This presentation contain different design consideration for manufacturing of product such as design of Environment, Design for Assembly, Design for Disassembly, Design for Recyclabilities & remanufacture, Energy Effficieny, Environmental Regulatory, Important Acts

1. DESIGN FOR THE
ENVIRONMENT

2. THE IMPORTANCE OF THE DESIGN
STAGE[1]70% of costs of product development, manufacture and use are
decided in early
design stages
For Example ,
Rolls Royce: 80% of costs decided at design stage,
as determined from an average among 2000 parts
GM truck transmissions: 70% of costs
decided at design stage
Likewise, it is clear that most decisions that affect future
environmental impacts are made at the design stage.

3. MAJOR DESIGN CONSIDERATIONS:
Industrial designers need to mind:
- Functionality and performance (product must do the job)
- Manufacturability, logistics (one should be able to make the
product)
- Reliability, safety (there must be some quality standard)
- Cost, market penetration (product needs to be competitively priced)

4. ENVIRONMENTAL
ISSUES [2]
1. Pollution
2. Global Warming
3. Natural Resource Depletion
4. Waste Disposal
5. Ocean Acidification
6. Ozone Layer Depletion

5. INTRODUCTION OF DFE [3]
 Environmental considerations into the design of manufacturing
processes and finished products.
 The first consideration in the first half of the 1980s.
 In the early 1990s,
Wide diffusion of new ideas and experiences developed With
the clear objective of integrating environmental demands in
traditional design procedures.
 New approach to DFE , GD , ECD , ED

6. CONT…
 DFE created in 1992 by a number of electronic firms that were
attempting to build environmental awareness in product
development.
 American Electronics Association was a first initiator of DFE (AEA
1992).
After that, this concept started to be used widely by many industries
that wanted to
integrate environmental awareness into product design.

7. DEFINITION
“A design process that must be
considered for conserving and
reusing the earth’s scarce
resources; where energy and
material consumption is
optimized, minimal waste is
generated and output waste
streams from any process can be
used as the raw materials

8. DESIGN FOR ENVIRONMENT
OBJECTIVES [4]
Environme
ntal
protection
—assurance
that air,
water, soil,
and
ecological
systems are
not
adversely
affected due
to the
release of
Human
health and
safety—
assurance
that people
are not
exposed to
safety
hazards or
chronic
disease
agents in
their
Sustainability
of natural
resources—
assurance that
human
consumption
or use of
natural
resources does
not threaten
the availability
of these
resources for

9. 9
DRIVING FORCES [5]
Design for
Environment
Sustainable
Development
Risk Management
Product
Stewardship
Customer
Satisfaction
International
Standards
Competitive
Pressures
Enterprise
Integration

10. MAJOR QUESTIONS ARISING IN
DESIGN FOR ENVIRONMENT[6]
1. Product or process?
Make the same product in a different way
Make essentially the same product, but with different materials
Make a different product that fulfills the same function
2. At which level?
Micro scale: Part of a product
A unit of production
Meso scale: The entire product
The entire factory
Macro scale: Meeting the function (service) in a new way
Rethinking the industry-environment relation (social concerns)

11. Primary goal:
SUSTAINABILITY
(responsibility toward future generations)
Basic approach:
INDUSTRIAL ECOLOGY
(imitation of nature)
In addition:
GREEN TECHNOLOGIES
(pollution avoidance rather
than pollution treatment)
Imitation of ecosystem:
ECO-INDUSTRIAL PARKS
(closing material loops,
energy efficiency)
DESIGN FOR ENVIRONMENT
(green design)
POLLUTION PREVENTION
(green processes)
DESIGN FOR PRODUCTDESIGN FOR PROCESS
Improved operating Practices, Technology Changes, Change of
materials

12. DESIGN FOR PROCESSExample of Design for Environment applied to a
manufacturing process
• Less air to be dust-free and less chance
of dust intrusion;
• In the absence of personnel inside the
controlled volume,
one can also take advantage of an
oxygen-free (pure nitrogen)
atmosphere
to reduce oxidation or other
undesirable side effect.

13. DESIGN FOR PRODUCT
For this Consider function rather than the object:
Can this function be met with a smaller/other product ??
For example :
Conventional oven → microwave oven
Wired telephones at home → mobile cell phones
Audiotape player → CD player → iPod
Film camera → Digital camera
Regular “snail” mail → email
Note: how in each instance, the function is met by a radically different
product, which
happens to use less material.

14. BASIC DFE PRINCIPLES [4]
Seven basic principles for companies that wish to integrate DFE into their innovation practices
Embed life-cycle thinking into the product
development process.

15. CONT…
Evaluate the resource efficiency and effectiveness of the
overall system.Concept of Eco-efficiency
“delivery of competitively priced goods and services that satisfy human needs and
bring quality of life while progressively reducing environmental impacts of goods
and resource intensity throughout the entire life cycle.”
Select appropriate metrics to represent product life-cycle
performance.Maintain and apply a portfolio of systematic design
strategies.Use analysis methods to evaluate design performance
and trade-offs.Provide software capabilities to facilitate the application of
DFE practices.
Seek inspiration from nature for the design of products
and systems.

16. METHODS FOR DFE [4]&[7]
Qualitative
Implemented in all stages of product design complementing life cycle
assessment (LCA)
Quantitative
Cover full LCA procedures from ISO 14040

17. QUALITATIVE METHODS + TOOLS
ASSOCIATED
Method Description Tool
checklist Questionnaire concerning
from raw material to
disposal
Eco design checklist
Environmental Effect
Analysis (EEA)
Relation between product
and environmental
consequences
EEA-Form
Product design Matrix Relationship product
operations and
environment
MET-MECO Matrix
Quality Function Relation of voice of Weight of importance

19. QUANTITATIVE METHODS
Method Stage Description
Life-Cycle Assessment Goal and Scope Type of information
needed
How data is organized
How result will be
displayed
Life-Cycle Inventory Input/outputs data
collection
Life-Cycle Impacts Impact calculation
Interpretation Result interpretation
Data deduction

20. QUALITATIVE VS QUANTITATIVE

21. DFE EXAMPLES[6]
Dyson Air blade
80% Energy saving
64% Faster
Removes 99.9% Air bacteria
Ford U Model cradle to cradle concept car
Hybrid electrician Transmission
45 miles/galon
300 miles near 0 emissions
99% reduction in carbon dioxide
0% waste desposal9 recycling or decomposed part )

22. CONT…
 BMW and Volkswagen are both using DFE to study the
disassembly and recycling of recovered materials in
automobiles. BMW has a goal of eventually making automobiles
out of 100% reusable and recyclables parts.
 Hewlett Packard design some of its inkjet printers under a DFE
framework. The outer casings include post-consumer plastic
from recycled telephones. The modular architecture and use of
few permanent screws make the printers easy to disassemble
for repair or recycling. Any plastic larger than 3 grams is
identified and marked by type. Components of the printer are
molded using a thin-walled process so less material is needed.
Power down and sleep modes means 50% less energy is used by
these printers than comparable inkjet printers.

23. DESIGN FOR DISASSEMBLY[4]&[8]
Definition: A process by which a product and its parts
can be easily:
Reused
Re-manufactured
Refurbished or
Recycled

24. REASONS FOR DISASSEMBLY
Enable maintenance
Enhance serviceability
End-of-life (EOL) objectives such as product
reuse, remanufacture, and recycling

25. TYPES OF DISASSEMBLY
Destructive disassembly
Reverse Disassembly
Two types of reverse disassembly:
Total
Selective

26. DFD BREAKDOWN
There are two levels of strategy in DFD
1. Product Disassembly
2. Material Disassembly
i.e. Disassembling a computer
in order to reuse switches,
boards, circuits, etc
i.e. Using the plastic in a computer for the outer shell
of another computer, i.e. melting it down

27. WHY USE DFD?
 Reduce Costs
1. Facilitate maintenance and repair
2. Facilitate part/component re-use, i.e. recovering
materials
Reduce Waste Disposal
1. Assist material recycling
Increase Product Quality
1. Assist product testing and failure-mode/end-of-life
analysis

28. HOW DO YOU IMPLEMENT DFD?
 Parts Connection
Use joints, snaps, or screws instead of welding,
soldering or glue Parts Standardization
The product can be disassembled with minimal work
and use minimal tools, i.e. the same size screw
throughout the whole product Parts Placement
Put parts that are likely to wear out at the same time
near each other so they can be easily replaced
simultaneously

29. WHAT INDUSTRIES USE DFD?
Construction
Technology
Furniture Manufacturing
Electronic Manufacturing
Automobile Manufacturing

30. WORKPLACE EXAMPLES OF DFD:
• Reducing the number and types of materials used
• Using single plastic polymers
• Using molded-in colors and finishes instead of paint,
coatings or plating
• Relying on modular designs for ease of disassembly of
dissimilar recyclable materials

31. IS IT EASY TO DISASSEMBLE YOUR
PRODUCT?
using the checklist
 What are the additional operations required for disassembly?
∆ fracturing
∆ drilling
∆ ungluing
∆ heating
∆ lubricating
 What are the bonding and fastening methods of parts and
components?
∆ insert molding
∆ cohesion
∆ adhesion
∆ mechanical fastening

32. CONT…
 What are the tools required for disassembly?
∆ special tool
∆ simple tool
∆ by hand
What is the level of difficulty for disassembly?
∆ technician needed
∆ assistant needed
∆ deformation required
∆ hold-down required
∆ difficult access
∆ difficult to view

33. DESIGN FOR RECYCLABILITY &
REMANUFACTURE[4],[9]&[10]
Re-use:
The series of activities, including collection, separation, and in some cases processing,
by which products are recovered from the waste stream for new use in their original intended manner.
Remanufactured components fall under the classification of re-use.
(Germans refer to this as “product recycling”.)
Recycle:
A series of activities, including collection, separation, and processing, by which
products or other materials are recovered from or otherwise diverted from the
solid waste stream for use in the form of raw materials in the manufacture of new
products.
Materials diverted for use as an energy source are considered separately
under the category of energy recovery

34. WHY
REMANUFACTURING/RECYCLING?
Reduces energy costs and environmental impact of:
1. Raw materials and natural resources
2. Manufacturing products
3. Shipping components and final product
 What are the environment savings?
1. Saves enough natural resources.
2. Saves enough energy to power 6 million automobiles!

35. APPROXIMATELY 85% OF THE ENERGY EXPENDED
IN THE MANUFACTURE OF AN ORIGINAL PRODUCT
IS PRESERVED IN THE REMANUFACTURED
PRODUCT.
 Remanufacturing Reclaims
Material
Energy from Casting,
Machining, etc.
Labor from original processes
Capital
Function/Design Intent
 Recycling Reclaims
Material
Source: MAI PPT

36. RECYCLABLES VS. NON-
RECYCLABLESClass of
non-renewable
material
Recycling
technically
feasible?
Recycling
economically
feasible?
Examples
I Yes Yes Most industrial
metals , Catalysts,
some solvents
II Yes No Packaging materials,
Refrigerants,
some solvents
III No No Coatings, pigments
Fuels, lubricants
Pesticides,
herbicides, fertilizers
Reagents,
explosives,
Problem! None of these
materials is renewable!

37. ECOLOGIC BENEFIT OF– AUTOMOTIVE
PARTS(DELCO CS 130 100A ALTERNATOR)
 Material analysis for
Delco CS 130 100A alternator:
1.Kwh used to create one NEW
alternator:61.1 Kwh
2.CO2 emissions to create one NEW
alternator:66.6 lbs
 Benefits from remanufacturing one
thousand produced Delco CS 130 100A
alternators each year:
1.Annual energy savings:37,700 Kwh
2.Annual CO2 savings:51,357 lbs

38. PUTTING RECYCLED MATERIALS IN
NEW PRODUCTS (CLOSING THE
LOOP)
Recycled plastics (shown in green) in the BMW 3-series

39. DESIGN FOR ENERGY EFFICIENCY[11]
Energy
Conversion
Energy Input
Useful Energy
Output
Energy Dissipated
to the Surroundings
InputEnergyTotal
OutputEnergyUseful
Efficiency 
Use manufacturing processes and produce products which
require less energy

40. CONT..
25% Of the gasoline is used to propel a
car, the rest is “lost” as heat. i.e an
efficiency of 0.25 (25%)

41. EQUIPMENT (LIGHTING, HVAC,
CONSUMER APPLIANCES) ARE MORE &
MORE ENERGY EFFICIENT
Lighting efficiency with
LEDs : from 20 toward 150
lumen / W
Heat pumps : from 20% to
25% of performance
increase with speed driven
compression motor
Consumer appliances :
Appliances complying with
the energy performance
labels are from 10 to 40%
more efficient
Photovoltaic cells are
integrated to architecture.
They provide 15% of 1000
W/m2
Global prices are less than
2€/W (target 2020)
Yet 1000 MW installed in
Japan

42. CONT…
Renovation and
upgrading of
existing
installation
Savings:
 Energy consumption
Improvements in :
 Curative maintenance
 Predictive
maintenance
Increase of net
financial result

43. ENVIRONMENTAL REGULATIONS[12]
India has provided for the protection and improvement for the
environment in its constitution and has taken several steps in
planning and policies to overcome the environmental problems.
According to the World Bank report (2007), by any
benchmark, India has an extensive environmental management
system with a comprehensive set of environmental laws,
regulatory instruments, and institutional frameworks to
implement environmental policy objectives.
There are over two hundred laws for the prevention and
control of industrial pollution include the following:

44. The Water (Prevention & Control of Pollution) Act, 1974
The Water (Prevention & Control of Pollution) Cess , Act, 1977
The Air (Prevention & Control of Pollution) Act, 1981
The Environment (Protection) Act, 1986
The Hazardous Waste (Management and Handling) Rules 1989, 2003,
2008
The Bio – Medical Waste (Management and Handling) Rules 1988, 2003
The Municipal Solid Wastes (Management and Handling) Rules 2000
The Plastics Manufacture and Usage Rules, 1999
The Noise Pollution (Regulation & Control) Rules, 2000
The Batteries (Management and Handling) Rules, 2001
Environmental Impact Assessment Notification, 2006
National Environmental Policy, 2006
Fly Ash Management Rule, 2008

45. BRIEF ON FEW IMPORTANT ACTS
ENVIRONMENTAL(PROTECTION)ACT,
1986
It was introduced as an umbrella legislation that provides a holistic
framework for the protection and improvement to the environment.
In terms of responsibilities, the Act and the associated Rules required for
obtaining environmental clearances for specific types of new / expansion
projects (addressed under Environmental Impact Assessment
Notification,2006) and for submission of an environmental statement to the
State Pollution Control Board.

46. CONT..
AIR(PREVENTION AND CONTROL OF POLLUTION)
ACT1981
Decisions were taken at the United Nations Conference on the Human Environment held in
Stockholm in June1972, in which India participated, to take appropriate steps for the
preservation of the natural resources of the earth, which , among other things, includes the
preservation of the quality of air and control of air pollution.
Therefore it is considered necessary to implement the decisions foresaid in so far as they
relate to the preservation of the quality of air and control of air pollution

47. CONT..
WATER(PREVENTION&CONTROL)ACT, 1974
The objectives of this Act is to provide for the Prevention and Control of Water Pollution
and the maintenance or restoration of the whole someness of water for the establishment,
with a view to carrying out the purposes aforesaid, of Boards for the prevention and control
of water pollution, for conferring on and assigning to such Boards powers and functions
relating there to and for matters connected there with.

48. CONT…
HAZARDOUS WASTES (MANAGEMENT AND HANDLING)
AMENDMENT RULES, 2003, 2008
These Rules classify used mineral oil as hazardous waste under the Hazardous Waste
(Management & Handling) Rules, 2003 that requires proper handling and disposal.
Organisation will seek authorisation for disposal of hazardous waste from concerned State
Pollution Control Boards (SPCB) as and when required.

49. CONT..
OZONE DEPLETING SUBSTANCES
(REGULATION AND CONTROL) RULES, 2000
THE ELECTRICITY ACT, 2003
Etc…
Etc…

50. REFERENCES
[1] 1991 National Research Council Report titled “Improving Engineering Design
[2] Maurizio_Bevilacqua,_Filippo_Emanuele_Ciarapica,-Design for Environment as a Tool for the Development of
a Sustainable Supply Chain
[3] [Fabio_Giudice,_Guido_La_Rosa,_Antonino_Risitano]-product design for environment
[4] [Joseph_Fiksel]_Design_for_Environment,_Second_Edi
[5] PRESSENTATION - DFE-Felicia Kaminsky-ESM 595F-2 November 2000
[6] http://engineering.dartmouth.edu/~d30345d/courses/engs171/dfe.pdf
[7] A Comparison between the Environmental Effect Analysis (EEA) and the Life Cycle Assessment (LCA)
methods – Based on Four Case Studies.-November 27 (Mon.) - 29 (Wed.), 2000 Sanjo-Kaikan (Conference Hall),
The University of Tokyo, Tokyo, Japan
[8] presentation by Tim Thorn & jesse miller –BYU-MARRIOTT SCHOOL OF MANAGEMENT

51. REFERENCES
[9] https://engineering.dartmouth.edu/~d30345d/courses/engs171/DfRecycling.pdf
[10] presentation by MAI - Automotive Remanufacturing
[11] presentation by - Jean-Christophe HUTT - Innovation & Technology for Energy Efficiency, Services Division-
Schneider Electric
[12] Analysis_of_existing_environmental_instruments_in_india - United Nations Development Programme
(UNDP), New Delhi

52. THANK YOU