accomplishments and opportunities: 2011 issst chicago,...

Environmental Accomplishments

and Opportunities:

Bob Pfahl2011 ISSSTChicago, IL

R.C.Pfahl5/8/01 Slide 1

• 2001 ISEE Denver CO Where we were• Industry’s Accomplishments 1991-2011

• CFC Elimination (Factory) 1991-1995• Pb-Free Elimination (Product) 1998-Present• Simplified LCA for ICT Products 2008-Present• Organizational Challenges 2001-2011

• 2011 ISSST Chicago IL Where we are• Environmental Opportunities 2011-21

• Products• Services• Research

• 2021 Concluding Thoughts

Outline


Environmentally Preferred Electronic Products for the Global Market

Dr. Robert C. PfahlDirector of Environmental TechnologyMotorola Advanced Technology Center

Schaumburg, IL

�

ProgressFor 1999


Outline 2001

• Environmental Drivers and Attributes• Proactive Activities in Industry• Fruitful Areas for Academic R&D• Conclusions


Environmental Drivers for Industry

• Societal Concerns– Sustainability– Global Warming– Pollution– Energy

• Societal Responses– Public Policy– Consumer Action


Executives Underestimate the Role of Corporate Environment and Social Responsibility in

Consumers’ Purchasing Decisions

4%

20%

4%

24%

3%

20%

1%

16%

0

0.05

0.1

0.15

0.2

0.25

Company Record onEnvironment

Fairness/Equity in Hiring Employs CommunityResidents

Company Record onWorker Safety

Corporate Executives Consumers

Percent Saying a Factor Is “Important” in Consumer Buying Decisions

Source: Porter Novell,, Survey of Factors Influencing Purchasing Decisions, 1995. DDB Needhom Lifestyle Survey, 1995. Chart: Adweek


CustomerLoyalty

Cost/LiabilityReduction

Right toOperate

New Market Strategic Planning/Marketing

R&D/DesignEngineering/

Marketing

Manufacturing/Operations

Public Affairs/General Counsel

U.S.

Europe

Japan

The Business Value ModelFrom: The Next Bottom Line: Making Sustainable Development “Tangible” -Arnold & Day, 1998

Business Value Action Organizational Lead

– Environmental Restoration

– Social Reconstruction

– Step Change– Business

Redefinition

– Design for Environment

– Service Intensity

– Pollution Prevention

– Yield Improvement

– Waste Treatment– Compliance


Regional Differences-2001

Regional Drivers

Global Solutions

Europe• Customer &

Regulation Driven• Product Focus• R&D: Model Focused


– Life Cycle Analysis– Material Flow

Analysis

Japan• Government/Industr

y Driven• Market Focus• R&D: Product

Focused – Hybrid Engines– Halogen Free

Plastics– Pb-Free Products

United States• Regulation Driven • Factory Focus• R&D: Manufacturing

Focused– CFC Elimination– VOC Reduction


Environmentally Preferred Product Attributes

• Are Highly Recyclable• Use Non-Hazardous Materials• Minimize Use of Energy • Minimize Use of Matter

1983First PortableCellular Phone

DynaTAC

1996First WearableCellular Phone

StarTAC®

1999


Proactive Activities in Industry-2001

• Reduced use of Materials of Concern– Lead (Pb)– Brominated Flame Retardants

• Energy Efficiency • End-of-Life: Product Recyclability• Tools


• Processing temperature must be below 260°C to avoid organic substrate damage

• Melting temperature below 230°C

• Requires minimal “two-phase” region to avoid disturbed joints

125

150

175

200

225

250

Tem

pera

ture

(C)

Physical Behavior - Melting Temperature

Recommended alloys from NEMI Pb-free project

Materials of Concern: Lead


Useful Tools and Their Effective Applications in Industry

• DfE Tools for the Designer• Input-output studies of Industries

– Improves the environmental performance of an industry

• LCA Studies along the food chain– Creates Understanding, cooperation, and profit

between Businesses

• LCA of Services– Could create alternative environmentally

positive solutions


Effective Application of Tools

……

Specialty Materials

……

……

……

……

……

……

…B

ase Stations..

Coal

……

…

……

…

Services

……

Cellular

Service

……………

Product / Systems

………

Cellular

Phones

Autom

obiles

…

Televisions

…

Subsystem

……………………

Components

Material & Energy Producers

……

Hydro-

electric

Nuclear

Reynolds

Alcoa

KR

UPP

US Steel

“Industries of the Future”Chemicals

Metal CastingEnergyAluminumSteel

… …

… ……..… …………………

DfEFood chain LC

A

Input-Output


Fruitful Areas for Academic R&D-2001

• Research and develop LCA for services

• Increase transparency of LCA Studies(ex: lbs vs. $)

• Establish best available sources of environmental data

• Develop simplified LCA

• Provide, through case studies of successes, a framework (“The triple bottom line?”) to stimulate environmentally proactive solutions


Conclusion-2001

“The Journey to a Sustainable World ”Has just begun

Industry’s Accomplishments

1991-2011


• ICOLP – Projects on CFC Elimination 1991-1995

• iNEMI – Roadmap of Environmental Conscious Electronics

(ECE) since 1996– Projects on Pb-free reliability since 1999– Projects on HFR-free reliability since 2008– Projects on PVC alternatives since 2009– Developing LCA tools for ICT products since 2009– Rare Earth Metals & Supply Chain Actions Project

2011

Environmental Consortial Activities

CFCElimination

ICOLPInternational Cooperative

for Ozone Layer Protection1991-1995


• Participants:• US EPA• Electronics industry through ICOLP• NGOs

• Environmental Objective• Eliminate use of CFCs for solder flux removal

• Unique Characteristics• Clear science implicating CFCs• A number of solutions were already being

developed to reduce cost• Aqueous Cleaners• No-clean

CFC Elimination


• Action Required: Reliability of solutions had to be verified

• Impact on Industry:• Resulted in Cost Reduction• Created a network of individuals

• Interested in the Environment • Who recognized the value of working together

• Recognition• Leading Firms and Individuals Received

Stratospheric Ozone Protection Awards from US EPA

– Reference: Pfahl, R. C. Jr. 1994. Design for environment: An R&D manager’s perspective. In The Greening of Industrial Ecosystems, edited by B. R. Allenby and D. J. Richards. Washington, DC: National Academy Press, pp. 208-216

CFC Elimination

iNEMI Projects for Pb-free Electronics

Meeting the Requirements of

the EU RoHS Directive

1998-Today


• Participants:• iNEMI Members including:

• OEMs• EMS Firms• Suppliers• NIST

• Environmental Objective1. Develop standard alloy to replace eutectic Sn-Pb2. Meet EU RoHS requirements

• Unique Characteristics• Driven by legislative action• Driven by customer requirements

Pb-Free Electronics


• Research to identify viable alternatives• Reliability studies on alternatives• Selection of alloy family • Process Development• Material development (paste and flux)• Application Development• Identify the reliability risk of potential

“whisker” growth from pure tin plating on components

• Reliability of solutions are still being verified

Pb-Free Electronics-Actions Required

Simplified LCA for ICT Products

2008-Today

Project Background

24

Roots of the project began in September 2008 at the iNEMI Sustainability Summit in Illinois

Discovered an area of Common Concern:ICT equipment LCAs are generally non-competitive – methods and data are similar for typical classes of products

About 90% of parts have common application in ICT product types / classes (we use the same suppliers)

Identified an Opportunity – can we use a “building block” approach in providing LCA-based eco-impact information for ICT product assets /sub-assemblies?

Develop an estimator – based possibly on asset / sub-assembly type, weight, size, number of devices by class, energy consumption per LCA stage, etc.Establish consensus within major ICT industry constituentsSystem agnostic, updateable databases via cross-industry information sharingEvaluator can also be used for company-specific products / projects – e.g. get credit for post-consumer content, energy efficiency feature, new material substitute (using primary data)

Project Participants

25

Organizational Challenges:Implementing a

Sustainability Program

2001-2011


CustomerLoyalty


Right toOperate



Marketing

Manufacturing/Operations


U.S.

Europe

Japan


Business Value Action Organizational Lead




Redefinition




– Yield Improvement



28

Environmental Organization: Cost/Liability Reduction

CEO

Corporate Offices

Company Operating Divisions



Site ES&H

Marketing

Corporate ES&HSite Focused Strategy

Environmental Technology• Tools• Materials• Processes

Sourcing

GRO Division Sourcing

Environmental Technology

Steering Committee

Sourcing Strategy

Committee

Environmental Executive

Committee

Based on:- Motorola- Lucent Technologies

Manufacturing R&D

Corporate R&D

Product Design Team

Division AMT


Environmental Organization: Customer Loyalty Business

CEO - Executive Committee

Corporate Offices




Division Environment and Strategy OfficeSets Product / Market Strategy

Environmental Operating Group

• Tools• Education• Supply Chain

Environmental Policy Office

Corporate R&D

Corporate Manufacturing R&D

• Processing• Materials

GRO

Site ES&H• ISO 14001

Implementation

Environmental Policy Committee

• Environmental Policy• General Strategy

Based on:- Philips


30

Environmental Operating Group

• Business Promotion • Environmental Marketing• Product Evaluation• Government & Public

Relations for Environment• Education• ISO 14001• Supply Chain Strategy



Environmental Committee

Executive Committee

Head Office R&D Divisions

Totally Recyclable Product Development Committee

Recycling and Pb Reduction

Used Product Recycling System Committee

Committee to Promote the “Love the Earth” Citizens

CampaignCulture Change


Environmental Site Specialist

Environmental R&D• Materials• Processes• Tools• New Opportunities

Set Strategy

Environmental Organization:New Market Business

Corporate Environmental Affairs Division

Energy Conservation Committee

Based on:- Matsushita- Sony- Fujitsu- Toshiba- Hitachi


31

CustomerLoyalty


Right toOperate



Marketing

Manufacturing/Sourcing/Operations



2008 ViewBusiness Value Action Organizational Lead




Redefinition




– Yield Improvement– Liability Reduction


OrganizationsWith Resources toDevelop and ImplementChange for:• Compliance• Leadership

Leadership


• Sustainability Policy Should be Established by a Corporate Organization

• Marketing and Business Strategy Should be Set by Business Groups

• Operational Development and Implementation Should be by the Business Groups.

Recommendations

2011

Environmentally Preferred Products


Environmentally Preferred Product Attributes

• Are Highly Recyclable• Use Non-Hazardous Materials• Minimize Use of Energy • Minimize Use of Matter

1983First PortableCellular Phone

DynaTAC

1996First WearableCellular Phone

StarTAC®

1999


36

Functional Dematerialization-Smart phones

36

• Telephone• Windows Mobile 6.1• Windows Media Player • QWERTY keyboard • 320x240 display• Opera browser • DataViz Documents to Go • Messaging• GPS receiver• Record and Play multiple

audio formats• Integrated 2.0 megapixel

camera• Video

• Capture at 15 fps • Playback up to 30 fps• Multiple video formats

supported• Up to 32GB of storage

GPSReceiver


37

Document Reduction: Music (Audio) Portability

37

iPod Touch(≤32GB)

Optical Storage(4.7GB ⇒ >75 Albums)

Solid State Memory

~60MB/Album>500 Albums

Rissa Studios

Environmental Impact of

Electronics

Electronics as a solution to Climate Change


Electronics as solution to climate change• Smart city planning• Smart buildings• Smart appliances• Dematerialization• Smart industry• I-optimization• Smart grid• Integrated renewables• Smart work• Intelligent transport

Potential Impact: Reduction of 1 billion tons of Green House Gas emissions

Sustainability

Lawrence Berkeley National Laboratory

Journal of Industrial Ecology• Premier journal in the areas of

analysis, trends, and critical assessments of innovations and technologies related to sustainability

• Deep historical ties to the research community on ICT and environment– “E-Commerce, the Internet, and the

Environment,” Volume 6, Number 2

• Ranked in top 1/3 of environmental science journals

• Special issue sponsor: Computer Sciences Corporation’s Leading Edge Forum

Lawrence Berkeley National Laboratory

Applications“Energy Benefits of Electronic Controls at Small and Medium Sized U.S. Manufacturers”

Eric Masanet, Lawrence Berkeley National Laboratory

Energy savings from one SME control system installation =

-1,400 efficient refrigerators, or

- 2,150 CFLs, or

- 20 upgrades to a Prius.

Combustion

Flue gas

Adjustable speed drives (ASDs)

Pump ASDDrives ASD

Air compressors

Schedule

Lighting

HVAC

All controls

Boilers

Motors

Air compressors

Lighting

HVAC

Combustion systems

Steam systemsMotor systemsHVAC systems

0

10

20

30

40

50

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000

Med

ian

leve

lized

CO

2ab

atem

ent c

ost (

CR

F=0.

15)

(200

9 $/

Mg

CO

2)

Median CO2 reduction (Mg CO2/year)

Installation typeControlsEquipment upgradesMaintenance

2011 iNEMI Roadmap

Environmentally Conscious

Electronics Chapter

Environmental Conscious Electronics (ECE)

The ECE Chapter has 5 Focus Topics 1. Materials2. Energy3. Recycling4. Eco Design5. Sustainability

43

It is one of 21 chapters in the iNEMI Roadmap. Each of these also considers the Environmental impact in their specific technical areas.

The 2011 roadmap became available on March 31st 2011.

Summary of key issues identified and being worked on

1. Materials– Un-Harmonized restrictions challenge science based

evaluation – Remaining Lead and halogen free challenges– Rare earth metals – Nano Materials

2. Energy– Efficiency – harmonized requirements and metrics– Carbon footprint - promote credible, workable methodologies

3. Recycling– Common approach and infrastructure – closer collaboration– Harmonize patchwork requirements– Market incentives for recovered materials

44

4. Eco-Design– Life cycle impact methodologies and database needs – Design tools that incorporate LCA analysis real time

5. Sustainability– ICT technology as an enabler to address climate change– Water and manufacturing eco-efficiency are emerging areas

45

ECE Chapter Continued

2011-2021R&D to Create Opportunities

Becoming more proactive in our

environmental collaboration


Effective Application of Tools: 2001

……

Specialty Materials

……

……

……

……

……

……

…B

ase Stations..

Coal

……

…

……

…

Services

……

Cellular

Service

……………

Product / Systems

………

Cellular

Phones

Autom

obiles

…

Televisions

…

Subsystem

……………………

Components


……

Hydro-

electric

Nuclear

Reynolds

Alcoa

KR

UPP

US Steel



… …

… ……..… …………………

DfEFood chain LC

A

Input-Output


Next Generation Tools/Data-2011

……

Specialty Materials

……

……

……

……

……

……

…B

ase Stations..

Coal

……

…

……

…

Services……

Cellular

Service

……………

Product / Systems

………

Cellular

Phones

Autom

obiles

…

Televisions

…

Subsystem

……………………

Components


……

Hydro-

electric

Nuclear

Reynolds

Alcoa

KR

UPP

US Steel



… …

… ……..… …………………

Simplified LC

A For Various Segm

ents

Transient Input-OutputFor new material applications

End of LifeImproved Knowledge and Better Data for EOL Scenarios

Improved Knowledge of User Behavior Use Phase

Simplified LC

AFor ElectronicM

aterials


Fruitful Areas for Academic R&D-2011

• Shared, peer reviewed, data bases

• Simplified LCA For Key Product Segments

• Eco-Reliability (Green applications need to have high reliability, multi-stage life cycles or short life time with full asset recovery

• Simplified LCA For Electronic Materials

• Environmental Evaluation of alternative biopolymers

• Sample Business Cases on Sustainability

• Improved Knowledge of User Behavior

Concluding Thoughts

Our Journey to 2021


Concluding Thoughts Where are we now

• New global environmental requirements continue to multiply – faster than industry can effectively respond

• Industry needs to be more proactive in developing solutions that:– Are based on science and engineering, delivering value to

customers– Are available in advance of new regulations– Can influence future regulations and stakeholder groups for

more sustainable results• Sustainability will be a major undertaking for industry

as well as society. • Electronic solutions can help to empower people to

live a more sustainable lifestyle


Concluding ThoughtsWhere do we want to be in 2021

• Our primary focus will be on Electronic Products empowering sustainable lifestyles

• Our secondary focus will be on– Continuing to reduce energy use of our products– Increasing the recycling and reuse of our products

• We will have expand our understanding of our ecologic impact on the world.

“The Journey to a Sustainable World ”Electronic Products are leading in the Journey

www.inemi.orgEmail contacts:

Bob [email protected]