rechargeable batteries--and visualized this on a separate Strategy Wheel.
Cordless Screwdriver: Long-term Goals
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The Strategy Wheels now communicate:
● Current environmental profile. ● Anticipated short-term improvement. ● Anticipated long-term improvement. ● Amount of achievable improvement.
STEP 4 WORKSHEETS FOR DOWNLOADING
DfE Improvement Options.rtf (2kb)
DfE Strategy Wheel Worksheet.rtf (15kb)
NOTE: Rich Text Format (.rtf) worksheets can be viewed and printed by most word processing programs.
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dfe overview Step 5: Study Option Feasibility dfe strategies The DfE Priority Matrix Worksheet categorizes each improvement option getting started according to: 1: design brief ● Anticipated environmental merit. 2: env. profile ● Technical, organizational and economic feasibility. 3: drivers ● Market opportunities. 4: options The project team should take note of those options can be matched to the DfE 5: feasibility drivers. (Step 3: Analyze Internal/External Drivers) worksheets The Worksheet can help a company systematically establish DfE priorities. Experience with DfE projects has shown that every area in the company download involved in product development--management, marketing, purchasing, acknowl. research and development, and production--should have representatives participate in a priority-setting workshop/meeting. The group should:
● List and assign a priority rating to each improvement option. ● Label each option as a possibility for implementation in the short term (ST) or long term (LT).
The group can estimate technical feasibility and market opportunities using techniques normally applied in your company.
STEP 5 WORKSHEET FOR DOWNLOADING
DfE Priority Matrix Worksheet.rtf (1kb)
NOTE: Rich Text Format (.rtf) worksheets can be viewed and printed by most word processing programs.
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dfe overview Worksheets for Downloading dfe strategies Getting Started includes downloadable worksheets. You can access the getting started worksheets in three ways: 1: design brief 1. Clicking on the hypertext link in the written portion of the text. 2: env. profile 2. Scrolling to the end of each section where relevant worksheet(s) are 3: drivers listed. 3. Using this page which includes all worksheets for this section of the 4: options Web site. 5: feasibility worksheets Project teams can download Rich Text Format (.rtf) worksheets to design its own project-specific worksheets.
download MET Matrix Worksheet.rtf (2kb) acknowl. DfE Checklist Worksheet.rtf (4kb)
Internal Drivers Worksheet.rtf (2kb)
External Drivers Worksheet.rtf (6kb)
DfE Improvement Options.rtf (2kb)
DfE Strategy Wheel Worksheet.rtf (15kb)
DfE Priority Matrix Worksheet.rtf (1kb)
NOTE: Rich Text Format (.rtf) worksheets can be viewed and printed by most word processing programs.
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