Life Cycle Engineering

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Life Cycle Engineering
MEC
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Contents

• Product Life Cycle.
• Life Cycle Design.
• Life Cycle Engineering.
• Design for Environment.
• Life Cycle Analysis.
• End of Life Disposition.
• Impact Assessment.

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Product Life Cycle

• Length of time that a product is available to
  customers.
• Starts when a product, good or service introduced
  into the market.
• Ends when removed from the shelves.
• Four stages in a product's life cycle
  introduction, growth, maturity, and decline.

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Combining Natural and Product Life Cycle
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Environmentally Conscious Design and Manufacturing

• To reduce existing and potentially harmful
  environmental impacts.
• To minimize both the use and generation of
  hazardous materials.
• Minimize energy consumption.
• To reduce environmental burdens through creation
  of innovative product designs.

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Environmentally Conscious Design and Manufacturing

• Reduction of hazardous substances in the
  processes.
• Analysis and development of waste-free and clean
  mechanisms/technologies.
• Develop and implement waste-free processes
  through total systems integration.
• Cradle-to-grave design for environment.

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Environmentally Conscious Design - Merits

• Reduced future costs for disposal.
• Reduced environment and health risks.
• Improved product quality at lower cost.
• Safer and cleaner factories.
• Better public image.
• Reduction in energy consumption and wastes.

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Material Recovery

• Design for recycling, remanufacturing and reuse
  of product parts.
• Ease of disassembly frees parts more easily at
  the end of the products life-cycle.
• Choice of design elements and procedures that
  allow outdated or run-down units to be reused,
  recycled, or discarded.
• Retired materials recovered and used.

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Life Cycle Design

• Life Cycle Engineering.
• Environmentally sound design of products based on
  the whole lifecycle.
• Starts from raw material exploitation and
  processing, preproduction, production,
  distribution, to use and returning materials back
  into the industrial cycles.
• Centres on design and production of products that
  have minimal environmental impact during the
  entire life-cycle.

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Life Cycle Design

• Considers environmental, performance and cost
  requirements throughout the duration of a
  facility.
• Supports a more balanced view of investment
  considering construction, maintenance, renewal
  and decommission issues.
• Motivation environment, economy, regulations
  and standards.

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Motivation for Life Cycle Engineering

• Emphasis on sustainability, diminishing material
  supplies, rising producer responsibility, product
  take-back legislation, and marketing of recycled
  material.
• Good material and manufacturing process selection
  improve technical efficiency, productivity,
  reduce the environmental impact.
• Use in automobile industry and the electronics
  and electromechanical industry.

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Motivation for Life Cycle Engineering

• A norm for global companies that want to remain
  competitive.
• Use of computer tools or utilities that require
  minimal user input, run automatically in the
  background of the design process.
• Design for the environment an element of LCE.

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Factors to be Considered in Life Cycle
Engineering Approach
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Design for Environment - Goals

• Efficiently manage renewable resources.
• Reduce the use of non-renewable resources.
• Minimize toxic release into the environment.
• Environmental issues addressed at each stage of
  products life-cycle.
• Five principles applied prevention,
  functionality thinking, life-cycle thinking,
  chain management and paradigm shifts.

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Design for Environment(DFE)

• Internal and external drives, and internal
  capacity and resources influence DFE evolution in
  electronics industry.
• Internal drives company environmental
  strategies and cost savings.
• External drives customer requirements and
  regulations.
• DFE to be integrated into early stages of design
  than left to the later detail stages.

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DFE Process
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Set DFE Agenda

• Identify internal and external drivers.
• Internal drivers
• - Low environmental impact raise product
• quality.
• - Communicating high level of environmental
  
• product quality improve a companys image.
• - Less material and less energy in
  production,
• considerable cost savings.

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Set DFE Agenda Internal Drives

• - Fostering Innovation.
• - Improving occupational health and
  safety.
• - Employee motivation.
• - A moral sense of responsibility for
• conserving the environment and nature.
• - Transition to cleaner lifestyles.
• - Demand for greener products.

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Set DFE Agenda External Drives

• External Drives
• - Environmental legislation.
• - Market Demand, well-informed
  industrial
• customers and end users.
• - Sustainability activities undertaken
  by
• competitors.
• - Trade organisation encouragement to
  take
• environmental action by sharing
  technology
• and establishing codes of conduct.

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Set DFE Agenda External Drives

• - Suppliers influence company behavior,
• introduce more sustainable materials and
• processes.
• - Social pressures.

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Set DFE Agenda

• Set environmental goals for the product
• - include long term environmental goals.
• - define how organization complies with
• environmental regulations.
• - how organization reduces environmental
• impact of its products, services,
  operations.
• Set up the DFE team
• - team composition depends on organization
• and needs of the specific project.
• - internal and external membership.

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Identify potential environmental impacts

• Anticipate impacts.
• Detailed assessment may not be possible at a
  conceptual stage.

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Choose and Apply DFE Guidelines.

• Guidelines to help make early decisions.
• Apply them throughout product development.
• Apply DFE guidelines to initial product design.
• Initial material choices made along with some of
  the module design decisions.
• Detailed impact analysis possible only after the
  design is more fully specified.

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Assessment of Environmental Impacts

• Based on detailed bill of materials (BOM),
  including sources of energy, component material
  specifications, suppliers, transportation modes,
  waste streams, recycling methods, and disposal
  means.
• Life cycle assessment (LCA) tools available to
  conduct environmental assessment.

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Comparing Environmental Impacts to DFE Goals

• Compare environmental impacts of evolving design
  to DFE goals established in the planning phase.
• Compared to judge lowest environmental impacts.

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Refining Product Design

• To reduce or eliminate any significant
  environmental impacts through redesign.
• Repeated to reduce environmental impacts to
  acceptable levels till environmental performance
  fits DFE goals.
• Redesign for ongoing improvement of DFE.

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Reflecting DFE Process and Results

• How well did we execute the DFE process?
• How can our DFE process be improved?
• What DFE improvements can be made on derivative
  and future products?
• Scale of 0 to 100 may be used.
• Effective DFE maintains or improves product
  quality and cost while reducing environmental
  impacts.

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Life Cycle Analysis

• Tool for evaluating the environmental effects of
  a product, process or system throughout its life.
• To identify improvement possibilities of
  environmental behaviour of systems.
• Considers the whole life cycle of a system.
• Collection and interpretation of material and
  energy flows.
• May require investment in measurement equipment
  for data acquisition.

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Life Cycle Assessment Triangle
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Goal Definition and Scoping

• Purposes of study clearly defined.
• Scope of study developed define system and its
  boundaries, assumptions and data requirements
  needed to satisfy study purpose.
• Functional unit defined performance of a
  product measured to serve as a basis for product
  system analysis and comparison with competing
  products.

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Life Cycle Inventory

• Various inputs and outputs (energy, wastes,
  resources) quantified for each phase of the life
  cycle.
• System represented by a flowchart to include all
  required processes extracting raw materials,
  forming them into product, using the resulting
  product, and disposing of and/or recycling it.

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Life Cycle Inventory
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Life Cycle Inventory

• Environmental burdens identified.
• Output of LCI presented in the form of an
  inventory table.

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Life Cycle Inventory
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Impact Assessment and Interpretation.

• Environmental burdens identified in the inventory
  stage quantitatively/qualitatively characterized
  as to their effects on local and global
  environments.
• Magnitude of effects on ecological and human
  health and on resource reserves determined.
• LCI burdens categorized in terms of ecological
  health, human health and resource depletion.
• Potential impacts within each category estimated.
• Impacts weighed and compared with each other
  (Valuation).

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Improvement Analysis

• Identifying chances for environmental
  improvement, preparing recommendations.
• An activity of product focused pollution
  prevention and resource conservation.
• Improvement proposals to be combined with
  environmental costs and other performance factors.

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Life Cycle Analysis Process of a Pencil
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End of Life Disposition

• Designers to identify ideal end-of-life
  strategies before specifying the structural
  attributes of the product.
• Post first life extension strategies include
  policies to reuse, remanufacture, recycle and
  recover the product at the end of its life.
• Remanufacturing an economically and
  environmentally superior end-of-life alternative
  to material recycling.

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Design for Disassembly Index

• Cost considerations comprise of costs of
  disassembly (labour) and disposal.
• Gain derived from sale of recovered material and
  components.

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Total Disassembly Time
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Total Disassembly Cost
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Total Disposal Cost
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Cost Drivers
Being the cost contributions associated with the
company, society and users.
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Tools for Environment Analysis

• Environmental analysis tools for LCA inventory
  assessment, impact assessment and improvement
  assessment.
• Inventory assessment identification and
  quantification of inputs and outputs, i.e. keeps
  track of materials, energy and wastes throughout
  the duration of a product system.

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Environment Analysis Tools

• Improvement assessment recognizing and
  implementing opportunities for reducing the total
  environmental impact.
• Further assessments to sustain data gathered
  during the inventory analysis.
• Development teams to measure all inputs and
  outputs entering the system.
• Useful outputs (products and their counterparts)
  and residuals leaving the system as emissions to
  air, water and land quantified.

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Impact Assessment

• Identifies the main impacts associated with the
  product.
• Evaluation (technical qualitative, quantitative
  characterization) of the inventory inputs and
  outputs in terms of their impact on the
  environment.
• Impacts characterized to compare different
  designs.
• Procedures, end-of-life and effects of residuals
  tracked.

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Impact Assessment

• Environmental impacts include resource depletion,
  ecological degradation, and the effects on human
  health and welfare.
• Models used to indicate depletion of resources
  and generation of residuals in a product system
  that pollutes environment.
• Impact analysis brings an environmental profile
  of the product system.
• Helps design engineers and planners to understand
  the environmental consequences of a design more
  fully.

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Criteria for Effective Environmental Consciousness

• Durability.
• Materials.
• Recyclability.
• Reusability.
• Maintainability/serviceability.
• Emissions.
• Energy consumption.

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Conclusion

• Life Cycle Engineering and Life Cycle
  Assessment are highly important to design and
  materials engineers because environmental
  considerations are increasingly important factors
  in design and materials selection. Creation and
  development of environmental management systems,
  including extended producer responsibility and
  product stewardship responsibility, pollution
  prévention strategies, "green" procurement
  guidelines, and eco-labeling programs are
  evidences of growing importance of life-cycle
  concerns.

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References

• Atila Ertas Hong-Chao Zhang, Life-cycle
  engineering Issues, tools and research,
  International Journal of Computer Integrated
  Manufacturing, 2003, Vol. 16, No. 45, pp
  307316.
• ASM International Materials Life-Cycle Analysis
  Committee, Life-Cycle Engineering and Design,
  ASM Handbook, Volume 20 Materials Selection and
  Design G.E. Dieter, editor, pp 96-103.

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References

• K.T. Ulrich and S.D. Eppinger, Design for
  Environment, Draft chapter for the fifth edition
  of Product Design and Development, McGraw-Hill,
  New York, 2011.
• https//www.investopedia.com/terms/p/product-life-
  cycle.asp
• Wikipedia and other Internet Sources..

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• Thank You.