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INNOVATION IN LIFE CYCLE ENGINEERING
AND SUSTAINABLE DEVELOPMENT
Innovation in Life Cycle Engineering
and Sustainable Development
Edited by
DANIEL BRISSAUD
Université de Grenoble, France
SERGE TICHKIEWITCH
Université de Grenoble, France
and
PEGGY ZWOLINSKI
Université de Grenoble, France
A C.I.P. Catalogue record for this book is available from the Library of Congress.
ISBN-10 1-4020-4601-4 (HB)
ISBN-13 978-1-4020-4601-8 (HB)
ISBN-10 1-4020-4617-0 ( e-book)
ISBN-13 978-1-4020-4617-9 (e-book)
Published by Springer,
P.O. Box 17, 3300 AA Dordrecht, The Netherlands.
www.springer.com
Printed on acid-free paper
All Rights Reserved
© 2006 Springer
No part of this work may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, microfilming, recording
or otherwise, without written permission from the Publisher, with the exception
of any material supplied specifically for the purpose of being entered
and executed on a computer system, for exclusive use by the purchaser of the work.
Printed in the Netherlands.
Contents
Introduction to Innovation in Life Cycle Engineering and Sustainable
Development by D. Brissaud, S. Tichkiewitch and P. Zwolinski ..............ix
of Grenoble, France...................................................................................xi
Eco-development of products and sustainable manufacturing strategies:
and P. Zwolinski ..................................................................................... xiii
Business Models
Feasibility and scope of life cycle approaches to sustainable consumption E.G. Hertwich and G.P. Peters...................................................................3
A business-oriented approach to the product life cycle G. Molcho and M. Shpitalni......................................................................17
Meeting the Climate Change Challenge C. Rynikiewicz...........................................................................................33
Assessing product life cycle strategies in the Japanese market Y. Ogushi, M. Kandlikar and H. Dowlatabadi .........................................49
Applications of service engineering methods and tool to industries T. Sakao, Y. Shimomura, M. Lindahl and E. Sundin.................................65
End-of-Life Strategies
Towards self-disassembling products J.R. Duflou, B. Willems and W. Dewulf ....................................................87
Indicators to measure sustainability of an industrial manufacturing E. Raizer Neto, M.T.Mariotte and R.T.P.Hinz........................................111
The key interests of the Integrated Design Centre by D. Brissaud
Integrated Design Centre 3S Laboratory, University,
vi Contents
Concepts and definitions for product recovery M. Lindahl, E. Sundin, J. Östlin and M. Björkman.................................123
Remanufacturing of flat screen monitors C. Franke, S. Kernbaum and G. Seliger .................................................139
Improving product recovery decisions through product information A.K. Parlikad, D.C. McFarlane and A.G. Kulkarni ...............................153
Photocopier remanufacturing at Xerox UK A. King, J. Miemczyk and D. Bufton.......................................................173
Dynamic process and operation planning for hybrid disassembly H.-J. Kim.................................................................................................187
Clean technologies for recycling H.V. de Medina .......................................................................................199
Identifying availability contribution of lifecycle-adapted services J. Fleischer and D. Nesges .....................................................................209
Product Development for Sustainability
Designing products that are never discarded P. Zwolinski and D. Brissaud .................................................................225
Guidelines in ecodesign: a case study from railway industry J. Lagerstedt and C. Luttropp.................................................................245
Identifying and assessing environmentally benign modules M. Voß and H. Birkhofer ........................................................................255
Strategies and material flow in ecodesign C. Luttropp..............................................................................................271
Screening life cycle modelling for sustainable product design M. Fargnoli and F. Kimura ....................................................................281
Using design for environment for redesigning a household appliance S. Kara, H. Kaebernick and S. Ibbotson.................................................293
Modular design of technical product-service systems J.C. Aurich, C. Fuchs and C. Wagenknecht ...........................................303
Contents vii
Estimating the environmental profile of early design concepts W. Dewulf, B. Willems and J.R. Duflou ..................................................321
Product Life Cycle Management
Design for environment by target life cycle costing D. Janz, M. Hornberger and E. Westkämper .........................................337
PLM to support hazard identification in chemical plant design F. Giannini, M. Monti, S. Ansaldi and P. Bragatto ................................349
Smart machining systems: issues and research trends L. Deshayes, L. Welsch, A. Donmez, R. Ivester, D. Gilsinn,
R. Rhorer, E. Whitenton and F. Potra ....................................................363
Development of methods to support the implementation of a PDMS J. Feldhusen, B. Gebhardt, N. Macke, E. Nurcahya and F. Bungert......381
The role of knowledge management in product lifecycle G. Colombo and D. Pugliese ..................................................................397
A product-process-organisation integrative model for collaborative design F. Noël ....................................................................................................407
Dynamic life cycle performance simulation of production systems J. Niemann and E. Westkämper ..............................................................419
LC universal model for the enterprise information system structure A. Bernard, M. Labrousse and N. Perry .................................................429
Authors index..........................................................................................447
ix
Introduction to
Innovation in Life Cycle Engineering
and Sustainable Development
This book presents a selection of papers related to the 12th CIRP Interna-tional conference on Life Cycle Engineering, held at the university of Grenoble, France, in April 2005. The CIRP Life Cycle Engineering con-ference is an annual event and contributes to a continuous updating of re-search in the field of environmental issues in mechanical engineering, de-sign and manufacturing.
The scientific committee members of the conference have selected all the lectures from complete papers, which is the guarantee for the conference of quite an outstanding scientific level. After that, a new selection has been carried out to retain the best publications, which establish in a book, a state-of-the-art analysis as regards Innovation in Life Cycle Engineering and Sustainable Development. The 30 papers in the book, were selected from the 71 papers presented during the conference.
Sustainable development is more and more at the core of governments and industries policy. Industrial production and consumption culture are facing dramatic changes due to pollution and waste problems, exhaustion of available non-renewable resources and rapid growth in world population. So, the environmental focus has shifted from production processes to the product's entire life cycle. The potential of technology to create synergies between environmental protection and economic growth has been recog-nized. Life cycle engineering aims at providing engineering tools targeted towards cleaner product-oriented activities for improving the environment while contributing to competitiveness and growth.
It is within this context that the following themes were highlighted during the conference:
x Introduction
Business models,which aims at determining how efficient can be a life cycle strategy from different point of view (customer, policy, environment, economics,…).
End of life strategies,
presenting recent approaches and technological solutions for end-of life treatments.
Product development for sustainability,
which aims at showing how designers integrate environmental considera-tions to improve their solutions.
Product life cycle management,
dealing with methods and tools to support life cycle considerations.
This book is divided into four sections reflecting the above themes and will be of interest to academics, students and practitioners, specializing in environmental issues in mechanical engineering. We hope that you will find it of the greatest interest to compare your various points of view within the field broached throughout the conference. We hope you all en-joy reading this book, which aims to be a reference textbook for all re-searchers in this particular field and for the teaching staff confronted with training methodologies in integrated design and environment. It will allow you to assess the scope of the development prospects in an extremely wide ranging field.
Finally, we would like to highlight the very significant input of the mem-bers of the organizing committee for the success of the conference and to express our sincere appreciation to all the authors and to the members of the international program committee.
Daniel Brissaud
Serge Tichkiewitch
Peggy Zwolinski
xi
Integrated Design Centre
3S Laboratory University of Grenoble, France
The Integrated Design Centre is part of the 3S Research Laboratory sponsored by the technological university of Grenoble (INPG), the scien-tific university of Grenoble (UJF) and the National Centre for the Scien-tific Research (CNRS).
Objectives
For more than ten years, the activity of the Integrated Design Centre has focused on the improvement of engineering design and on the develop-ment of mechanical products/systems. New models, methods and com-puter tools dedicated to Integrated Design into a context of Concurrent En-gineering have been developed. This aims at contributing to a better understanding of engineering design and to an improvement of the per-formance of design considered as a collective activity and a complex proc-ess. As seen by the research team, Design is a collaborative and distributed activity, that covers the whole product life cycle. It incorporates analysis as well as synthesis activities. Such a context involves ‘skilled actors’ having points of view, knowledge and tools, interactions with an organization, shared knowledge, decision-making processes, as well as technologies for cooperation activities, for the multi-representation and for shape genera-tion of a product. The main topics are the product-process integration and the integration of downstream activities within the design process (manu-facturing, assembly, recycling, etc.), CAD and geometric modelling, de-sign methodologies and collaborative engineering involving new IT tech-nologies. Research is carried out strongly connected to other disciplines (i.e. industrial sociology, cognitive ergonomics, computer sciences, ap-plied mathematics, etc.).
3 main research directions
Methodologies for Integrated Design, Collaborative Engineering, Inno-vation. This research axis is based on observations conducted on real de-sign processes. On-site studies in companies, experiments about the design activity to set up methodologies for analysing the design process are real-ised. They lead to methods for incorporating innovative solutions in a de-sign process and they help for the management of the concept of value throughout the design process. Software tools and models for defining the product model and an integrated design environment for multi-actors: net-work-based, plug and play approaches, are proposed. Some experiments
xii
are conducted to characterized synchronous and asynchronous tasks among distant or co-located designers. Concepts for providing common work environments between designers having different skills are proposed. Experiments for the evaluation of software tools used in a collaborative context help to validate these concepts.
Product-process integration in design. This second research direction focuses on the formalization of knowledge and on methods related to proc-ess and production skills in mechanical design. The different explored fields are manufacturing processes (forging, assembly, machining, process planning, aluminium extrusion, composite materials), end of life processes (disassembly, recycling, re-use), tolerancing. Models for the dynamic be-haviour of a machining system to improve the design process, to set up new technologies for the drilling process are examples of detailed contri-butions whereas concepts of product-process co-development, of product life cycle address a global level of the design process. Development of software demonstrators for product-process integration are realized to help the validation of the proposed approaches.
Digital Mock-ups for Integrated Design. This direction is necessary to provide methods for performing shape changes with a digital product models. Geometry simplification, adaptation for design and downstream processes, design data adaptation and idealization for mechanical simula-tions, free-form shape parameterisation and deformation, shape optimisa-tion, surface mesh generation and adaptation are examples of researches to produce such mock-ups. Methods for knowledge, know-how and services management around digital mock-ups are also addressed through the capi-talization, re-use of models concerning mechanical analyses of the prod-ucts. Thus, new concepts for the use of digital mock-ups in design can be evaluated through the development of software demonstrators and libraries for digital mock-ups of products.
The whole team in April 2005. Prof. Daniel Brissaud, Prof. Jean-Claude Léon, Dr. Jean-Luc Marcellin, Dr. Philippe M Marin, Dr. Philippe R Marin, Mrs Fadila Messaoud, Dr. Peter Mitrouchev, Dr. Gabriel Moreau, Dr. Frédéric Noel, Dr. Henri Paris, Dr. Frank Pourroy, Dr. Guy Prudhomme, Dr. Guillaume Thomann, Prof. Serge Tichkiewitch, Prof. François Villeneuve, Dr. Peggy Zwolinski.
Sabeur Bettaieb, Cyrille Beylier, Vincent Capponi, Vincent Cheutet, Alexan-dre Ciclet, Lidia Dejeu, Guillaume Drieux, Rosalinda Ferrandes, Gilles Foucault, Alexis Gehin, Okba Hamri, Nizar Haoues, Denis Lovinfosse, El-Hadi Mechekour, Chaiwat Noomtong, Kusol Pimapunsri, Bruno Radulescu, Vincent Riboulet, Ger-man Ruiz, Aurélie Vacher, Frédéric Vignat, Omar Zirmi, Said Zirmi.
Integrated Design Center
xiii
Eco-development of productsand sustainable manufacturing strategies
The key interests of the Integrated Design Centre
The Integrated Design Centre objective is to: promote the change toward sustainable manufacturing paradigms
- lifecycle orientation of the manufacturing industries - development of product oriented services
increase engineering competence - methods and tools for design and engineering
contribute to environmental goals - protection and conservation of natural resources: increase of material
life time - clean processes: sustainable protection and consumption practices - eco-product development: optimization of products’ life cycle
This paper aims at presenting the recent and on-going research studies in the field at the Integrated Design Centre.
Maintenance
Energy consumption
Remanufacturing - Reuse
Energy and material saving
Manufacturing
Design Distribution
UseEnd of life
Transport
Packaging
Wastes - pollution
Energy consumption
Legislative constraints
Design parameters :
material, joining techniques,
structure, pollution,...
Life cycle
Maintenance
Energy consumption
Remanufacturing - Reuse
Energy and material saving
Manufacturing
Design Distribution
UseEnd of life
Transport
Packaging
Wastes - pollution
Energy consumption
Legislative constraints
Design parameters :
material, joining techniques,
structure, pollution,...
Life cycle
Manufacturing
Design Distribution
UseEnd of life
Transport
Packaging
Wastes - pollution
Energy consumption
Legislative constraints
Design parameters :
material, joining techniques,
structure, pollution,...
Life cycle
xiv Eco-development of products and sustainable manufacturing strategies
Product Profiles to design remanufacturable products
The remanufacturing is an end of life strategy that reduces the use of raw materials and saves energy while preserving the value added during the de-sign and manufacturing processes. But, in most of the cases, remanufactur-ing processes must be adapted to existing products because products have not been designed to be remanufacturable. However, the process adapta-tions increase costs and this can lead the overall benefits obtained with the remanufacturing process to be reconsidered. The aim of our research was to propose an approach for the designers to integrate remanufacturing con-straints throughout the design process and mainly in the earliest phases. For the product profiles definition, 8 categories of design criteria were identified based on a survey of about thirty products successfully remanu-factured. The methodology is supported by REPRO² (REmanufacturig with PROduct PROfiles), a tool developed for a real integrated design of remanufacturable products.
Environment and lifecycle product design
The optimization of the product life cycle stages needs an integrated defi-nition of the product throughout designing. New environmental objectives lead to support new design situations calling upon new competences, knowledge and tools. It opens the way to research on new design method-ologies based on the entire lifecycle of the product, with benefit to the en-vironmental impacts, a clean consumption and a sustainable production, and resulting in an increase of the innovative power of companies.
Eco-development of products and sustainable manufacturing strategies xv
Economic &
Technical aspects
Environmental &
Market aspects
Refurbishment &
Valorisation
Structure of the product
& quality tests
Upgradeable architecture
Energy and materials saving
Durabilityof parts
To reduce the use of natural resources
?Profiles of products
emanufactured products
Economic &
Technical aspects
Environmental &
Market aspects
Refurbishment &
Valorisation
Structure of the product
& quality tests
Upgradeable architecture
Energy and materials saving
Durabilityof parts
To reduce the use of natural resources
? Upgradeable architecture
Energy and materials saving
Durabilityof parts
To reduce the use of natural resources
?Profiles of productsProfiles of productsProfiles of products
emanufactured products
From Integration of remanufacturing constraints during the design process ofproducts, PhD thesis, 2004, Miguel Angel LOPEZ-ONTIVEROS
Change in manufacturing industry to support ‘sustainable products’
A ‘sustainable product’ is a product which life is extended by partly or en-tirely re-using for a new life cycle. It contributes to a world where material is used up to its final properties and where energy consumption and wastes are minimized by keeping product added-value in use. It also impacts new ways of consumption. The project aims at examining the necessary condi-tion to transform the industrial organisation to develop and manufacture sustainable products. It focuses on products remanufacturing and reuse strategies and covers the new economic and social paradigm to implement, the environmental impact to minimize and the engineering methodology and tools to develop.
From Integrated design of sustainable products, PhD thesis, in progress, Alexis GEHIN
xvi Eco-development of products and sustainable manufacturing strategies
Environment-based design methodology for innovative products
A 2 years observation of the industrial practice has been realised at RENAULT. It was a mean to identify the tools and approaches used in a firm. The aim of the study was to define the industrial concept of recy-clability to translate this constraint to the design. Integration resulted in adding Recyclability as constraints equivalent to the usual three industrial constraints - Quality, Delay and Costs – to control the development proc-ess of a new product.
From Integration of the recycling constraint during the design process, PhD thesis, 2000, Thierry GAUCHERON
Disassembly for product recycling
Recent actions engaged by manufacturers are focused on the recycling rate required by the European Directives on EEE. Along with traditional recy-cling process as shredding, improving product end-of-life treatment needs the disassembly of the product or part of it. A "Noble" recycling must be managed easily from this. Product disassembly offers new solutions for valorisation: reuse of components, high quality material recycling with better economical indicators and decrease of landfilled wastes. The design work should be assisted by methodologies early in the conceptual design phase of the product and supported by CAD/CAM software identifying and evaluating assembly/disassembly sequences and issues.
Eco-development of products and sustainable manufacturing strategies xvii
From Development of disassembly methodologies for product end of life: Applica-tion to electric and electronic products, PhD thesis in progress, Nizar HAOUES
Other studies
A new manufacturing paradigm: the extended products and their design, PhD thesis in progress, Nicolas Maussang
Trajectories to implement eco-design support in a company practices, PhD thesis in progress, Tatiana Reyes
The validation and improvement of a product remanufacturability assessment and design aid, Engineering
final project, Jamie O’Hare
xviii Eco-development of products and sustainable manufacturing strategies
Main recent publications
Lopez-Ontiveros M.A., Zwolinski P., Brissaud D. — Integrated design of remanufacturable products based on product profiles, Journal of Cleaner Production, to be published.
Gehin A., Brissaud D., Zwolinski P. Imaging a Tool to Implement Sustainable End-of-Life Strategies in the Product Development Phase, in: Actes du 10ème congrès ERSCP, Anvers ERSCP 2005.
Maussang N., Brissaud D., Zwolinski P. Design of Product-Service Systems, in: Actes du 10ème congrès ERSCP, Anvers ERSCP 2005.
Zwolinski P., Prudhomme G., Brissaud D. Environment and design : Toward methods and tools for integration and co-operation, in Methodsand tools for cooperative and integrated design, Kluwer Academic Pub-lishers – ISBN 1-4020-1889-4, 223-232, 2004.
Zwolinski P., Lopez-Ontiveros M.A., Brissaud D. — Product end of life characterisation for integrated design, International Journal of Production
Brissaud D., Zwolinski P. End-of-Life-Based Negotiation Throughout the Design Process, Annals of CIRP, vol 53/1/2004, 155-158, 2004.
Haoues N., Zwolinski P., Cornier A., Brissaud D. — How to integrate end of life disassembly constraints in the early design phases? Interna-
64, 2004.
Haoues, N., Froelich, D., Zwolinski, P. — Disassembly for Valorization in Conceptual Design. In proceedings of the SPIE : International Confer-ence on Environmentally Conscious Manufacturing IV, Philadelphia, Oc-tober 2004., Volume 5583, 31-42, 2004.
Lopez M., Zwolinski P., Brissaud D.— Profile of products for the crea-tion of remanufacturable products during the conceptual design phase. Proceedings of CIRP seminar on life cycle engineering 2003, Copenhagen (Denmark), 11p, 2003.
Prudhomme G., Zwolinski P., Brissaud D. Integrating into the design process the needs of those involved in the product life cycle, Journal of
Contact: [email protected], [email protected]
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Engineering and Computers, vol.6, No 7, 85-89, 2004.
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Engineering Design, vol. 14, No 3, 333-353, 2003.