00156-Develop Environmental Friendly Product by Using GDA and LCA.doc

develop environmental friendly product by using gda and lcaaiju wang, jim liumatc-asia, motorola (china) electronics ltd.no.10, avenue 4, teda, tianjin 300457, chinatel: +86+22-25328282 ext. 2004, fax: +86+22-25328296 a4588a18121abstract with increasing concern on the environmental impact of products, most manufacturers are seeking ways toreduce the environmental impact of their products and processes. design for environment (dfe) was afundamental requirement for any new product design in motorola. this paper introduced two main dfetools used in motorola, green design adviser (gda) and life cycle assessment (lca). two examples are given to show the dfe applications at motorola, which include environmental preferred product (epp)and water borne paint decorating technology. challenges and opportunities for environmental technology development are also discussed in detail.keywords design for environmental (dfe), environmental preferred product (epp), weee, rohs1. introductionsince the environmental problem becomes extremely serious on the earth, many countries have paid great attention to environmental preferred products and process. to push the manufacturers produce environmental friendly products, legislations on recycling, packaging and hazardous material elimination are announced. european union and china has enacted two legislations, one is waste in electrical andelectronic equipment (weee) directive, which proposes a recyclability (after recycling process) of electronic products should reach 65% in 2006. another directive is on the reduction of certain hazardoussubstances in electrical product, which prohibits lead (pb), mercury (hg), cadmium (cd), hexvaluent chromium (cr vi), and two types of brominated flame retardants, polybromined biphenyls (pbb) and polybromined biphenyl ethers (pbde) from being used in electronic and electronics equipments from 1stjuly 2006 1. products that do not implement with these regulations would not be permitted to enter market. at the same time, many countries use eco-labels to stimulate the production of green products andencourage the consumers to choose the environmental friendly products. as a global leading company obligate for environmental protection, motorola always put many efforts to minimize the negative impact of its products 2. motorolas vision is to be the global corporate leaderfor progressive and best-in-class environmental, health, and safety performance for our practices, processes,products, and services. we seek to design all of our products for innovative performance, lowenvironmental impact, and to have superb benefits to the environmental quality and the safety of our users 3.design for environment (dfe) is a critical means of realizing its environmental goals at motorola. unlike traditional endmost waste treatment solutions, dfe tries to prevent potential environmental problems at very early stage of product design, and to reduce and eliminate the environmental impact ofour product from raw material extraction and part sourcing though manufacturing, transportation, use, and end of life. dfe starts with the development of environmental goals within a set of environmental policy,needs, and concern categories, considering the whole life cycle of the product. there are two different methods for implementing dfe. one is to consider each stage of the product life cycle respectively and aims to fulfill the goals for each stage. for example, design for recycling is focus on disposal stage and trying to satisfy the requirements like recyclability, disassembly time and cost. the tool used for this is green design advisor (gda). the other is based on life-cycle assessment approach and calculates theenergy and material flows in the product life cycle. the tool is life cycle assessment (lca) 4. in this paper these two methods were introduced in detail, and two successful examples are given. 第 1 页2. green design advisorgreen design advisor (gda) is a software tool developed by motorola and university of erlangen, which uses very specific and complex rules to simulate the multistage recycling process and supply environmental information to the designer. the gda uses eight metrics to evaluate the environmental performance of a product. these metrics arenumber of materials, mass, energy use, toxicity index, recycled content, recyclability, time for disassembly, and end of life value.the gda enables our product designers to compare different materials and processes that could be used to create a product. this gives design engineers the ability to select and improve the best product design based on their potential environmental impact. the following figure summarizes the calculation methodology of gda. productproductmodelcriteriavaluesrecyclabilitypreferencefunctions1.00.506040200data.toxicityenergy10080percent recycled.1.00.5000,5toxicity index1,01,5 2,02,51.00.501000energy use kj500010000100000multiattributevalue analysistotal scoreraw datagda scoresfigure 1 gda calculation methodology one produce model example is given in figure 2, generated by the gda.figure 2 one gda modeling of one motorola product for product modeling all parts and the connections between the parts have to be defined. a connection can link two or more parts, and it represents only the relationship between the parts, not the joining elementitself. the joining elements, like screws, have to be entered as parts. the parts will be represented by ellipses, the connections by circles. the material composition and the weight of the parts have to specified. the parts with the same materials will be displayed colored same.the results based on gda were given in figure3. comparing the environmental impact of two competing designs for a test product, illustrating that design b has a lower overall environmental impact. acertain amount of secondary metal and regrinds plastic was contained in its parts, and its housing wasdecorated with environmental friendly paint. moreover, lead free sold was used in its pwb, therefore a recyclability of 71% was gotten from gda calculation, which will fulfill the weee requirements for 2006 of 65% (material recovered), and its toxicity is quite lower than that of design a.第 2 页 sco re sc o sco recost of disposalrecyclabilitymass10.50recycled contentdesign adesign btoxicityno. of materialsfigure 3: an application of green design advisor gda is mostly useful in product detail design, and can also support the other design phases. forexample, it can be used to build up some of the basic designs by introducing specific materials and joining techniques. this will accordingly improve the environmental performance of the materials and connections, such as high recyclability, low toxicity, short disassembly time, less energy consume and etc, and help toeliminate what have particularly poor environmental performance. at the same time products that have been fully developed can be evaluated by the tool to calculate a metric for retrospective analysis andtracking 5.3. life cycle assessmentunlike gda is applied for the whole product, life cycle assessment (lca) is a systematical method used to assess the environmental impact of all mass and energy flows of the life cycle of a product/process. the life cycle of a product includes the extraction of raw materials, the manufacture of components, implementation of the product, the usage of products; the disposal and treatment of the end-of-life product (see figure 4). lca is very helpful in alternative product/process comparison or product/process improvement from the environmental point of view. generally a lca study includes 4 steps:1. goal and scope definition: a statement of the purpose of the study and the determination of the system boundary.2. inventory analysis: a quantification of material and energy use, recovery, and waste for the studied system.3. impact analysis: an examination of the contribution of material and energy use, recovery, and waste to impacts to the environment. 4. interpretation: a technique to identify, quantify, check and evaluate the results of the inventory and impact assessments.inputsenergyraw materialacquisitionengineeredmaterialsacquisitionmaterialsoutputsproductsby-productsprocessmaterialsmanufacturing& assemblyuse &serviceend of life& assemblyserviceairemissionswateremissionssolidwastefigure 4: life cycle assessment第 3 页following presents an application case of life-cycle assessment, which is a study made to compare the environmental impacts caused by different paints. the housing mass share in a cellular phone is about 20%,therefore its decoration techniques are very significant within the whole life cycle of whole product. currently, two kinds of paints are very popular in plastic housing decoration. they are solvent based paint and water borne paint. but different paint has different impacts on the environment and human beings.there is a need at motorola to develop low cost painting which has little environmental impact. to make the study covers all aspects of this project; the paint manufacture process and painting process were as research object. to guarantee the validity of the study results, the scope of the study should include the key processesand flows in the life cycle, which may cause important environmental impacts. at the same time, someminor processes and flows should be ignored to decrease the complexity of the study. the criteria to judge if the process/flow should be ignored is to see the environmental contributions of it. the system scope may be adjusted throughout the life cycle study. in this project, with the assistant of lca software theproduction of most of the operational materials can be traced back to the related original materialproduction and basic resources such as air, ores, fuel, water, oil and etc. the following is the lca model on solvent & water based coat manufacturing and painting process.solvent based painting water based paintingfigure 5 modeling of solvent & water based coating to decorate 10k housings surface, the environmental impact caused by solvent and water based paint are presented in figure 6. it shows that solvent paint has the bigger contribution to the negative environmental impact. compared with these two decorating technologies, painting with solvent basedcoating has bigger impact on photochemical oxidant potential (pocp), acidification potential (ap), aquatic eco-toxicity potential (aetp), eutrification potential (ep), glob warming potential (gwp), human toxicitypotential (htp), ozone depletion potential (odp), and emission to air (etair). on the other hand, waterbased painting has bigger emissions to water and soil (etwater, etsoil). 100%50%0%pocpapaetpepgwphtpodpetair etwater etsoilwater-painting6.5925 14.401 13.869 1.3181 5819.3 499.96 0.001 37041 2.39e+ 32.98solvent-painting 13.153 14.893 16.095 1.3676 5884.9 501.40.001 37066 2.38e+ 30.35figure 6: environmental impact to decorate 10k housings of cellular phones第 4 页after inventory and impact analysis, we got the following conclusions. from the environmental point of view, paint manufacture and painting mainly leads to voc emissions, which are the key contributors tophotochemical oxidant potential (pocp). water borne paint is a new decorating technique with low voc6, but it easily leads to water pollution by organic materials, furthermore its solid waste is greater than that of solvent paint. the main reason is that solid mass share in water borne paint is higher than that in solvent paint, and it needs 34g paint per piece, however it only needs 2.02.5g per piece for solvent paint. moreover, before manufacturing and painting of water borne paint, the pipe and equ