green design of electronic...

EcoEco--Design and Green Manufacturing Team Design and Green Manufacturing Team EcoEco--Design and Green Manufacturing Team Design and Green Manufacturing Team

Eco-Design Team

Green Design of Electronic Products

15 April 2010

Speaker:Wi K C Y A i t P f PhDWinco, K.C. Yung, Associate Professor, PhDEcoDesign and Green Manufacturing TeamDepartment of Industrial and Systems Engineering,

1

Department of Industrial and Systems EngineeringDepartment of Industrial and Systems Engineering The Hong Kong Polytechnic UniversityThe Hong Kong Polytechnic University

Hong Kong Polytechnic University


AgendaEco-Design Team

Agenda

What is Ecodesign?Ecodesign – 6 RE PhilosophyEcodesign – 6 RE PhilosophyApplied ecodesignEcodesign in European Union (EuP & ErP)Ecodesign in European Union (EuP & ErP)Ecodesign ideas for mobile phoneS t diSome more case studies

2



What is Ecodesign?Eco-Design Team

What is Ecodesign?

Minimization of life cycle impact

Energy

EcoDesign

Energy

MaterialsgPackaging and Transport

Chemical substances, Potential toxicity

Durability, Recyclability

3



Ecodesign measurement in fiveEco-Design Team

Ecodesign measurement in five focal areas Energy

kWh based on assumption of consumer behaviour

Weightk b ( f i t ti ) kg, number (of wires, components, connections)

Packaging kg volume ratio’s kg, volume, ratio s

Hazardous substances chemical content procedure chemical analysis chemical content procedure, chemical analysis

Recyclability Material Recycling Efficiency, disassembly time

4


Material Recycling Efficiency, disassembly time


Ecodesign definitionEco-Design Team

Ecodesign definition (ISO/TR 14062) ISO/TR 14062

( )

Integration of environment aspects into product design and development

ISO 14062 Technical Report Guidelines to integrate environmental issues into product Guidelines to integrate environmental issues into product

development Addition to ISO 14001 Report describes the essential Ecodesign (DfE) processes Report gives opportunities, ideas = not prescriptive

5



Ecodesign definitionEco-Design Team

Ecodesign definition (EU directive 2005/32/EC)( )

According to Directive 2005/32/EC for Energy-According to Directive 2005/32/EC for Energyusing product

EcoDesign means the integration of environmental aspects into product design with the aim of improving the environmental performance (parameters) of the EuPe o e ta pe o a ce (pa a ete s) o t e uthroughout its whole life cycle.

It’s philosophy is to reduce the environmental impacts It s philosophy is to reduce the environmental impactsthroughout the whole product life cycle by better product design

6



Ecodesign 6 RE philosophyEco-Design Team

Ecodesign - 6 RE philosophy1. Re-think the product and its functions, e.g., how the product

may be used more efficientlymay be used more efficiently.

2. Re-duce energy and material consumption throughout the product’s life cycleproduct s life cycle.

3. Re-place harmful substances with more environmentally friendly alternativesfriendly alternatives.

4. Re-cycle. Select materials that can be recycled, and build the product in a way that it can be easily disassembled forthe product in a way that it can be easily disassembled for recycling.

5. Re-use. Design the product so parts can be reused.g p p

6. Re-pair. Make the product easy to repair so that the product does not yet need to be replaced.

7


Source: UNEP Guide to LCM


Position of applied ecodesignEco-Design Team

Position of applied ecodesign

Design for Functionality

EcoDesign Design for X

X(Value in the shop) (Minimization of

impact over life-cycle)

X =• Energy minimization• Dematerialization• Minimizing packaging

and transport• Chemical contentChemical content

reduction• Recycling

A lot of products are bought on basis of fashion, not on basis of functionality!

8


y


Design for functionalityEco-Design Team

Design for functionality

Real function: Transport, Pictures

Design for Functionality

Pictures

Cost of ownershipDesign for Functionality p

Convenience, health and safety

Feel good, Quality of life

9



Design for functionalityEco-Design Team

Design for functionality Embodiments always require certain physics Embodiments always require certain physics,

chemistry, …A lot of the environmental load is already fixed!A lot of the environmental load is already fixed!

First Design Strategy: First Design Strategy: What is the real function needed and what physics is needed?physics is needed? Real function includes intangibles! Alternative physics example: Liquid Crystal Display Alternative physics example: Liquid Crystal Display

instead of Cathode Ray Tube

10



EcoDesign --> Design for XEco-Design Team

EcoDesign --> Design for X

Minimization of life cycle impact

EnergyEnergy

MaterialsEcoDesign

Packaging and Transport

Chemical substances, Potential toxicitytoxicity

Durability, Recyclability11



Example of Design for XEco-Design Team

Example of Design for X

Recuperation of resourcesp

Amount of resources savedDesign for Recycling

Purity / Level of reapplication

Toxic control of left over

12



Ecodesign in European UnionEco-Design Team

Ecodesign in European Union (EuP & ErP)( )

Two Directives related to ecodesign have been adopted by the European Union: Directive 2005/32/EC (EuP) and Directive 2009/125/EC (ErP)Directive 2009/125/EC (ErP).

Both ecodesign directives are EU framework directives. This means they set forth the general plan but not the specifics.means they set forth the general plan but not the specifics.

Two ecodesign Directives are virtually identical (almost word-for-word) except for scope.

Directive 2005/32/EC regulates energy-using products (EuP) while its replacement Directive 2009/125/EC regulates energy related products (ErP) 20 November 2009energy-related products (ErP), 20 November 2009.

13





Energy-using products (EuP) require energy (electricity, fossil fuels or renewable energy) input to work as intended; includesfuels or renewable energy) input to work as intended; includes products that generate, transfer or measure energy; excludes products that transport people or goods

Energy-related products (ErP) impact energy consumption d i th i l i l d t ti t i lduring their use; examples include construction materials such as windows & insulation and water-using products such as shower heads & taps; includes EuP; excludes products p ; ; pthat transport people or goods

14





The new ErP Directive will now include a broader range of products. In addition to products which use, generate, transfer orproducts. In addition to products which use, generate, transfer or measure energy, certain energy-related products that could also contribute to significant energy saving during use will be included.

The Eco-design Directive for Energy-related Products establishes a framework under which manufacturers and importers of Energy-

( )related products (ErP) will, at the design stage, be obliged to increase energy efficiency and reduce products’ negative environmental impacts.

15





EuP/ErP Directive does not include any ecodesign requirements until an implementing measure that provide the prescription for compliance for each product category is issuedproduct category is issued.

Products of concern will continue be defined by Implementing Measures that will be required to meet the generic and specific eco design requirements as definebe required to meet the generic and specific eco-design requirements as define as follows: Generic Eco-design Requirements

E d i i t b d th l i l fil h l fEco-design requirements based on the ecological profile as a whole of a product without set limit value for particular environmental aspects

Specific Eco-design RequirementsA tifi d d bl d i i t l ti t ti lA quantified and measurable eco-design requirement relating to a particular environmental aspect of a product, such as energy consumption during use, calculated for a given unit of output performance.

16





To date, implementing measures have been issued include:

17





Manufacturers of a product covered by an implementing measure have these three obligations prior to placing themeasure have these three obligations prior to placing the product on the EU market (or in service): Conformity assessment that the product meets all relevant requirements CE mark affixed to the product EC declaration of conformity issued per Annex VI in ErP Directive

Manufacturers located outside the EU may not fulfill these obligations directly, but must engage either an "authorized representative" or the importer to do so on their behalf.

18



Ecodesign ideas for mobileEco-Design Team

Ecodesign ideas for mobile phonep

Selection of products Five mobile phone models (all of which possess the

same functions) were selected for this case study. Three products were made in Korea, and two were made

in Europe.A h d d b XX h A phone produced by company XX was chosen as a reference product, and the phones produced by the other Korean companies were selected as competitorother Korean companies were selected as competitor products.

.19


Source: www.ecodesign-company.com/documents/ECODESIGN_ISO14062.pdf




Life cycle thinking of mobile phones Existing LCA results of a mobile phone Existing LCA results of a mobile phone

(MOCIE 2001) was used to identify key life cycle stages. A di t th fi i t l 59% f ll i t l According to the figure, approximately 59% of all environmental impacts caused by mobile phones derive from the raw material acquisition stage.

Other literatures also reported similar results saying that more that 60% of all impacts derives from the raw material acquisition stage (Pfahl 2001, Vallés et al 2001).(Pfahl 2001, Vallés et al 2001).

Thus, the raw material acquisition stage is chosen as the most significant life cycle stage of a mobile phone.

20






Environmental benchmarking for mobile phonesMarking of hazardous componentsMarking of hazardous components No markings of hazardous compounds can be found in mobile

phones. Hence, the EU regulation entitled “Restriction on the use of certain hazardous substances (RoHS)” has been used to set up the benchmarking parameter.

Hazardous substances considered in the benchmarking parameter a a dous substa ces co s de ed t e be c a g pa a eteinclude cadmium, lead, mercury, hexavalent chromium, Poly Brominated Biphenyls (PBB) and PolyBrominated Diphenyls Ether (PBDE)(PBDE).

21






Environmental benchmarking for mobile phonesSurface area of PCB (Printed Circuit Board)Surface area of PCB (Printed Circuit Board) Since the same type of PCB has been used in all mobile phones compared in the

benchmarking process, the amount of hazardous substances used for the manufacturing of PCB is proportional to the surface area of PCB.manufacturing of PCB is proportional to the surface area of PCB.

Since a smaller surface area is desirable to minimize the environmental impacts of PCB, the target surface area was chosen as the smallest surface area, 30.40cm2, realized by Competitor 2’s product.

Thus, the environmental improvement target of the PCB surface area was to reduce surface area of existing PCB by 24%

22






Environmental benchmarking for mobile phonesNumber of components on PCBNumber of components on PCB Integrated circuit (IC) chips are designed to perform integrated functions of individual

components such that they are superior to individual components in function and in environmental performance.environmental performance.

Since a fewer number of components lead to lesser environmental impacts by PCB, the target should be the smallest number of components realized by European 1’s product.

Thus, an environmental improvement target is 22%.

23






Environmental benchmarking for mobile phonesSurface area of the LCD The amount of hazardous substances used for the manufacturing of a LCD is

proportional to the surface area of a LCD Since a smaller surface area is desirable in minimizing the environmental impacts of an

LCD the target surface area was chosen as the smallest surface area 6 785cm2LCD, the target surface area was chosen as the smallest surface area, 6.785cm2, realized by European 1’s product.

Thus, the environmental improvement target of the LCD surface area was to reduce its surface area by 52%surface area by 52%

24






Environmental benchmarking for mobile phonesRatio of weight/length of charger cable The ratio between length of the charger cable and weight indicates material

consumption for the charger; thus, a ratio between the length and weight of the charger cable was chosen as a benchmarking parameter for comparison.

A smaller ratio is desirable in minimizing the environmental impacts of a charger cable, the smallest target ratio, 0.14 was chosen.

Thus, the reference product’s environmental improvement target of the length and weight ratio of the charger cable was to reduce its ratio by 60%weight ratio of the charger cable was to reduce its ratio by 60%.

25






Environmental benchmarking for mobile phonesWeight of packaging material Packaging represents typical environmental problems of a product, the lesser the weight

is the better the environmental performance. Since lighter packaging is desirable in minimizing the environmental impacts of

packaging the target weight was chosen as the smallest value 167 94 realized bypackaging, the target weight was chosen as the smallest value, 167.94, realized by European 2’s product.

26






Environmental benchmarking for mobile phones Similarly, analysis was conducted for weight of product, number and weight ofSimilarly, analysis was conducted for weight of product, number and weight of

accessory parts, number of types of material, number of parts etc.

27






Environmental information for mobileinformation for mobile phones Ecodesign information

for a mobile phonefor a mobile phone came from the environmental improvement target values of each benchmarking parameter and its ecodesign guidelines.

28






Rough ecodesign ideas of a mobileideas of a mobile phones The brainstorming

technique wastechnique was used to generate ecodesign tasks or ideas using the ecodesign information.

29




Case studies 1Eco-Design Team

Case studies 1Product: UHF receiver unit for carCompany: CEL Connaught Electronics

CEL manufacture the electronic component in cars that receive and manage the remote vehicle security keyless entry (RKE) signal from the key fob transmitter.

Country: IrelandSource: http://www.envirocentre.ie/envirocentre.asp?id=15&cid=40

security keyless entry (RKE) signal from the key fob transmitter. The UHF receiver unit, fixed within the car, consist of a printed circuit board packed with a number of

electronic component while also achieving significant environmental benefits, namely a 40% reduction in materials content (particularly hazardous materials) and a three fold reduction in the unit’s energy demanddemand.

The investigation and reduction of the environmental impacts associated with the life cycle of the product to include the following: The size of the unit’s UHF receiver was reduced and integrated into the

motherboard The composition and number of components in the finished unitmotherboard. The composition and number of components in the finished unit was reduced. The study enabled these environmental improvements to be achieved while reducing manufacturing cycle time and also reducing process and product costs.

The amount of energy used by the unit in operation was reduced three fold The amount of energy used by the unit in operation was reduced three fold. The wastes generated during the life cycle of the product were reduced due to

a 40% reduction in materials content, particularly hazardous materials. CEL evaluated the use of lead free solder and tested it in the production of this

product This enabled CEL to compare the solderability and solder strengths of30


product. This enabled CEL to compare the solderability and solder strengths of a lead and lead free alternative.



Case studies 2Product: Apple iMacCompany: Apple

Energy efficiency: In the new iMac, Apple managed to reduce the energy consumption in standby

Company: AppleCountry: United StatesSource: www.apple.com/environment

mode to 88%. Further energy savings have been realized through the use of efficient power supplies, as illustrated by the 50% decrease in off-mode power usage.

Packaging Packaging for iMac ses 59% less plastic 20% less paper and takes p 40% less ol me Packaging: Packaging for iMac uses 59% less plastic, 20% less paper, and takes up 40% less volume than the iMac G4 flat panel.

Extending life of the product: Apple Do-It-Yourself Parts & Service program enables consumers to purchase and install selected components for a number of Apple systems themselves, including

31


memory, modems, hard drives and many others.



Case studies 2Product: Apple iMacCompany: Apple

Design for recycling:

Company: AppleCountry: United StatesSource: www.apple.com/environmentg y g

Ease of access and disassembly: They strive to simplify the disassembly of their products to encourage recycling. For example, by using fewer screw types to reduce the number of times a recycling operator needs to change the tool-head during disassembly.

Use of highly recyclable materials: Apple uses materials such as polycarbonate for iBook Use of highly recyclable materials: Apple uses materials such as polycarbonate for iBook and iMac enclosures and aluminum for MacBook Pro, Power Mac G5 and Cinema Display enclosures.

Simplification of material types: Large mechanical plastic parts consist of compatible materials or just one material and larger plastic parts are marked with ISO 11460 and ISOmaterials or just one material, and larger plastic parts are marked with ISO 11460 and ISO 1043 plastic codes to aid in sorting.

Use of materials that yield higher secondary material value: Apple uses plastic enclosure parts that do not contain flame retardants, which can reduce the quality of the plastic when

l drecycled.

Product take-back policy: In 2001, the Apple Recycles program began a take-back service for their customers. This program has recycled over 90% (by weight) of all the electronic equipment

32


p g y ( y g ) q pcollected.



Case studies 3Product: Extractor fan for cooking hoodCompany: ATAG Home Products Nederland

Dutch company ATAG developed a modular extraction fan equipped

Company: ATAG Home Products NederlandCountry: NetherlandsSource: http://www.ezp.novem.nl/english/toon.asp?id=25

Dutch company ATAG developed a modular extraction fan equipped with an efficient carbon filter containing openings of various sizes (3.4 MJ saved annually per apparatus, compared to a traditional cooking hood).

No pipe leading to the outside is needed. The filter pattern contains openings of various sizes through which

the extractor surface is fully used, even at the edges effective i i id d l i i ( li dextraction is provided at a lower capacity energy savings (realized

through the reduced extraction of warm air) are around 3.422 MJ annually per apparatus, compared to a traditional cooking hood vibration-free motor.vibration free motor.

During re-circulation, carbon filters are used to remove smells from the air and to re-inject purified air into the kitchen. A pipe leading to the outside is therefore not needed.

33




Case studies 4Product: Phone made with Bioplastic and KenafCompany: NEC

A new mobile phone has gone on sale in Japan that uses bioplastic for its casing The

Company: NECCountry: ArgentinaSource: http://www.learn-ecodesign.net/casesResult.asp

A new mobile phone has gone on sale in Japan that uses bioplastic for its casing. The casing was jointly developed by electronics firm NEC and textiles and plastics group Unitika.

Adding kenaf fibres improved the strength and heat resistance of Unitika PLA . g p gThe temperature at which the PLA changes form could be improved by over 20%.

The Foma N701iECO phone uses polylactic acid (PLA) resin reinforced with kenaf fibres to replace oil-based plastics for the case.

Fall impact durability was increased by adding a biomass-based plasticiser and filler. O ll i l 90% f h i i Overall, approximately 90% of the casing is derived from biological sources.

NEC plans on substituting more than 10% of the oil based plastics in its electronic products with

34


oil-based plastics in its electronic products with bioplastics by 2010.



Case studies 5Product: FAGOR ElectrodomesticosCompany: Front loading washing machine

The company implemented Ecodesign on a washing machine eliminating heavy metals

Company: Front loading washing machineCountry: SpainSource: IHOBE, A Practical Manual of Ecodesign, 2000

The company implemented Ecodesign on a washing machine eliminating heavy metals and brominated flame retardant, increasing the recyclability (up to 40%), making dismantling easier and establishing contacts with recycling companies.

Implementation in washing machine: Implementation in washing machine: Elimination of heavy metals and halogenated/brominated flame

retardants (compliance with RoHS Directive) Increase in recyclability of the product (up to 40%) Marking of plastic components > 50 grams for recycling (according to

standard ISO 11469) Easy dismantling of heavy and voluminous components and electronic

components (design for dismantling approach) p ( g g pp ) Creation of a logo and information sheet for users (collection and

recycling) Editing of a product Information manual for recyclers (components,

instruction for treatments etc)35


instruction for treatments, etc) Gain of an innovative image of the product and of the company itself



Case studies 6Product: Computer mouse, Eco-mouseCompany: KERP

The Eco-mouse demonstrate the benefits of a comprehensive ecologically based

Company: KERPCountry: AustriaSource: www.kerp.at/index.php/_komaus/507/0/

The Eco-mouse demonstrate the benefits of a comprehensive, ecologically based approach with: improved management of the power consumption; use of components with low levels of hazardous substances; use of components with low levels of hazardous substances; a casing made of renewable materials; lead-free soldering; and recycling-oriented product design recycling-oriented product design.

The objective of the design process was to create a role model for EcoDesign of electrical and electronicrole model for EcoDesign of electrical and electronic products and to show the innovative benefits of EcoDesign.

36



Eco-Design Team

~~~END~~~END

37


green design of electronic...

Documents