UNIT 13 PRODUCT DESIGN FOR

ENVIRONMENT
Structure
13.1 Introduction
Objectives
13.2 Product Design for Environment
13.3 What is Design for the Environment?
13.4 Applications of Design for Environment
13.5 Life-cycle Perspective of Product Design
13.6 Advantages from Design for Environment
13.7 Getting Started : Used of DfE
13.8 DfETools
13.9 Who Use DfE
13.10 Trends and Future Importance of DfE
13.11 Related Legislation and Regulations for DfE
13.12 Some Case Studies of Companies Embracing Design for Environment
13.1 3 Summary
13.14 Key Words
13.15 Answers to SAQs

13.1 INTRODUCTION
During the long period in the life cycle of a product, a burden is imposed on the
environment, starting from its production stage to its disposal. It is important therefore,
that all possible improvements are made during the design and development stages of the
product in order to provide products with a lesser burden on the environment, and overall
product life cycle must be evaluated in terms of environmental burden. Considerations
include energy conservation, resource conservation, recycling characteristics and the use
of harmhl substances. Companies can conduct product assessments, to work towards
reducing the environmental burden throughout the life cycle of the product. This unit
describes advantages of using Design for Manufacturing (DfE) and goes on to describe
various DfE tools. Some typical cases are described of the companies which have
successfully used DfE for their products.
Objectives
After studying this unit, you should be able to
describe design for environment,
explain how it is used,
describe different design of environment tools, and
know the trends and future of design for environment.

13.2 PRODUCT DESIGN FOR ENVIRONMENT

In earlier good old days a product used to be designed, manufactured and sold to the
customer with little or no subsequent concern. In the seventies, with the emergence of
life-cycle engineering and concurrent engineering, companies became more aware of the
need to include serviceability and maintenance issues in their design processes. This
I Product Design and
Development
approach caused the developers, from the outset, to consider all elements of the product
life cycle from conception through disposal, including quality, cost, and user
requirements. Although concurrent engineering seems to span the entire life-cycle of a
product, its traditional focus has been on design, manufacturing, and maintenance.
One of the most striking areas where companies now have to be concerned with is the
environment. The concern regarding environmental impact stems from the fact that,
whether we want it or not, all our products affect in some way our environment during
their life-span. Figure 13.1 gives a schematic representation of a system's life-cycle.
Materials are mined from the earth, air and sea, processed into products, and distributed
to consumers for usage, as represented by the flow from left to right in the top half of
Figure 13.1,
Manufacture

Mining

Disposal

Energy
d I
Clean Fuel
1 = Direct recyclinglreuse
2 = Remanufacture of reusable components
Recovery with Production via 3 = Reprocessing of recycled material
Incineration pyrolysis 4 = Manornerlraw material regeneration

Figure 13.1 :A Generic Representation of a Product's Life-cycle

from Cradle to Grave and Reincarnation

In general, environmental impact comes from (excessive) consumption of natural

resources and emissions of pollutants to air, water, and land. We are all familiar with the
negative eflects of air emissions. Recognition of its effects has led, among others, to the
Clean Air Act and Corporate Average Fuel Economy legislation in some countries.
However, recently the end-of life and disposal issues have received more attention. The
emergenceof product take-back legislation in Europe (e.g. the German Closed-Loop
Economy Law) has forced manufacturers world wide to think more and more about how
to dispose appropriately of their products through recycling and reuse (as represented in
the flow from right to left and up in the lower half of Figure 13.1) and to include product
retirement issues such as recycling and disassembly as a real requirement in their design
process. The term "de-manufacture" is often used to characterize the process opposite to
manufacturing necessary for recycling materials and products. Material de-manufacture
refers to the process of breaking down long polymers into smaller polymers which are
then used for stock in new materials.
There are several motivating factors for a company to become more environmentally
responsible. Some of them are :

I Legislation
For example, the US Clean Air Act has limited the use of a number of materials
and (European) take-back legislation is driving Design for Recycling efforts.
Customer Demand
Awareness of environmental issues is increasing among customers. Some
customers are even willing to pay more for a product if it is green. Also, industrial
customers (e.g., Original Equipment Manufacturers) do not want (future)
environmental liability for a supplier's product.
Eco-Labeling Programs
How "green" is a product? Having an eco-label becomes a competitive advantage.
Is0 14000 Product Design
for Environment
The I S 0 14000 (environmental management standards) certification may become a
crucial element in doing business, like I S 0 9000 (quality management standards).
Many companies have noted that "Design for Environment" (DfE) makes good business
sense and has many other positive effects. For example, the reduction of material
diversity leads to less diverse inventory, volume purchasing, and the opportunity to focus
on a reduced number of (core) manufacturing processes. Life extension practices place
renewed emphasis on design for serviceability which typically pleases customers.
Environmental concerns are also stimuli for finding new creative solutions and products.
Many companies have realized the need to become more environmentally responsible.
However, many are struggling with the questions how to move towards becoming a more
environmentally responsible company in general and how to include environmental
issues in product design in particular. There is no unique solution, but in order to move
towards integrating environmental issues in product design, a company should ask itself
(at least) the following questions :
(a) What are the organisational motivation and targets for integrating
environmental issues?
(b) What are the (current) organisation capabilities?
(c) What new practices, tools, and organisational structures are needed?
(d) What is the best way of implementing the necessary changes?
(e) What are mechanisms for continuous assessment, feedback, and
improvement?
SAQ 1
(a) Why is it necessary to consider environment issues in the product design?
Can the environment consideration be included in concurrent engineering
approach?
(b) What are at present the motivating factors for a manufacturing company to
be environmentally responsible? How else companies be made more
environmentally responsible?
(c) What is meant by 'de-manufacturing'? Who does it and why?

13.3 WHAT IS DESIGN FOR THE ENVIRONMENT?

Design for the environment, sometimes called eco-design or green design, is a systematic
way of considering the entire life (or life cycle) of a product up front, during design.
Design for environment (DfE) entails the integration of environmental considerations
into the product design and development process. Designers use DfE tools and
techniques to improve the environmental performance of products while reducing costs,
improving competitiveness, and stimulating innovation. It is important to note that
successfkl DfE practices in product design and de'velopment balance environmental
considerations with cost, performance, safety, fknctionality and quality criteria.
acts are considered, this
Product Design and SAQ 2
Development
Define DfE. Distinguish it from DfS by taking an example.

Application of DfE typically involves three main elements :

(a) an understanding of product impacts and aspects;
(b) application of specific product design strategies; and,
(c) integration of tools and techniques within the product development process.
First, companies must develop an understanding of the environmental impacts and
aspects of a product over its life cycle (i.e. from raw materials extraction, through
production, distribution, use and end of life). In order to gain this understanding, life
cycle assessment tools are often used.
Second, this understanding is applied through specific design strategies or guidelines to
improve the product's environmental pcrformance (e.g. reduce material use, reduce
energy consumption, reduce number of parts). Companies select specific design
strategies based on :
(a) the product's main environmental impacts;
(b) technical feasibility;
(c) cost; and,
(d) ability to meet other criteria (such as performance, safety, etc.).
Figure 13.2 illustrates seven core DfE strategies for product improvement.
New Concept
Development

Optimise
End-of-Life
Systems

Reduce Impact
during Product Us

Production
Distribution

Figure 13.2 :The Strategy Wheel

Finally, companies applying DfE often use specific tools such as checklists, performance
indicators, goals and decision checkpoints within the product development process.
These tools ensure that environmental considerations are applied throughout the design
and development of the product. Some companies integrate these tools with their quality
 management systems (e.g., IS0 9001) or their environmental management systems Product Design
(IS0 14001). This ensures consistent application of DfE and continuous improvement of for Environment
environmental performance throughout the company's products.
SAQ 3
(a) Take example of a product. Trace its impact on environment over its various
life cycle stages with regard to consumption of physical resources and
energy.
(b) Write short note on the different DfE strategies.
(c) Discuss how check lists can be used for giving environment consideration in
product design.
(d) How can DfE be integrated with other considerations in product design?
(e) On what factors do specific product design strategies differ when applying
DfE?

13.5 LIFE-CYCLE PERSPECTIVE OF

PRODUCT DESIGN
Each stage of life-cycle of a product (materials selection, manufacturing, use, end of life)
- introduces opportunities to design in new types of alternative materials, fasteners,
optimal shapes, or renewable power. DfE checklist questions listed for each life-cycle
stage can guide exploration of these options. (See sample DfE checklist at the end of
Unit.) The resulting decisions, based upon the environmental impacts of the product,
most often complement or even enhance other considerations such as customer appeal,
safety, time to market, cost reduction, and manufacturability.
DfE is not a stand-alone process; rather it is integrated to enhance a current design
process. Integration can be as basic as adding a checklist of key questions that cover the
entire life cycle of the product to give the design team a holistic perspective. These
questions also serve as a springboard for discussion and generation of new ideas.
Materials selection
During this stage, the raw materials and parts used in a product are selected, then
procured. This stage offers a window to consider a vast array of innovative
options, such as the wide variety of plant or biobased materials (including plastics)
available for use in products.
The product designer may consider :
Is the Product Designed
(a) to be made from recycled, recyclable, or compostable materials?
(b) to avoid or minimise the use of restricted or hazardous materials
contained in the product?
(c) to ininimize the number and types of materials contained in the
product?
(d) such that if plastics are used, are they clearly marked by an
identification system such as IS0 1 1469?
It is increasingly important to determine the exact composition of raw materials
and parts that will be used in a product. Companies are now surveying the
suppliers of raw materials and parts to avoid any material composition surprises.
 . Product Design and This prevents problems when marketing products to customers with specific
Development materials requirements while complying with a number of international regulations
related to restrictions on use of certain materials.
For example, a yellow pigment may be enhanced by the addition of cadmium.
Hexavalent chromium, a restricted use material in some countries, could be used to
coat nietal parts to prevent corrosion. If these materials are not declared by the
suppliers, the recipient manufacturer could unknowingly be using materials'it
wants to avoid. In such a case, the manufacturer may want to work with its
suppliers to explore viable alternatives. Several DfE software programs that
compare environmental impacts of various materials can also aid in selecting and
sourcing preferable materials.
Manufacturing
For this life-cycle stage, recognising the varying needs of design team members
representing various departments in a manufacturing facility is key. For example,
the production department's performance may be measured on how many products
are produced within a certain time period (manufacturing cycle time). A research
and development (R&D) department may be interested in containing the level of
cost per unit. Representatives of the marketing department will want to use
environmental hprovements as selling points to customers. Often improving the
environmental attributes of a product will address these various concerns
simultaneously. Responding to the needs and the focus of various department, with
proposed improvements, can build the support needed for design changes.
As in nature, a basic objective of any product design should be to minimize the
number and types of manufacturing process steps used - to simplify. Each
additional manufacturing step creates an opportunity for errors that can generate
waste and cost.
1 The product designer may consider :
Is the Product Designed to
(a) avoid the need for using hazardous or restricted materials during the
manufacturing process?
(b) optimise assembly during the manufacturing process (relates directly
to disassembly)?
(c) avoid energy-intensive processes during manufacture (for example,
multiple heating or cooling cycles)?
(d) minimise waste during the manufacturing process (avoiding surplus
coating, cut-away, trimming and by-products)?
Product use
This stage pertains to the period a product performs a service or function for the
user. Some companies have begun basing their marketing on providing a service or
function - not selling a product. Xerox was one of the first to successfully market
this idea: selling copying services through lease of their copiers. The copiers
continue to be owned by Xerox, where they are refurbished for reuse, upgraded, or
recycled as part of a closed-loop system. This avoids disposal of the copiers in the
waste system when they are no longer useable by the customer. Citing the example
of another company with the name Interface, a commercial flooring manufacturer,
leases carpeting and other flooring to businesses as part of a closed-loop system
where the flooring materials are recovered for recycling.
The product designer may consider :
Is the Product Designed to
(a) be easily disassembled for repair, upgrade, or reuse?
m (b) avoid disposable components such as one-time use cartridges,
containers, or batteries?
 For products requiring a power source, is the product designed to: Product Design
for Environment
(a) use electric power efficiently or use renewable energy?
(b) use batteries that are easily identifiable by type and are removable?
Transport and Packaging
Reducing the impacts and costs of distribution and packaging supports all of the
life-cycle stages of a product.
The product designer may consider :
Is the Product Designed to
(a) reduce the need for protection with packaging when possible?
(b) use packaging that contains recycled content or compostable
materials?
(c) avoid the use of restricted or hazardous materials in inks, pigments,
and materials used to package the product?
(d) use reusable transport packaging when possible?
End of Product Life
A goal for this stage is to make reuse or recycling of products easier, so that
recovered materials can be used as resources rather then end up as costly wastes.
Design for disassembly (DfD) allows products to be easily taken apart for reuse or
recycling of components and materials.
The product designer may consider :
Is the Product Designed to
(a) be easily disassembled so that components can be reused, recycled, or
composted at the end of product life?
(b) be made of materials that are labeled, are easy to identify by type, and
are easy to separate?
(c) avoid special handling materials or components at the end of product
life because none of the materials used are on the customer's
restricted use list or are hazardous?
SAQ 4
Why is consideration of environment issues very important in the product design
related to its 'end of life' phase?

13.6 ADVANTAGES FROMDESIGN FOR

ENVIRONMENT
Design for environment is advantageous for a company's internal operations. For
instance, it helps in achieving
(a) Cost savings through :
(i) reduced raw material use,
(ii) lower energy required for production,
Product Design and (iii) reduced waste and waste management costs,
Development
(iv) more efficient assembly and production processes, and
(v) reduced material handling costs.
[A medical products manufacturer used DfE to redesign an oxygenerator,
and ended up in a 75 to 85 percent reduction in chemical use and wastewater
loading, amounting to an annual saving of $2.1 million.]
(b) Stimulating innovation within design and development staff;
(c) Improved health and safety through :
(i) reduction or elimination of toxic substances,
(ii) reduction or elimination of harmful emissions, and
(iii) reduced need for pollution prevention equipment.
(d) Improved worker motivation, satisfaction and morale, and
(e) Reduced risk and liability.
Companies may be further benefited from :
(a) improved brand image as leaders and innovators [For instance, Ford Motor
Company has implemented what it calls "class-leading actions." As a result,
all newly developed Ford vehicles are 85 percent recyclable, and contain
20 to 50 parts, as for example, air intake manifolds, insulation, carpets, etc.
made from iecycled materials such as used bumpers, tires, plastic bottles,
carpets, computer housings, and clothing.];
(b) the establishment of new markets opportunities;
(c) improved ability to meet product standards and regulations; [For example,
the restrictions in the European Union RoHS directive (Restriction of
Certain Hazardous Substances, effective July 2006) set maximum levels for
lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyls
(PBBs), and polybrominated diphenyl ethers (PBDEs) in some electronic
products. Companies using DfE are already prepared for restrictions such as
RoHS, preventing delays.];
(d) the acquisition of new customers and market share; and
(e) reduced product risk and liability.
SAQ 5
Take example of a product and show how companies may benefit when DfE is
applied. Write a short note on the economics of applying DfE.

13.7 GETTING STARTED : USE OF DfE

A key to successful integration of DfE into current design procedures is keep the process
streamlined and practical to use. A cumbersome, complex DfE process that is separate
from current procedures is unlikely to be used on a long term basis. Companies with an
environmental management system (IS0 14001) often integrate DfE into their system
from the start or incorporate it later during a continual improvement review. Whatever
62 means are used to integrate DfE into design need to fit with the culture of the company.
The following steps may be used as a guide for initiating use of DfE. Once established, Product Design
enhancements such as computer analysis programs can be added later. for Environment

(a) Establish internal support

(b) Build a team
(c) Select and customize a DfE tool
(d) Integrate into current design procedures
Step 1 :Establish Internal Support
An important first step is to establish support for this opportunity to improve or
enhance current design procedures by introducing DfE to other employees and
management. Showing some good video on DfE at a meeting is a great way to
start. This brief video may outline DfE basics - what, how, why and who - with
testimonials from companies which already use DfE. Follow-up discussions and
meetings are essential to engage fellow employees and gain key management
support. Inviting guest speakers from companies currently using DfE or some type
of green design process can also be helpful.
Step 2 : Build a Team
Expanding a product design team to include a biologist and representatives from
environmental, health and safety department (EHSD) can open new avenues for
design. A biologist could contribute design ideas from a biomimicry perspective,
tapping into the vast resources of natural design. EHSD staff can contribute
information related to regulatory or customer restrictions and hazardous waste
management costs; the materials process group can suggest alternative materiab.
Traditional members continue to be essential; representatives from the marketing,
research and development (R&D), production, and engineering departments each
contribute key information and considerations to the process.
Step 3 : Select a Tool or Method
There are a number of methods or tools that provide a framework for design teams
using DfE. These range from a basic checklist or flow chart to supplemental
software programs. Investing time and resources into selecting and customizing the
right tool that reflects the values and the culture of a company is key. While there
are various methods of implementing DfE, a core element is the entire team's use
of a life-cycle perspective up front during product design. At the same time, each
individual team member is encouraged to bring forward options and new ideas.
Step 4 :Integrate DfE into Design Procedures
If written design procedures such as a guide manual are typically followed during
product design, DfE checklist or flow chart pages can easily be added as tools for a
team to use early in the process. Less-formal design procedures can also use the
same type of basic tools. It is important to customize che,:.~~stsand flow charts to
reflect the primary environmental concerns and culture of the company. For
example, if the product is manufactured ir :L,.,*- oarticularly sensitive to water
use, that aspect could be reflected in the checklist by assigning more points or
weight to the "yes or no" questions about water use.
The method used is less important than providing an opportunity for a design team
to take a life-cycle perspective, then leverage their aggregate ingenuity. It is also
important to build ample time into the process for individual team members to
research and present new, improved design attributes.
SAQ 6
Explain the steps necessary for introducing DfE culture in an organisation.
Product Design and
Development 13.8 DfE TOOLS
There are many methods or tools that can inspire design teams to develop innovative
attributes in products - attributes that simultaneously.benefit the consumer, manufacturer,
and the environment. To ensure long-term use, it is important to choose a design tool or
method that is compatible with the processes and culture of the company.
There is no one "right way" to integrate DfE into product design. What is important is to
have a system in place that motivates product design teams to improve design. DfE
guides design teams through a life-cycle perspective with built-in windows of
opportunity to optimize design. A checklist is a good tool to start with. Software tools or
flow charts can then be added later. Either the use of stand-alone or any combination of
tools could be the right choice for a company.
A description of each of the following types of DfE tools is included in this Unit :
(a) Checklist,
(b) Flow charts,
(c) Eco-Indicator 99, and
(d) Software tools.
Investment in selecting and customizing a tool that will be integrated into the design
process will generate payoffs for inspiring better design, generating cost savings, and
potential gains in market share on a long-term basis.
Checklist
A checklist is a simple way to integrate DfE into design. In the following, sample
checklists are given for the various life cycle stages. Each section of this sample
checklist has "open-ended" questions to start dialogues between design team
members, as well as "yes or no" questions that address specific concerns.
To give design teams new perspectives, this tool covers all of the life-cycle stages
of the product upfront. At the same time, it opens windows of opportunity for
considering design alternatives and use of innovative solutions.
Before using this sample checklist, it needs to be customized with questions
relevant to the design of a particular product line and the culture of the company.
For example, a major medical products manufacturer may use open-ended
questions such as "Can we design it so that it could be upgraded and put back into
the marketplace?" in its Product Sustainability Review (PSR). In addition, the
answers can be "weighted" or assigned points that reflect the areas of most
concern. Scores from the checklist are for internal, comparison use only.
Flow Charts
Flow charts offer a visual, decisive method for guiding and analyzing a product's
design features. By using flow charts, a product design team can easily progress
through key decision-making points. For example, in one of the flow charts in one
company's "Environmental Product Evaluation Plan," the first question is: "Are
chemicals really necessary?" If a product and related manufacturing process does
not require chemicals, the evaluation is complete. If chemicals are needed, the
design team must complete this flow chart, then fill out justification paperwork.
The result is a built-in incentive to minimize the use of chemicals in the design of
products, since fewer chemicals means less paperwork and justification. This can
prevent the accrual of costs, due to unnecessary use and disposal of chemicals over
many years. Depending upon how they are constructed, flow charts can be used as
a stand-alone tool or as part of an array of tools that initiate use of DfE in a way
that is compatible with the practices and culture of a company.
 Eco-Indicator 99 Product Design
for Environment
Eco-indicator 99 is a method of evaluating the impacts (human health, ecosystem,
and resources) of various materials and processes. It was developed by Pre
Consultants for the Dutch government. A Complete Eco-indicator 99 Manual for
Designers can be seen at http://www.pre.nl/downloadlEI99~Manual.pdf.
When using this tool, it is necessary to keep in mind that the impact measurements
are geographically based (derived from impacts on a particular region) and
primarily have an environmental, not public health bias. Also most of the emphasis
on impact measurement tends to be relative to the environment and not worker
exposure. These are good tools to provide guidance during decision making, but
one must bear in mind that the results are not precise, undisputable values. As with
other tools, the quantified results are for internal comparison use only and would
not, for example, be included on a product label as being absolute values.
1 Software tools
There are a variety of software tools that are useful for guidance in the decision
making by product design teams. Some of these tools have materials selection
emphasis, providing comparative graphs and charts to assist with determining
which material may be best to use. They can be used in conjunction with checklist
that covers the rest of the life-cycle stages. These tools are especially useful for
providing comparative data for team members who want more measurement.
While these tools often involve a financial investment, demonstration models may
be available on a trial basis by contacting the vendor.
Some websites providing software tools useful for DfE are given below :

www .pre.nl/simapro/default.httn
Boustead
www.boustead-consulting.co.uk
Umberto
www.pre.nl/umberto/default.htm
Gabi
www-gabi-software.com
Eco ZT
www.pre.nl/eco-itleco-it.htm
Idemat
www.io.tudelft.nI/research/dfs/idemat~OnI~db/od~frame.htm
Ecoscan
www.ind.tno.nl/en/productlecoscan/
P2 Edge
http://avaiIabletechnologies.pnl.gov/infotechenergy/pol.stm
Eco-indicator 99

DFE
www.ind.tno.nl/product development/sustainable concepts/dfe/
download.html
MERGE TM
Product Design and
Development
13.8.1 DfE Tools for Material Selection 1
Necessary information may be obtained directly from parts and raw materiald suppliers.
Many companies mail surveys to suppliers to obtain this information prior to signing
purchasing contracts to ensure raw material puritylquality.
Discussion Questions
Are there plant or biobased materials or by-products from other processes
1
that can be used as raw materials for this product?
Are there recyclable or compostable materials that can be used in this
product?
Award 1 point if answer is yes and award 0 points if answer is no, unless
otherwise noted.
(a) What percent of your company's suppliers for this product or component
have an environmental management system (EMS) in place? (circle one) 0%
or unknown and award 0 points.
0% 0 points
1 to 5% 2 points
6 to 25% 3 points
26 to 50% 4 points
>SO% 5 points

(b) What percent of your company's suppliers for this product or component
have formal energy conservation practices in place (such as the
Environmental Protection Agency's Green Lights Program)? (circle one)
0% or unknown 0 points
1 to 5% 2 points
6 to 25% 3 points
26 to 50% 4 points
>50% 5 points

(c) The parts or materials in this product do not contain any of the restricted
materials (or in an amount lower than what is allowed).
A : Restrictions in Use of Materials or develop a custom list with customers.
Award (5) points for each material not in the part or material
(1) Yes, describe briefly

13.8.2 DfE Tools for Manufacture

Discussion Questions
Can this product be manufactured with low-temperature or low-energy use
processes (for example, low-temperature lamination process)?
Can this product be manufactured without the use of hazardous chemicals or
restricted metals?
1 point = yes, 0 points = no, unless otherwise noted
(a) Is the number of types, composite mixtures, and amounts of materials used
in this product minimised?
( ) Yes, describe briefly

( 1 NQ
 (b) Are the number and types of manufacturing steps minimized (simplification Product Design
to prevent errors and waste)? for Environment

( ) Yes, describe briefly

ON0
(c) Does the product contain materials that are considered to have the least
environmental impact?
( ) Yes, describe briefly
ON0
(d) Is as much recycled and/or renewable material as possible used in this
product?
( ) Yes, describe briefly
ON0
(e) Is the amount of material used in the product and during the manufacturing
process (surplus coating, cut-ways, trimming, by-products) minimized?
( ) Yes, describe briefly
ON0
(f) If plastics are used, are they clearly marked by an identification system such
as I S 0 1043-l?
( ) Yes, describe briefly
ON0
(g) Do the manufacturing processes for this product minimize the use of
energy-intensive steps (for example multiple heating and cooling, use of
inefficient motors)?
( ) Yes, describe briefly

ON0
(h) Is there minimal transport between manufacturing and assembly points?
( ) Yes, describe briefly
ON0
(i) Is the consumption of water and generation of water pollutants avoided or
minimised during the manufacture of this product?
( ) Yes, describe briefly
ON0
(j) Is the generation of air pollutants avoided or minimized during the
manufacture of this product?
( ) Yes, describe briefly
( ) No
13.8.3 DfE Tools for Product Use
Discussion Questions

Could this product be made to use a renewable or alternative (such as a fuel

cell) source of energy?

Could this product be designed for repair or upgradeable by the consumer

(e.g., use of modules or readily available replacement parts)?
1 point = yes, 0 points = no, unless otherwise noted 67
Product Design and (a) Is the product easily disassembled for repair, upgrade or reuse?
Development
( ) Yes, describe briefly

( 1 No
Are parts readily available for repair of this product?
( ) Yes, describe briefly

ON0
Have potential barriers to recycling been avoided, such as use of fillers,
additives, embedded metal threads in plastics, paint applied to plastics, or
use of materials of unknown composition?
( ) Yes, describe briefly

( No
Does the design avoid disposable components such as "one-time use"
cartridges, containers, or batteries?
( ) Yes, describe briefly

ON0
lf the product uses electric power, has energy efficiency been optimized?
( ) Yes, describe briefly

ON0
Are all batteries in the product easily identifiable by type and removable?
( ) Yes, describe briefly ---

( No
Is the generation of water pollutants avoided or minimized during the use of
this product?
( ) Yes, describe briefly

>
( No
Is the generation of air pollutants avoided or minimized during the use of
this .product?
( ) Yes, describe briefly

ON0
13.8.4 DfE Tools for Packaging and Transport
Discussion Questions
Is there a creative way to reduce packaging while still meeting labeling and
market demands (enhance the product's image)?
If the packaging container is reusable, can it be made to be easily collapsed
or folded and then reassembled?
1 point = yes, 0 points = no, unless otherwise noted
(a) Has the amount of packaging materials for the product been minimized?
( ) Yes, describe briefly

( 1 No
 To aid in reuse or recycling, do packaging closures use paper tape and Product Design
starch-based glues? (Avoid plastic tapes, plastic envelopes, and a lot of for Environment
staples.)
( ) Yes, describe briefly
T
ON0 I

If the packaging is paper, is it made with at least 30% post-consumer content

or a non-wood alternative such as kenaf?
( ) Yes, describe briefly
( ) IVo
If the packaging is plastic, is it appropriately marked (according to
IS0 1 1469)?
( ) Yes, describe briefly
( No
Do the packaging and ink printing meet the 100 ppm limit for combined
concentrations of lead, cadmium, mercury, chromium-VI, including inks,
adhesives, and coatings?, www.packaginglaw.com/index~mf.cfm?id=l53 )
( ) Yes. describe briefly
0No
If paperboard and/or paper is used for packaging, is it unbleached or made
from a totally chlorine free (TCF) or elemental chlorine free (ECF)
bleaching process?
( ) Yes, describe briefly
( ) No
If adhesives and inks are used, are they water based and/or soy (plant based)
instead of solvent based?
( ) Yes, describe briefly
ON0
Can the shape of the package be altered to improve case/palletization
/transport efficiency?
( ) Yes, describe briefly
ON0
Is the lightest weight of packaging material used?
( ) Yes, describe briefly

ON0
13.8.5 DfE Tools for End of Product Life
Discussion Questions
Are there new types of fasteners or joining technology that could be used to
make this product easier to disassemble?
Can the product be designed with residual value in mind, so that it or its
parts have monetary value at the end of usefulness (an incentive to reuse,
recycle, or compost the product or parts)?
1 point = yes, 0 points = no, unless otherwise noted
(a) Is the product easily disassembled for reuse, recycling, or composting at the
end of product life? (1 point = yes, 0 points = no)
( ) Yes, describe briefly

( >No
Product Design and (b) Are the materials used in the product easy to identify by type and to
Development separate?
( ) Yes, describe briefly -

ON0
(c) Are any of the materials used in the product required to be disposed of as
hazardous waste?
( ) Yes, describe briefly
( 1 No
(d) Has the intentional introduction of "restricted use" materials been avoided?
( ) Yes, describe briefly
: , (>No
Total Points :
SAQ 7
(a) Explain the use of Flow Charts as a DfE tool by taking an example.
(b) Prepare a note on the various DfE tools.

13.9 WHO USES DfE?

Industry
Design for environment is a tool used within the industrial design, product design
and development functions of many manufacturing companies. Companies leading
the way in the application of DfE are prevalent in the following sectors:
automotive, furniture, consumer products, building materials, electronics and
packaging.
Companies use DfE as a means to address and implement sustainability, eco-
efficiency, pollution prevention, product stewardship and cleaner production
within the core business practice of product design and development.
Government
Government is driving the industry adoption of DfE through :
Legislation and Regulation
Product take-back and restricted substances legislation (particularly in
the automotive, electrical and electronics sectors) is driving
companies to design their products for ease of disassembly and
recycling and free of hazardous substances and materials.
Assistance Programs
Some governments (e.g. Canada, the European Union, the United
States, Australia and Japan) provide technical and financial assistance
to companies for DfE projects and implementation. These national
and regional programs are primarily voluntary, providing either direct
assistance or via partners or third party consultants.
Green Procurement : Some companies have implemented DfE
programs enabling them to develop products to meet specific green
procurement requirements of government purchases.
SAQ 8 Product
for Envirc
What measures can government take to drive the companies adopt DfE? Name
some industries, which according to you, must adopt DfE whether under pressure
from government/general public or not.

13.10 TRENDS AND FUTURE IMPORTANCE OF DfE

Design for environment practices will become more common in industry in the coming
years. Several key issues are driving this growth :
(a) increasing demand for product innovation and differentiation;
(b) brand and company differentiation to maintain competitiveness;
(c) increasing costs and scarcity of raw materials;
(d) increasing cost of energy;
(e) increased consumer awareness around environmental and climate change
issues that may translate into changes in purchasing requirements and
behavior;
(f) renewed green purchasing initiatives by governments that may create a
demand for products with improved environmental performance,
environmental labeling and product certification;
(g) increasing demands from supply-chain and business customers stimulating
more open and transparent communication and business relationships;
(h) legislation and regulations that influence the materials, substances, and
chemicals (used in products and production); and,
(i) the growing sophistication and activism of consumer organisations and
environmental groups that may result in specific materials; substances and
chemicals being targeted (e.g., PVC) as detrimental to human and
environmental health.
- - - -

13.11 RELATED LEGISLATIONAND

REGULATIONS FOR DfE
Although there is currently no legislation or regulation requiring the application of DfE
within companies, DfE can be used to achieve compliance. In gene-31, it is anticipated
that there will be an increasing focus on the early design stages of products and services
to achieve more sustainable forms of production and .~nsumption.
The European Commission has drafted the End-Use-Equipment Directive that would
require manufacturers (of products and equipment that use energy during the use phase)
to report on how they are integrating environmental considerations into their product
design processes and environmental management systems. Extended producer
responsibility legislation, such as the End-ojlLi$e Vehicle Directive in the EU and product
specific landfill bans and recovery regulations (e.g., covering mercury thermometers) are
also driving DfE activities.
In addition, the International Organization for Standardization (ISO) is soon going to
publish a Technical Report entitled I S 0 14062 Environmental Management: Integrating
Environmental Aspects into Product Design and Development. I S 0 14062 has been cited
within several policy documents as a guide for companies seeking to integrate DfE into
their activities.
Product Design and SAQ 9
Development
Prepare a brief report on the worldwide government regulations/legislations for
adopting DfE by companies producing automobiles

13.12 SOME CASE STUDIES OF COMPANIES

EMBRACING DESIGN FOR ENVIRONMENT
Case of SC Johnson
This company operates in 6 0 countries manufacturing domestic products, such as
furniture polishes, air fresheners, glass and surface cleaners, insecticides, insect
repellents and shaving gels. The concept of DfE is actively pursued and rewarded
across the company operations. Where possible, SC Johnson uses recycled
materials for packaging. Over five years, the company reduced the use of virgin
packaging components by 26.8 per cent. Aerosol packaging contains at least 25 per
cent recycled steel and is itself recyclable, and shipping containers have a 95 per
cent recycled content. The company also researches environmental data on raw
materials to select ingredients with lower environmental impacts.
SC Johnson now makes only two types of bottles and spray triggers. This
simplified production line reduces energy consumption, a significant cost benefit.
Manufacturing processes are regularly assessed to reduce air emissions, waste
emissions, wastewater, energy and fuel usage; the company's goal is to reduce
waste output by 50 per cent each year. Air water and solid waste disposals in
operations have been roughly halved over five years, and before conventional
waste management practices are employed all recycling opportunities are explored.
SC Johnson evaluates product ingredients against current scientific research,
identifying any ingredients for removal from products. All company products and
processes exceed legislative requirements for environmental performance. The
company uses independent audits, ongoing internal evaluations, and management
and employee training programs to achieve continuous environmental
improvement. Employees attend regular environmental training sessions, and an
induction program trains new staff on company's environmental programs. The
company's global environmental management program and high level of
environmental performance are improved by regular reviews of relevant scientific
information and existing and impending environmental legislation. Global
environmental performance is tracked annually according to internal
environmental targets.
Case of Faribault Mills
Faribault Mills began looking for innovative, environmentally friendly fibers for
making blankets to substitute for man-made synthetics, which use non-renewable
resources and do not break down in landfills. The answer was Ingeo, a naturally
derived fiber from corn, manufactured by Dow. The process for making the fiber is
based upon a natural process - fermentation of simple plant sugars from corn,
which creates a polymer that is in turn spun into a fiber.
Faribault Mills finds Ingeo to be economically and environmentally sustainable,
with superior performance characteristics. Blankets made from this material are
recyclable or biodegradable at the end of usefulness.
(www.moea.state.mn.us/p2/aovaward04.cfm)
Case of Toyota Product Design
for Environment
Toyota has started using bioplastics for car floor mats and for spare tyre cover in
some of its cars. Bioplastics are derived from agricultural products such as sugar
cane, corn, and tapioca. The Toyota biotechnology division is working with some
60 companies, including office equipment makers such as Fujitsu and NEC, to
supply them with bioplastics.
.
www.toyota.co.ip/en/more than carstbio afforest/satsumaimo.html
Case of Cargil Dow
Cargill Dow uses renewable materials for packaging. One such material is
Polylactide (PLA), a polymer produced from lactic acid derived from cornstarch
dextrose through fermentation.
This biodegradable material is currently used to make clear food clam-shells, trays,
dairy containers, consumer and electronics packaging, cold-drink cups, shrink
wrap, and windows for envelopes.
Currently most PLA is made from corn, but Cargill Dow is also working on using
corn stover (residue left in the fields), grasses, wheat, rice straw, and sugar cane
residue. At the end of usefulness, packaging made from this material can be
composted along with food waste.
www.naturewo~-ksllc.com
Case of Steelcase
Steelcase manufactures Think chair, which it claims to be 99 percent recyclable
and can be disassembled by hand tools in 5 minutes so that components can be
returned to the raw materials stream. The chair is expected to have a 20-year life
expectancy that will likely be extended through office donations of the chairs to
nonprofits, homes, and schools for a second life.
Steelcase considered the impact of the 14 raw materials used to manufacture the
Think chairs. After evaluating potential materials, only those that were at little,
low, or moderate risk to humans and the environment were used. The chairs are
claimed to contain 41 percent recycled-content materials and are often shipped to
customers in reusable totes rather than cardboard boxes. As part of their focus on
sustainability, the company launched the Steelcase Environmental Partnership to
help customers determine the most environmentally responsible way to manage
any Steelcase furniture at the end of its usehlness.
www.steelcase.com_
Case of Interface
Interface, the world's largest manufacturer of commercial carpet, worked with
biologist Dayna Baumeister of the Biomimicry Guild during the design of Entropy
carpet. The concept came during an exploratory walk the design team took in a
forest. The result was use of a random, disorder built-in pattern that mimics that of
' B forest floor. Made from recyclable nylon, using a single dye lot that has 48
different color ways, the Entropy carpet has become one of the company's
bestselling designs.
Entropy carpet tiles can be moved anywhere, face any direction; if a carpet tile
wears out in a high traffic area or gets stained, it can be readily replaced. The
randomness hides any evidence that older tiles are among newer ones.
www.interfaceflooring.corn/sustain/seven.htn~l
Case of Fuji Xerox
Fuji Xerox uses life-cycle concepts to design copy machines with reuse and
recycling in mind. Used products collected from customers are disassembled and
cleaned, checked for quality, then reused. Materials from parts that cannot be
reused are recycled for use in new components. The end result is a closed-loop
system.
Product Design and Some of the basic reuselrecycling design principles used to support the closed-loop
Development system include creating parts that are :
(a) made for long life and reuse,
(b) easy to separate or disassemble,
(c) made of materials that can be readily recycled, and
(d) standardised with components common to existing and future models.
Information gained in these closed-loop processes is used to further improve
designs to increase reuse and recycling of parts.
www.fxap.com.sg/abouEnvt.isn
Case of Mercedes Benz
The new A-Class Mercedes Benz automobile has 26 components made from
natural fibers such as flax, hemp, coconut, and sisal. For example, the covers for
the front seat backrests are made of natural materials and plastic. The company
sees the use of natural materials as an important contribution to reducing carbon
dioxide emissions. Abaca, a natural fiber grown in the Philippines, could even
replace glass fiber as a strengthening agent for the car body plastic parts due to its
exceptional tensile strength, lower weight, superior ease of use and suitability for
recycling. Overall materials selection is made on the basis of low consumption of
resources, outstanding recycling properties, a minimal energy requirement, and
low emissions during manufacture, processing, and use.
A total of 54 components in this vehicle are made from high-quality recycled
plastics.

Case of Nokia
The Nokia Research Center has developed a prototype phone with a built-in
"active disassembly" mechanism to aid in recycling materials at the end of the
product's life. This mechanism stays dormant during the use phase of a product,
but is activated when an external trigger such as heat is applied when it is time to
disassemble the product. This enables more efficient and safe recycling of product.
For example, "shape memory" materials, such as a threaded screw or snap-fit
connector, are molded and lose their shape when heat is applied (no threads on the
screw, no curve on the snap-fit part) and then return to their original molded shape
as they cool. When this type of connector is used in conjunction with strategically
placed springs, a product such as this prototype cell phone self disassembles when
heat is applied. The key is to design products so that it is unlikely they will be
exposed to the external disassembly trigger (in this case, a specific amount of heat)
during normal or even harsh use of the product.
www.nokia.com
Case of Baltix
Baltix manufactures office furniture from natural materials, including wheat straw,
sunflower husks, and recycled paper, currency, and plastics. No harmful adhesives,
formaldehydes, or volatile organic compounds are used in the products. By
accepting the office hrniture back for reuse or recycling when it is no longer
useful, Baltix provides a closed-loop solution that keeps old office furniture out of
the waste stream.
Case of D~esignTex
DesignTex manufactures fabric that is made from natural fibers like wool and
ramie. The design team screened and selected every process and related ingredient
used to produce the fabric. All the raw materials were put through "intelligence
filters," where each potential dye or process chemical was analyzed so that any
 known or suspected carcinogen, mutagen, teratogen, bioaccumulative chemical, or Product Design
endocrine disruptors are eliminated. "This complete screening of ingredients for Environment
ensures that these fabrics are entirely safe, always."
An added advantage is that there is no waste stream from the mill that
manufactures the fabric. Any by-products or trimmings are either reused in the
manufacturing process or made into a compostable felt used by gardeners to
insulate crops. DesignTex fabric is designed to biodegrade and decompose
naturally back into the soil and to nourish the earth, completing the life-cycle
circle.
www.clin~atex.com

13.13 SUMMARY
In this unit, you have studied product design for environment. It is now recognised that
product have environmental irhpact over the course of their entire life cycle, from
extraction and procurement of raw materials through manufacturing, distribution, uses
and disposal.
Design for environment (DSE) is described as a design which addresses all
environmental impacts of a product through out the complete life cycle of the product,
whilst aiming to enhance other criteria like function, quality and appearance. Many
'companies have now realised that design for environment make good business sense.
Each states of life cycle of a product introduce opportunity to design in new types of
alternative materials, fasteners, optimal shapes and of renewable power. In this unit we
have provided you checklist questions which guide you exploration of various options.
Checklist, flowchart, eco-indicator and software tools are the DFE tools which you have
studied in this unit. Some case studies of companies embracing design for environment
have been provided for better learning insight.
After studying this Unit, the student will understand why it is important to consider
environmental issues while designing a product, whether it is selection of materials,
processes of manufacture and assembly, or procedures for its uselmaintenance. The
student should also become aware of various DfE tools.
The success story of various companies which have adopted DfE should help the student
in realising the fruits of using DfE in a better way.

13.14 KEY WORDS

Environmentally Responsible : ERM has been defined as an economically driven,
Manufacturing (ERM) system wide and integrated approach to the
reduction and elimination of all waste streams
associated with the design, manufacture, use
andlor disposal of product and material.
Design for Environment (DFE) : It basically involves the incorporation of
environmental consideration into the design and
redesign of products, processes, and technical and
management system.
New Product
Development Process
: It is the process embodies all of the steps
necessary to take the product from concept to full
t
production.
Product Life Cycle : Product life cycle refers to the succession of the
stages the product goes through. Every product has
stages like development, introduction, growth,
maturity and decline.
75
Product Design and
Development 13.15 ANSWER TO SAQS
Please refer the preceding text for all the Answers to SAQs.

FURTHER READING
Geoffrey Boothroyd, Peter Dewhurst and Winston Anthony (2002),Product Design for
Manufacture and Assembly, CRC Publisher.
Mike Baxter (1995),Product Design, CRC Publisher.
Norman Gaither and Greg Fraizer (2002), Operations Management, Thomson and Sons.
S. N. Chary (2005),Production and Operations Management, Tata McGraw-Hill
Company.
Kanishka Bedi (2007),Production and Operations Management, Oxford Universal.