THE PROCESS OF DESIGN FOR ENVIRONMENT

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THE PROCESS OF DESIGN FOR ENVIRONMENT

• The majority of a products environmental impact
  is decided in the design stage

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Design

• Verb
• To work out or create the form or structure of
  something
• To plan and make something in a skillful or
  artistic way
• To intend something for a particular purpose
• To contrive, devise, or plan something

• Noun
• The way in which something is planned and made
• A drawing or other graphical representation of
  something that shows how it is to be made
• A pattern or shape, sometimes repeated, used for
  decoration
• The process and techniques of designing things
• A plan or scheme for something
• Something that is planned or intended

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What does product design do?

• Conceptualizes attributes/performance of product
  (marketing)
• Determine assembly of interacting components
  (design engineering)
• Determines process and efficiency of production
  (operations management)
• Requires organizational coordination
  (organizational management)

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Product Attributes

• Core attributes actual use, psychological,
  problem reduction (e.g. safety)
• Supplemental attributes features, quality,
  styling, packaging, labeling, brand
• Extended attributes credit, warranty, delivery,
  installation, after-service

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Design for Environment

• The systematic consideration of design
  performance with respect to environmental,
  health, and safety objectives over the full
  product life cycle
• The systemic integration of environmental
  performance throughout the product life cycle in
  the conceptualization and planning of a product.

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Objective of DfE

• Use design to reduce the overall environmental
  impacts of a product--dramatically.

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Tools of DfE

• Practices the range of ways that energy and
  material reduction, recycling and safe disposal
  can be designed into the product
• Whole system designoptimizing the performance of
  all the parts working together.
• Product design teams

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Who does DfE?
Parts Manufacture
Materials Processing
Product Assembly
Social Infrastructure Govt, industry
assoc.s, NGOs, etc.
Resource Extraction
Distribution
Physical Infrastructure roads, sewers, land use,
electricity, etc.
Recycling
Consumption
Materials Collection
Material Energy Inputs
Pollution Outputs
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Who is involved in DfE Stakeholders

• Government
• Trading Partners
• Community
• Employees
• Investors
• Insurers
• Media
• Pressure Groups
• Customers

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What values can be created through DfE?

• Improved product quality
• Healthy working environment and staff commitment
• Improved community relations
• Positive pressure group relations
• Improved media coverage
• Green Products and byproducts
• Cheaper finance
• Lower insurance and legal costs
• Assured present and future compliance
• Improved materials and energy efficiency
• Reduced cleanup and decommissioning costs
• Reduced supplier and customer costs

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Two things to keep in mind

• All companies are service companies
• Design for Environment (DfE) and Life Cycle
  Analysis (LCA) are interdependent

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The Service Economy

• Meaning Sell services rather than products.
  Value is created by offering customers a
  consistent flow of satisfaction rather than an
  accumulation of goods.
• Manufacturing companies capture benefits of
  increased resource productivity and closed-loop
  activities.
• Service companies compound downstream savings and
  avoid stocking and labor costs.

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The Service Economy

• Some businesses get their income from embodying
  their product in a good, some get their income
  from embodying their product in a service, and
  most get their income from selling a combination
  of both
• All business are selling a service or function
  produced through the use of resources, labour and
  capital
• DfE works best when focused on providing the
  function while reducing energy and material
  requirements

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Defining the product and its impact
Type of Facility or Business Product Process Equip., Energy,Mats, Bldg, Infra.
Customer comes to the business Customer comes to the business Customer comes to the business Customer comes to the business
Dry cleaning Hair Salon Hospital Clean clothing Hair maintenance Health maintenance Solvent cleaning Chem/Physical Treatments Medical care
Service goes to customer Service goes to customer Service goes to customer Service goes to customer
Appliance repair Grounds care Package delivery Reconditioned appliance Property maintenance Package transport Part and function maintenance Moving, fertilizing, etc. Pickup, movement, delivery
Remote delivery of service Remote delivery of service Remote delivery of service Remote delivery of service
E-banking Burglar alarms Financial services Bldg monitoring Elec. Transactions Elec. Comms
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DfE for Services

• What? An assembly of buildings, products,
  infrastructure, and other services
• Why Shifts the focus from incremental
  modifications of firm level practices to change
  through the product cycle

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Components of a Service Business
Product DfE Influence
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Service DfE Practices

• Audits, LCA, Environmental impact statements
  (EIA)
• Green organization
• Purchasing, accounting, marketing, human
  resources, operations, logistics.

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Service DfE Whole System Design

• Focus on service
• Integrating components and practices to achieve
  synergies and avoid overlaps
• Considering full range of values that can be
  created
• Throughout product cycle of various components
  and services used

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Services DfE Design Team

• Appropriate task force or project team from
  various activities
• Include external consultants, government and
  community
• Use charrette as model?

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Product Design Team Members
Roles in DfE
Top Management Initiate DfE program and define product objectives
RD/Product Development Incorporate DfE criteria into product and process development, seek advice from other departments, etc.
Site/Facilities Design facilities to take advantage of new technologies, conservation sequence of design, synergies with processes, neighbors, nature.
Operations (house-keeping/engineering) Contribute detailed knowledge of processes and opportunities for improvement
Environment, Health and Safety Contribute environmental expertise to designers and RD people new to environmental improvement objectives, advise on regulations
Accounting Provide true costing of alternative technologies to justify capital investments in DfE
Purchasing Find alternative technologies to be included in DfE, collaborate with suppliers on needed DfE
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Product Design Team Members
Department Roles in DfE
Marketing Communicate customers needs, expectations and potential needs, educate customers on usage, devise selling and pricing strategies for lifecycle based products.
Suppliers Provide info on environmental impact of company, products and green alternatives design new green products
Distributors Provide info on environmental impacts of distribution green demand advertise and educate for green performance
Community Relations Communicate concerns of external stakeholders help create social and physical infrastructures
Customers Optimize environment performance (use, recycling, etc.) feedback info
External Stakeholders Redesign regulations, provide suggestions, monitor, aid product-cycle system design
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DfE Services

• Green hotels
• Organic food experience
• LPG taxis
• Ecotourism
• Green building services
• Financial services
• Environmental services (engineering, design,
  management, remediation, community facilitators,
  etc.)

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Turn one of these into a closed loop service
company

• Mobile phone company
• Bottled water company (e.g. 500ml bottles)
• Construction company

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DfE for Material Goods
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DfE for Material Goods Practices

• Design for recovery and reuse
• Design for material recovery
• Avoid composite materials
• Specify recyclable materials
• Use recyclable packaging
• Design for component recovery
• Design for reusable containers
• Design for refurbishment
• Design for remanufacture

• Design for energy conservation
• Reduce energy use in production
• Reduce device power consumption
• Reduce energy use in distribution
• Reduce transportation distance
• Reduce transportation urgency
• Reduce shipping volume required
• Use renewable forms of energy

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DfE for Material Goods Practices cont

• Design for disassembly
• Facilitate access to components
• Optimize disassembly sequence
• Design for easy removal
• Avoid embedded parts
• Simplify component interfaces
• Avoid springs, pulleys, harnesses
• Avoid adhesives, and welds
• Avoid embedded parts
• Design for simplicity
• Reduce product complexity
• Reduce number of parts
• Design multifunctional parts
• Utilize common parts

• Design for material conservation
• Design multifunctional products
• Specify recycled materials
• Use remanufactured components
• Design for material longevity
• Extend performance life
• Upgradeable components
• Reusable platform
• Serviceability Durability
• Design for closed-loop recycling
• Design for package recovery
• Design reusable containers
• Develop leasing programs

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DfE Practices cont

• Design for waste minimization
• Design for source reduction
• Reduce product dimensions
• Specify lighter-weight materials
• Design thinner enclosures
• Increase liquid concentration
• Reduce mass of components
• Reduce packaging weight
• Use electronic documentation
• Design for separability
• Facilitate material identification
• Use fewer types of materials
• Use similar, compatible materials
• Avoid material contaminants
• Design for waste recovery and reuse
• Design for incineration

• Design for chronic risk reduction
• Reduce production releases
• Avoid toxic/hazardous substances
• Avoid ozone-depleting chemicals
• Use water-based technologies
• Assure product biodegradability
• Assure waste disposability
• Design for accident prevention
• Avoid caustic flammable materials
• Provide pressure relief
• Minimize leakage potential
• Use childproof closures
• Discourage consumer misuse

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DfE Examples

• Reduce device power consumption (for consumer
  use) energy star appliances efficient lighting
• Design for material recovery Color coding of
  disposable camera plastic parts printed codes on
  computer parts
• Design for component recovery recovery of
  photocopy toner and printer cartridges
• Design for disassembly facilitates automobile
  disassembly plants

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DfE Examples

• Design for waste minimization concentration of
  soaps, detergents etc. elimination of boxes and
  other large packaging
• Design for waste recovery turning tires into
  fuel turning smokestack emissions into
  wallboard turning construction waste into
  construction materials
• Design reusable containers reusing steel and
  plastic drums and pallets folding shipping
  crates
• Avoid undesirable substances elimination of CFCs
  and phosphates

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Examples of DfE Practices

• Reduce device power consumption (for consumer
  use) energy star appliances efficient lighting
• Design for material recovery Color coding of
  disposable camera plastic parts printed codes on
  computer parts
• Design for component recovery photocopy toner
  and printer cartridges have been made to be
  remanufacturable with equal performance of new
  cartridges
• Design for disassembly electronic devices and
  automobiles are being designed so that they can
  be easily taken apart in disassembly plants and
  the parts recycled
• Design for waste minimization soaps, detergents
  etc. have been concentrated boxes and other
  large packaging have been eliminated
• Design for waste recovery flyash from coal
  burning is turned into wallboard building
  materials are made to be reusable or recyclable
• Design reusable containers reusing steel and
  plastic drums and pallets folding shipping
  crates
• Avoid undesirable substances elimination of CFCs
  from refrigerators and air conditioning
  elimination of phosphates from soaps and
  detergents and elimination of VOCs from some
  paints, glues and building materials

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Interrelationships among DfE Practices
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DfE Products

• Energy fuel cells, solar, wind, biomass,
  geothermal, tidal, LPG.
• Materials carbon fibers, aluminum, reusable
  building materials, super-windows, toxic
  replacements, biodegradable plastics, natural
  materials.
• Devices and Subsystems high-efficiency motors,
  catalytic converters, sensors, fatter wires and
  pipes, water aerators.
• Environmental Technologies graywater recycling,
  soil bioremediation, scrubbers, and integrated
  pest management.
• End-Use Products natural fiber clothes (also
  rugs, handbags, curtains, golf bags, etc.), cell
  phones, flat panel screens, electric vehicles,
  cosmetics, houses, non-toxic paints and
  buildings, hemp surfboards, solar powered
  electronics.

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Whole System Design

• Screening methods
• LCA assessment methods
• Trade-off methods
• Decision making methods

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LCA-DfE Impact Matrix
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House of Quality Matrix
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DfE MetricsHow do you total up impacts over the
product cycle?
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Interrelationships among DfE Practices in the
Electronics Industry
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What Roles do other Corporate Activities Play in
DfE?
Support Activities Top Management
Environment, Health Safety
Research Development
Purchasing
Accounting
Human Resources
Management
Primary Activities
Marketing
Distribution
Production
Engineering
Logistics
Design For Environment
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Product Design Team Members
Roles in Collaboration on DfE
RD/Product Development Incorporate DfE criteria into product and process development, seek advice from other departments
Site/Facilities Design facilities to take advantage of new technologies, conservation sequence of design, synergies with processes, neighbors, nature.
Top Management Initiate DfE program and define product objectives
Operations (house-keeping/engineering) Contribute detailed knowledge of processes and opportunities for improvement
Environment, Health and Safety Contribute environmental expertise to designers and RD people new to environmental improvement objectives, advise on regulations
Accounting Provide true costing of alternative technologies to justify capital investments in DfE
Purchasing Find alternative technologies to be included in DfE, collaborate with suppliers on needed DfE
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Product Design Team Members
Department Roles in Collaboration on DfE
Marketing Communicate customers needs, expectations and potential needs, educate customers on usage, devise selling and pricing strategies for lifecycle based products.
Suppliers Provide info on environmental impact of company, products and green alternatives design new green products
Distributors Provide info on environmental impacts of distribution green demand advertise and educate for green performance
Customers Optimize environment performance (use, recycling, etc.) feedback info
External Stakeholders Redesign regulations, provide suggestions, monitor, aid product-cycle system design
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DfE at Xerox

• Remanufacturable machines and components
• Reuseable printer and toner cartridges
• Energy efficient machines
• Paper, energy and hazardous waste saving machines
• Electronic documentation software services

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Xerox Supplies Return Programs Total Waste
Diverted from Landfill
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DfE for Buildings
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Environmental Impacts of Residential and
Commercial Buildings in the US

• Primary energy
• 36.4 of total
• Electricity consumption
• 65.2 of total U.S. electricity in 2000
• Green House Gas Emissions
• 36 of CO2 emissions and 30 of total greenhouse
  gas emissions
• Waste generated by construction and demolition
• 136 million tons annually 92 from demolition
  and renovation only 20 to 30 recycled or reused

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DfE Principles (Practices) for Buildings

• Smaller is better
• Design an energy-efficient building
  (internally/externally)
• Design buildings to use renewable energy
• Optimize material use
• Design water-efficient, low-maintenance
  landscaping
• Make it easy for occupants to recycle waste
• Look into the feasibility of using graywater
• Design for durability
• Design for future reuse and adaptability
• Avoid health hazards radon, mold, VOCs,
  pesticides

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Whole System Design Tools

• Constructing models of the building to see how
  the pieces can fit together and for use in wind
  tunnel etc. experiments
• Three-dimensional computer modeling
• Full-size models of sections of the building
• Energy modeling programs
• Computational fluid dynamics to see how air will
  move in and around a building
• Resource mapping to discover local materials

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Design Team (Charette) Members

• Developer
• Architect
• Engineers
• General contractor
• Subcontractors
• Engineers
• Government planners
• Neighbors
• Employees

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DfE Proposal Outline

• Define your product describing how it generates
  value for various stakeholders
• Propose new design for product and explain how
  practices/technologies utilized will reduce
  impacts throughout the product cycle (with
  metrics)
• Explain interdependencies among the different
  stages of the product cycle created by your DfE
  project
• Devise an industrial ecology that will enable
  your company to realize its DfE objectives
  through the use of physical and social
  infrastructures.
• Explain the values providing the incentives for
  transactions to link each stage of the product
  cycle.