DESIGN FOR

ENVIRONMENT Main reference :

Karl T. Ulrich & Steven D. Eppinger, Product Design and Development,
McGraw Hill, 5th Edition, 2012.

Teaching Module, BMFR 2113

Masni-Azian, A. 2012
 JUST SOME THOUGHT
Think environment, think GREEN.
Did you know
that using black display on computer screen is believed to
cut down energy usage?

Maybe NOT .
Studies shown that the result varies with different computer
type (LCD vs. CRT)

Meanwhile, you just have to bear with me and my black slides

And please dont print this slides with black background though.
Masni-Azian, A. 2012
 ABOUT DFE
A method to minimise
activities than can jeopardise
the environment.
To create a more sustainable
society.
Effective DFE can maintain or
improve quality and cost.
But. Why DFE? Why NOW?

Masni-Azian, A. 2012
 OUR ENVIRONMENT TODAY

Sungai Juru, Penang (2007)

Batu Feringghi, Penang (2010)

Masni-Azian, A. 2012
 OUR ENVIRONMENT TODAY
Partial deglaciation of the The coast of Philippines
Greenland ice sheet

Global warming Resource depletion Solid waste Land

Temperature increase Limited supply Scrap , disposed in degradation
Accumulation of GHG Nonrenewable natural incinerators or landfills Adverse effect of
in the upper atm. resources (gas, oil, coal) --- or RIVERS! raw material
Accelerate because of Incinerator : generate extraction and
CO2, CH4, CFC. air pollution and toxic production.
From where? Industrial ash. Reduced soil fertility,
processes and Landfills : release soil erosion, salinity
products! methane gas. of land and water,
and deforestation.
 OUR ENVIRONMENT TODAY
Oil spill at Gulf of Mexico Maryland powerplant Siberian tiger, Antarctic ozone hole, 2000
in danger of extinction

Water pollution Air pollution Biodiversity Ozone depletion

Source : discharge Source : emission from Variety of plant and Ozone layer protects
from industrial factories, incinerators, animal species within earth against the
processes (includes power plants, an ecosystem harmful effects of suns
heavy metals, solvents, residential area, unbalanced! radiation.
oil, acids). vehicles. Affected by land Degradation : caused
Affects ground water, CO2, NOX, SO2, O3, clearing due to urban by nitric acids (burning
drinking water and the VOCs. development, mining, fossil fuels) and
ecosystem. etc. chlorine compound
Causes mass extinction (CFCs).
 YET
Tak apalah.
Somebody will pick it up.
Tak apalah.
Its expensive to pay for waste
management service. Lets just
dump it in the river.
Masni-Azian, A. 2012
Ah well
Its time to care now, and its time to change.
When it comes to product development
process, change should start at the early
stage.
Why?
Deliberate decisions on material use,
energy efficiency and waste avoidance can
minimise environmental impacts.
How can we change?
By understanding the products life-cycle.
. And be more responsible.
 PRODUCT LIFE CYCLES
It is the basis of DFE.
Should be closed-loop system of product life cycle + the natural life-cycle.

Non-Renewable

Renewable
Production
Resources Raw A) Remanufacture
Materials
NATURAL PRODUCT
BIOLOGICAL INDUSTRIAL
Natural decay
LIFE CYCLE LIFE CYCLE
Distribution

(c) Deposit in Recovery B) Reuse

landfill
Organics
Use
Inorganics
Landfill
Toxics Incineration
Disposal
Masni-Azian, A. 2012
 PRODUCT LIFE CYCLE
How to achieve environmental sustainability?

1 Eliminate use of nonrenewable resources

(including non renewable sources of energy)

2 Eliminate disposal of synthetic and inorganic

materials that do not decay quickly.

3
Eliminate creation of toxic wastes that are not
part of natural life cycles.

Masni-Azian, A. 2012
 DFE PROCESS
McDonough and Braungart (2002) introduced DFE
method that focuses on 3 key areas of product design.

MATERIAL DISASSEMBLY RECYCLABILITY

CHEMISTRY
What are the chemical Can the product be taken apart at Are the materials readily separable
composition of the materials? the end of their useful life in order for recycling categories? Can the
Are they safe for human and to recycle their materials? materials be recycled at the end of
environment? the products useful life?

Masni-Azian, A. 2012
 DFE PROCESS
Product Planning 1) Set DFE Agenda

Concept Development
2) Identify Potential Environmental Impacts

3) Select DFE Guidelines

System-Level Design 4) Apply DFE Guidelines to Initial Design (s)

Detail Design 5) Assess Environmental Impacts

Compare
6) Refine
to DFE
Design
Goals

Process Improvement 7) Reflect on DFE Process and Results

Masni-Azian, A. 2012
 (1) DFE AGENDA

INDENTIFY INTERNAL AND SET DFE GOALS SET-UP DFE TEAMS

EXTERNAL DRIVERS
Discussion on WHY organisation
have to pursue DFE.
Internal drivers : within
organisation
Example : Product quality, public
image, cost reduction, ethical
responsibility.
External drivers : outside
organisation but still affect the
organisation.
Example : environmental
legislation, market demand,
competitions, suppliers, social
pressures.
Masni-Azian, A. 2012
Set long term environmental
objective / vision.
Strategise!
Example :
Zero defect
Zero landfill
All green electrical energy use
Reduce use of raw material to
50%
Eliminate emission and reduce
energy consumption during use.
Must involve participation from
cross-functional departments
(engineering, design, materials,
production, purchasing,
marketing, etc.)
DFE team should be involved
throughout the development
stage as early to ensure DFE
considerations are taken into
account.
 (2) IDENTIFY POTENTIAL
ENVIRONMENTAL IMPACT
Consider environment impact at conceptual stage even if there is little or
no specific data (qualitative assessment).
What are the significant sources of potential environmental impact in
each life cycle stage?

** Refer Exhibit 12-7 in book.

Masni-Azian, A. 2012
 (3) DFE GUIDELINES
DFE guidelines is established based on the
potential environmental impact identified
earlier.
Allows project team to apply it throughout
product development project.
Example :
Ensure that wastes are biodegradable.
Minimise number of components.
Allow easy repair and upgrading.

** Refer Exhibit 12-8 and Appendix in book.

Masni-Azian, A. 2012
 (4) APPLY DFE GUIDELINES
The DFE guidelines are applied to all stages of
product life cycle.

Production
Raw
Materials Cheaper product
(reduced number of
OUTCOME parts).
An environmentally
Distribution friendly product
(wise selection of
materials and
Recovery
processes).
A happy customer.
Use A happy earth.

Masni-Azian, A. 2012
 (5) ASSESS ENV. IMPACT
ASSESSMENT : is a must!
WHY? Continual improvement
Requires detailed understanding of how the product is to be
produced, distributed, used over lifetime, and disposal method.
HOW?
Detailed BOM.
Identify sources of energy
Recycling method
Life-cycle assessment (LCA) tools
requires training, time, and data.
SO?
Compare the result (environmental impact)
analysed to the DFE Goals (from STEP 1)

Masni-Azian, A. 2012
 (6) REFINE PRODUCT DESIGN
First time may not be the
best improve, improve,
improve!
Further reduce or eliminate
any significant
environmental impacts
through REDESIGN.
Team may identify room for
improvement even after the
project has started.

Masni-Azian, A. 2012
 (7) REFLECTION
Finally, REFLECT the DFE process and results.
Achieve? Or not?

How can our

What DFE
DFE process be
improvements
improved?
can be made on
derivative and
future products?
How well did
we execute the
DFE process?

Masni-Azian, A. 2012
 YOUR ASSIGNMENT IS

Identify the life-cycle for a car.

In your opinion, what are the negative environmental
impact faced by our country which is caused by automobile
transportation.
Suggest the improvement that can be incorporated
throughout the development of domestic transportation by
considering the environmental aspect.
Masni-Azian, A. 2012
Masni-Azian, A. 2012