Integrated design of remanufacturable products based on product profiles

The mass of products at end of life becomes a real problem for the environment. Thus, industrials are turning their attention to strategies for the management of products at the end-of-life. 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 design and manufacturing processes. But, in most of the cases, remanufacturing processes must be adapted to existing products because products have not been designed to be remanufacturable. However, the process adaptations 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 constraints throughout the design process; mainly in the earliest phases. The eco-methodology assists designers in two steps. They are first helped in improving the reliability of a remanufacturing end-of-life strategy for that product on the bases of the analysis of the project context. Then they are guided towards a product whose properties are adapted to remanufacturing. Our approach is built upon remanufacturable product profiles (RPP) encapsulating the knowledge on both remanufacturing contexts and remanufactured product properties.For the product profile definition, eight categories of design criteria were identified based on a survey of about 30 products successfully remanufactured. A statistical analysis was made to identify clusters of products. Then, product profiles were extracted while examining the links between internal and external criteria for each group.This methodology is supported by the tool REPRO² (REmanufacturig with PROduct PROfiles) that we have developed, which should lead to a real integrated design of remanufacturable products. Indeed, designers assisted with this tool, made early design by product profiling. It gives specific information to improve the internal technical definition of the product under study from a remanufacturing point of view.     

A game theory framework for cooperative management of refillable and disposable bottle lifecycles

Firms engaged in industrial ecology hope to reduce environmental impacts and costs, improve resource efficiency, and create symbiotic relationships that reduce transaction costs and enhance information flow. However, current LCA tools do not explain firms' incentives to implement the principles of industrial ecology, or how an individual or firm can affect the products and processes at other firms. Game theory, on the other hand, allows investigation of the willingness of producers and consumers to seek strategies that promote the common interest of the system while not harming their own interests. This paper applies game theory to the lifecycle of bottle packaging, and presents a framework for analysis of the choice between refillable and disposable bottles. Although refillable bottles may be more cost effective in the long run, bottlers only have incentive to use refillable bottles when they are sure that consumer return rates will be reasonably high. It has been found that consumers who keep or dispose of refillable bottles, or respond to deposit/refund return incentives by reducing their demand, may drive costs up and encourage adoption of disposables. A simple model is provided which finds the optimal bottler strategy as a function of the bottler's expectations for consumer cooperation.     

Development of an eco-ideation tool to identify stepwise greenhouse gas emissions reduction options for consumer goods

Pressure on consumer goods manufacturers to develop new products with significantly less environmental impact is growing, through increased consumer awareness of environmental issues and governments setting ambitious emissions reductions targets. A strategic response to this pressure is to prepare a portfolio of innovative product ideas to meet a range of future emissions reductions targets. However, although extensive work exists on ideation (the generation of novel product ideas) and eco-design (design for reduced environmental impact), eco-ideation (generation of ideas that particularly aim to reduce environmental impacts) has had little attention. The challenge of eco-ideation is to release the creativity of a broad range of employees, only few of whom may be familiar with the drivers of environmental impact.This paper proposes a novel tool to facilitate the generation of radical product and process ideas giving step-change reductions in greenhouse gas emissions. The features of products and processes that drive greenhouse gas emissions across the product life cycle were characterized with a set of indicators. A simple visual tool was created to show these indicators on a sliding scale between best and worst imaginable performance. A leading question associated with each slider was designed to stimulate lower impact ideas. The tool was iteratively refined and simplified through structured testing with individuals from across a range of roles and differing knowledge of environmental impacts. The final eco-ideation tool used 14 scales, with leading questions for each scale developed to stimulate idea generation.The tool’s effectiveness was evaluated through use in a series of 15 individual workshops and compared with the outcomes of an equal number of conventional 12-person group-brainstorming sessions. The comparison suggests that using the simple tool generally leads to a wider range of more radical ideas than emerge from group brainstorming.     

Applying 3DCE to environmentally responsible manufacturing practices

A review of recent literature in the fields of operations, supply chain, and management indicates there is on-going interest in improving new product development (NPD) performance. Three-dimensional concurrent engineering (3DCE), the simultaneous design of product, process and supply chain have been proposed as a way to improve traditional NPD outcomes, such as reduced time to market, lower costs, and improved customer acceptance. There appears to be a lesser concern associated with the environmental impacts of new products. Environmentally responsible manufacturing (ERM) on new product development focuses on reduced emissions, hazardous materials elimination, and lower product weight without sacrificing functionality. This paper explores the following issue: will employing 3DCE to integrate NPD and ERM yield better benefits than the separate and uncoordinated application of environmental goals and NPD initiatives?     

直升机机载产品环境鉴定试验故障分析

目的探究机载产品在鉴定试验阶段故障频发的原因,并改进机载产品研制流程中的不足之处。方法收集某型直升机机载产品50项环境鉴定试验故障,并对环境试验故障进行分析。结果环境试验故障主要为三防及振动试验故障,其故障发生的原因主要为材料及表面处理方法选用不当、设计缺陷和质量控制程序不够严格。结论针对该分析结果提出机载产品在设计过程中,需要通过尽早安排环境研制性试验、建立环境数据库、模拟仿真进行环境适应性设计和加强质量管理等措施,避免机载产品在鉴定试验阶段故障频发的问题。     

Cradle-to-cradle design: creating healthy emissions – a strategy for eco-effective product and system design

Eco-effectiveness and cradle-to-cradle design present an alternative design and production concept to the strategies of zero emission and eco-efficiency. Where eco-efficiency and zero emission seek to reduce the unintended negative consequences of processes of production and consumption, eco-effectiveness is a positive agenda for the conception and production of goods and services that incorporate social, economic, and environmental benefit, enabling triple top line growth.Eco-effectiveness moves beyond zero emission approaches by focusing on the development of products and industrial systems that maintain or enhance the quality and productivity of materials through subsequent life cycles. The concept of eco-effectiveness also addresses the major shortcomings of eco-efficiency approaches: their inability to address the necessity for fundamental redesign of material flows, their inherent antagonism towards long-term economic growth and innovation, and their insufficiency in addressing toxicity issues.A central component of the eco-effectiveness concept, cradle-to-cradle design provides a practical design framework for creating products and industrial systems in a positive relationship with ecological health and abundance, and long-term economic growth. Against this background, the transition to eco-effective industrial systems is a five-step process beginning with an elimination of undesirable substances and ultimately calling for a reinvention of products by reconsidering how they may optimally fulfill the need or needs for which they are actually intended while simultaneously being supportive of ecological and social systems.This process necessitates the creation of an eco-effective system of “nutrient” management to coordinate the material flows amongst actors in the product system. The concept of intelligent materials pooling illustrates how such a system might take shape, in reality.     

我国包装废物产生及回收现状分析

针对我国包装废物产生、回收、最终处置的各阶段现状进行调查和分析,主要对于我国现阶段塑料、纸制品和金属制品的包装产生消费量进行综合分析,并实地对居民生活小区零散个体回收者的包装废物回收量和包装废物再生企业包装废物原料回收渠道以及最终流入生活垃圾填埋场的包装废物含量进行了调研. 将包装废物产生量、回收量与最终处置量相比较的结果可以看出,现有回收体系对于部分包装废物回收效果较好,例如包装废物中PET聚酯瓶和金属罐的回收效果最好;而没有经济利益的塑料袋几乎完全没有得到回收再生,是回收工作的难点. 再进一步通过对复合包装再生企业和PET聚酯瓶再生企业的回收体系的实例分析,提出我国现存包装废物回收体系中存在的问题.      

Supply chain collaboration to achieve toxics use reduction

The use of lead poses significant hazardous occupational exposure to workers in the electronics industry, and also causes environmental challenges at the end of product life. For the past decade, there has been a global effort in the electronics industry to initiate a move towards using lead-free materials for the production of printed circuit boards. However, there are technical and economic challenges, such as long term reliability and rework capability, that remain to hinder the universal implementation of lead-free materials. As a result, many electronics products are still currently manufactured and assembled using materials containing lead.The costs for investigating and evaluating the various lead-free electronics materials and manufacturing processes can be cost prohibitive for an individual company to undertake alone. Consequently, the New England Lead-free Electronics Consortium was formed as a collaborative effort of New England companies spanning the electronics supply chain to help move the industry towards lead-free electronics. The Consortium is a working collaboration of industry, government, and academia. For the past several years, the Consortium has conducted research and testing for using various lead-free materials for the manufacture of printed circuit boards. The Consortium has been successful in identifying lead-free materials and processes to address the challenges of assembly and rework. The Consortium is currently conducting research to address the long-term reliability challenge of lead-free electronics.     

Water,wastewater and waste management in brewing industries

Water and wastewater management constitutes a practical problem for the food and beverage industry including the brewing industry. In spite of significant improvement over the last 20 years, water consumption and disposal remain critical from an environmental and economic standpoint. This paper gives an overview of the world beer market in order to highlight the heterogeneity in capacity of global beer production. From a synthesis of existing literature, water consumption is analysed and the most common treatments and the associated costs are reported. Finally, biological and technical alternatives including membrane operation processes and economic reality are described.     

EcoDesign and The Ten Golden Rules: generic advice for merging environmental aspects into product development

The most important moment in product development is when demands and specifications are decided for the product that is being planned. The specification defines the goal for the product development process. It is a very important steering opportunity for the continuing work and for environmentally driven demands that are to be addressed in the product development phase. The designers are said to have the key to sustainable product development through EcoDesign. Many tools have been developed in order to help them to achieve this objective. However, most tools are seldom used primarily because of a lack of sustainability oriented requirements in specifications for products. If there is no demand for improved environmental performance, then there is no need for EcoDesign tools. The lack of market demand for environmentally improved products is therefore, a crucial factor. In other words: It makes no sense to grab a screwdriver from your toolbox if you have a nail in your hand. On the other hand if you have a hammer in your hand you tend to see everything as nails! The hypothesis of this paper is that there is a strong need for a tool to facilitate the integration of reasonable environmental demands into the product development process. The presented tool, “The Ten Golden Rules,” can be helpful in this effort. A helpful tool must be well adapted to the task and therefore it is important that the individual product developer/designer can develop personal versions from the generic guidelines. The Ten Golden Rules provide such a possibility. They provide a common foundation, for all in the team, which can be used as a base and guidelines for development of situation specific product-design challenges.     

Ecodesign methods focused on remanufacturing

Understanding the product's ‘end-of-life’ is important to reduce the environmental impact of the products' final disposal. When the initial stages of product development consider end-of-life aspects, which can be established by ecodesign (a proactive approach of environmental management that aims to reduce the total environmental impact of products), it becomes easier to close the loop of materials. The ‘end-of-life’ ecodesign methods generally include more than one ‘end-of-life’ strategy. Since product complexity varies substantially, some components, systems or sub-systems are easier to be recycled, reused or remanufactured than others. Remanufacture is an effective way to maintain products in a closed-loop, reducing both environmental impacts and costs of the manufacturing processes. This paper presents some ecodesign methods focused on the integration of different ‘end-of-life’ strategies, with special attention to remanufacturing, given its increasing importance in the international scenario to reduce the life cycle impacts of products.     

The recycling cycle of materials as a design project tool

Currently, a large number of companies consider recycling of materials as an opportunity to maximize profits and to reduce the environmental impact generated by these materials after they are disposed. However, there is also a strong constraint on the use of recycled materials mainly due to the lack of technical/scientific information, which would relate their physical properties to their recycling cycle. This information should be used in the initial phase of the product design to serve as reference for the simulation of a project to point out the physical properties obtained from recycling the Projected material (Pm). Thus, it would be possible to foresee some recycling strategy to keep the good characteristics of recycled materials by encouraging their use, regardless of the product to be designed.Therefore, the Recycling Cycle of Materials (RCM) is a tool that provides scientific/technical support in the selection of materials. It uses the information related to the physical properties of the Pm as a parameter for product design after five recycling cycles. For the case study, this tool has been applied to obtain the basic material of ABS/PC blend. Subsequently, this blend was evaluated using DSC, FTIR, traction and impact methods to obtain delimiting data for the definition of the mechanical properties resulting from the application of RCM.     

A matrix for selecting sustainable floor coverings for buildings in Sri Lanka

This paper presents a method to facilitate the decision-making process in selecting sustainable floors (elements) for buildings in Sri Lanka, taking into consideration environmental, economic and social assessments of materials used for these elements. Two types of elements are selected for this study, namely, tile and vinyl tile. Environmental burdens associated with these elements are analyzed in terms of embodied energy and environmental impacts that are relevant to Sri Lanka, such as global warming, acidification and nutrient enrichment. Economic analysis is based on market prices and affordability of materials. Factors considered for the social analysis are thermal comfort, good interior (aesthetics), ability to construct fast, strength and durability. It was found that tile elements are superior to vinyl tile elements on environmental scores if processes of complete life cycle of these elements are taken into account. On social score also, tile elements (104.8) are better than vinyl tile elements (51.15). But on economic score, vinyl tile elements are better. These scores are presented in a matrix which will help in selecting sustainable floor coverings for buildings.     

Does the potential of the use of LCA match the design team needs?

Today, most people involved in the industrial engineering community (consultants, manufacturers, researchers and institutional actors) assert that Life Cycle Assessment (LCA) is the most successful tool to assess environmental considerations in the product design process. This assertion is addressed in this article through a simultaneous check of the potential of this tool and the environmental needs of the design team. After a comparison of this potential to these needs, the following assertions may be made: (1) LCA is not an adequate tool for the designer, because its utility in the design process is limited to an analysis of existing products or well defined products at the final stages of the design process, and (2) LCA is not useful in creating a learning dynamic (awareness) within the company, because it does not improve the legitimacy or the credibility of environmental considerations. Moreover, it may generate confusion within the design team while restricting the capacity for innovation within the company. This paper concludes that, in the product design field, the LCA tool should be considered as a specialized tool handled by a specific player (the environmental actor) and should be dedicated to the strategic evaluation of new concepts.     

A hierarchical end-of-life decision model for determining the economic levels of remanufacturing and disassembly under environmental regulations

Remanufacturing, in contrast to material recycling and disposal, can reduce environmental impacts by retaining the geometrical form of the product, thereby regarded as a more eco-efficient approach. In this paper, an end-of-life (EOL) decision model for remanufacturing options is presented to facilitate remanufacturing. The proposed model, in order to maximize the economic value of remanufacturing options while meeting environmental regulations, takes an integrative approach to EOL-option decision-making. Also presented in this paper is a hierarchical approach that represents both the overall hierarchical structure of a product and the interconnections among components. Illustrative examples are provided to demonstrate the effectiveness of the model.     

Product-service systems in the automotive industry: the case of micro-factory retailing

Solutions to the economic and environmental impacts of the automotive industry have largely focused on technological innovation at the level of products or processes. This paper argues that, in order to achieve sustainability, change processes must be undertaken at the functional and systemic level.The concept of product-service systems (PSS) represents a valuable opportunity to introduce such changes. PSS is predicated on new forms of product ownership, stewardship, design and producer–consumer interaction. The challenge now is to investigate ways in which the PSS concept might be introduced at the empirical level.The paper suggests that the adoption of micro-factory retailing (MFR) ideas offer a means of introducing such a system-level change in the automotive industry. MFR is based on novel approaches to vehicle design that facilitate the economic viability of small-scale localised manufacturing sites. It is argued that such an approach to vehicle production, allows the adoption of a full scale PSS at local levels. Furthermore, via aspects such as the unification of the commerce and manufacturing function, and the proximity of manufacturing and servicing sites to users, the MFR approach may also offer distinct advantages compared with prevailing visions of PSS.     

Eco-design implemented through a product-based environmental management system

Lucent Technologies (Lucent) has undergone considerable change in business strategy with the outsourcing of manufacturing activities. In order to control the significant environmental aspects of hardware products, Lucent's wireless business unit, Mobility Solutions, determined it would concentrate on the design of products: focusing on eco-design enables product sustainability to be improved, with each product generation providing a ‘start of pipe’ (front end) solution with attendant efficiencies.Mobility Solutions pioneered a product-based environmental management system (PBEMS) to formally address the impacts of wireless hardware products on the environment throughout the entire product lifecycle, regardless of where products are developed. This management system looks beyond the environmental impacts of manufacturing to include conceptual design, development, use by the customer, and final product disposal.The success of this approach can be attributed to the integration of eco-design with traditional hardware product realization processes. Through the PBEMS, business and environmental processes are simultaneously utilized to manage significant product aspects and to incorporate sustainability principles during product design. Many innovative eco-design tools are applied during the product realization process to identify areas for improvement of future products, and to verify that each generation of existing products is more sustainable than its predecessor. These eco-design tools include eco-roadmapping, design for environment guidelines and checklists, and lifecycle assessments.The Mobility Solutions PBEMS conforms to the requirements of the ISO 14001 international standard and has achieved third-party certification. By implementing environmentally responsible characteristics through eco-design programs, employees, customers, and the world community benefit from a consistent approach to the environmental management of wireless hardware products. Mobility Solutions continues to reap the value of sustainable product design that is both good for the environment and makes sound business sense.     

Life cycle engineering methodology applied to material selection,a fender case study

Materials selection is a multidisciplinary activity, which integrates a large number of knowledge fields and professional domains. In fact a material selection decision should capture not only the functional performance required for the application but should also consider the economical and environmental impacts originated all along the product life cycle. In this paper a life cycle engineering (LCE) approach is proposed to support material selection, integrating the performance of the material for the specific application in technological, environmental and economical dimensions throughout the duration of the product. The methodology proposed compares a set of candidate materials and, through the aggregation of the three dimensions (technical, economical and environmental), identifies the “best material domains”. These “best material domains” are presented in a ternary diagram, which allows a global comparison of the candidate materials and supports an informed decision as regards the selection of the “best material” according to different business scenarios and corporate strategies. The methodology was applied to a case study aiming the use of new metallic materials (high strength steels and aluminium alloys) for an automobile fender currently made of mild steel and the evaluation of potential benefits as regards the global performance of the material.     

借鉴国外经验建立与完善我国低碳产品认证制度

面对全球日益兴起的“低碳经济”理念,包括我国在内的很多国家都将其作为转变经济发展方式实现绿色发展的契机。低碳产品认证是推进中国低碳经济走向绿色发展的重要举措。本文通过借鉴国外低碳产品认证的经验,提出应从关注环境保护与气候变化协同效应、选择适合的产品类型、逐渐实现产品生命周期碳排放管理等方面提升和推动我国低碳产品认证工作的发展。     

环境管理手段体系研究

社会经济的快速发展和环境保护的日趋重要,要求环境保护与社会经济协调发展。科学有效地应用环境管理手段,是促进协调发展的有效途径之一。为了促进环境管理手段作用的有效发挥,完善环境管理,在分析现有的5种环境管理手段的基础上,提出了环境管理参与手段和环境管理投资手段,并对这两个新的手段的必要性和内容做了分析。通过对环境管理手段关系的论述,构建了环境管理手段体系,对环境管理手段体系的目标、架构、作用和内容进行了分析论述,并研究了环境管理手段的选择与实施方法。