getting started with eco-design - guidance for innovative product developers
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11 June 2010
Commercially Confidential S3908-P-090 v1.0
Getting Started with Eco-Design
Guidance for innovative product developers
Authors: Rachel Harker, Nathan Wrench
Commercially Confidential 2 11 June 2010 S3908-P-090 v1.0
Who we are
Founded 1960, owner Altran 300 engineers, designers & scientists
Contract design & development house Developing breakthrough products
Creating & licensing IPCambridge UK & Boston MA
Specialists in: consumer products, medical technology, wireless, defence & security, cleantech
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For start-ups to Bluechips we develop radical products from new science or technology
Radical product innovations
End to end product design
Integrated eco-design
Transfer to manufacture
Faster time to market…
…with less risk
IP platform springboards
Turning Ideas into Reality
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A Flavour of Our Work
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The world’s first virtually waterless washing machine prototype using revolutionary polymer technology.
Less water. Less energy.
6 11 June 2010 S3908-P-090 v1.0
Getting Started with Eco-design
The business case for eco-design1
Legal landscape2
Today’s presentation
The tools of the trade3
Case study of eco-design based innovation
Getting started
4
5
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1. Business case for eco-design
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Firms will have to integrate eco-design into innovation & NPD practises
Commercial pressure
– Green products are more desirable
– It promotes lean engineering which can reduce operating & product costs
– Investor pressure to mitigate commercial risks of climate change
– The competition has already begun
Legal requirements
– Multiple expansive directives already in force (e.g. RoHS, WEEE, EUP)
– More to come in response to Climate Change & international competition
Business case for eco-design
Eco-design offers opportunities for major competitive advantage now
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Market demand for eco-friendly products will increase
Business case for eco-design
64%
36%
64% of US consumers say they would replace older appliances with newer energy efficient appliances if home energy prices rise significantly (Source: CEA Market Research)
Commercially Confidential 10 11 June 2010 S3908-P-090 v1.0
There are substantial cost savings to be made
Business case for eco-design
£150k saved in first year after re-design of medium volume electronic product
– Fewer parts– Circuit boards reduced by 5 to 1– Fasteners reduced by 30%– Removal of glues and thinning materials
– Assembly time reduced by 68%
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2. Legal Landscape
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EC aiming for more sustainable resource use & reduction in landfill
Philosophy of Extended Producer Responsibility based on ‘polluter pays’ principle
OEM is responsible for end of life management
Aim is to encourage:
– Less toxic materials
– Use of more recycled materials
– Reduction in material usage
– Easy end of life treatment
– Re-use & recycling
Legal landscape
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Several expansive directives support Producer Responsibility
Battery directive – restricts chemicals and deals with waste management
RoHS directive
– Lead-free electronics assembly
– Also restricts cadmium, mercury & hexavalent chromium, PBB, PBDE
WEEE directive
– Financial or physical responsibility for products at end of life
Packaging (Essential Requirements) Regulations – minimise & recover
EUP directive
– A framework for the setting of eco-design requirements for Energy Using Products
– Increase energy efficiency and reduce negative eco-impact
Legal landscape
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3. Tools of the trade
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Many eco-design tools & methodologies available
Typically used for 3 categories of design: buildings, processes and products
Facilitate eco-improvements through light touch approaches or comprehensive integrated processes
Product development tools & methodologies can help you:
– Make design & development decisions that reduce eco-impact
– Evaluate alternative technical solutions
– Compare your performance vs the competition
Tools of the trade
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Many eco-design tools & methodologies available
Guidelines and check-lists
Management methodologies and tools
One-score indicators
Life cycle assessment tools
Tools of the trade
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A few guides, checklists and tools can quickly improve knowledge and practise
Smart ecoDesignTM strategy wheel
– Quick tool to assess environmental strengths and weaknesses of a product
EcoDesign checklist
– Guidance and compliance with RoHS and EUP www.cfsd.org.uk/seeba
Guide - Cleaner Product Design: A Practical Approach
PACK-IN – The Packaging Indicator Tool www.envirowise.co.uk
QWERTY/EE concept
– Evaluates recyclability
– Includes economic factors for take back and recycling
– Jaco Huisman, Delft University of Technology 2003
Tools of the trade
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Life Cycle Analysis is the standard method for assessing environmental impact
Environmental impact is determined by the whole product life cycle
Assess products at each phase of life from ‘cradle to grave’
Life phase impacts vary greatly from product to product
Tools of the trade
http://www.ami.ac.uk/courses/topics/0109_lct/
material extraction material processing manufacturing use waste management
recycle re-manufacturing Re - use
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The Ei-99 system is a comprehensive life cycle analysis tool which assigns points to each life phase based on three damage categories:
Outputs score in points per unit of product
Facilitates comparison between:
– Different or competing products
– Technical solutions or designs
Impact on ecosystems
Impact on human health
Impact on resources
Tools of the trade
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Damage toecosystems( % plant species
* km2 * year )
Damage tohuman health
( disabilityadjusted life
years (DALY) )
Resources(MJ surplus energy)
Regional effect on species numbers
Local effect on species numbers
Effect on target species
Ecotoxicity: toxic stress (PAF)
Climate change (disease + displacement)
Surplus energy at future extraction
Ozone layer depletion (cancer + cataract)
Radiation effects (cancer)
Respiratory effects
Cancer
Decrease of natural areas
Altered pH + nutrient availability
Concentration in soil
Concentration of greenhouse gas
Availability of fossil fuels
Concentration of ores
Concentration of ozone depl. subst
Concentration radionuclides
Concentration fine dust. VOC
Concentration air, water + food
Land use &conversion
NOxSOxNH3
PesticidesHeavy metals
CO2HCFC
Nuclides (Bq)SPMVOCsPAHs
Extraction ofminerals &fossil fuels
STEP 1 STEP 2 STEP 3
Mining
Converter
Milling
Pressing
Transport
Disposal
Inventoryanalysis
Resource analysisLand-use analysis
Fate analysisExposure &
effect analysisDamageanalysis
Normalisationand weighting
Tools of the trade
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4. Case study of eco-design based innovation using Life Cycle Analysis
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Consumer appliance manufacturer developing next generation mini fridge
Requirements:
– Better cooling performance
– Reduced noise
– Improved capacity
– Low impact on cost
Poor consumer reviews highlighted high energy use of existing platform
– Improved environmental impact had become an imperative
Case study
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Ecovation technique used to drive the technical development
Generated a range of potential technical solutions
Quantified & ranked 3 platforms in terms of
– Cost
– Performance, size, noise
– Overall environmental impact using Ei-99 scale
– Benchmarked against existing product
The process identified a new platform with:
– Substantially better cooling performance
– Environmental impact reduced by a factor of 3
– Only marginal impact on build cost +5% (in line with customer expectation)
Case study
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The existing appliance had a very high impact during use phase
Due to inefficient thermoelectric (Peltier) cooling with relatively poor insulation
Case study
Production 6.74
Packaging 0.17 Transport 0.57
Use 51.68
Disposal -1.13
-10
0
10
20
30
40
50
60
Current appliance
Impa
ct (E
i-99
Poi
nts)
Total = 58.03
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Concept 1 - Incremental ‘improvement’ by retaining Peltier cooling and adding extra cold store
Improved cooling performance plus meets noise and size targets
But eco-score deteriorated for both production and use
Case study
Production 8.59
Packaging 0.17 Transport 0.57
Use 53.23
Disposal -1.73
-10
0
10
20
30
40
50
60
Peltier + cold store
Impa
ct (E
i-99
Poin
ts)
Total = 60.84
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Concept 2 – Adopt an absorption cycle (used in camping fridges/mini-bars)
Improves overall eco-impact and performance
Dramatically improved energy efficiency reduces eco-impact during use phase
Slightly higher eco-impact during production phase
Reduced noise
Case study
Production 7.89
Packaging 0.17 Transport 0.57
Use 14.78
Disposal -1.35
-10
0
10
20
30
40
50
60
Absorption cooling
Impa
ct (E
i-99
Poi
nts)
Total = 22.06
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Concept 3 – Vapour compression cycle
Better energy efficiency dramatically improves eco-impact of use phase
Poorer noise was offset by improved cooling performance was used to offset noise
Eco-score reduced by factor of 3! (even with slightly higher production impact)
Case Study
Production 7.85
Packaging 0.17 Transport 0.57
Use 9.3
Disposal -1.62
-10
0
10
20
30
40
50
60
Vapour compression
Impa
ct (E
i-99
Poi
nts)
Total = 16.27
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Improvements translated to strong marketing advantage
€40 / year saving for the average consumer
Overall performance improved
Case study
ECO-Score of appliance concepts
6.74 8.59 7.89 7.850.17
0.17 0.17 0.170.570.57 0.57 0.57
51.6853.23
14.789.3
-1.13 -1.73 -1.35 -1.62
-10
0
10
20
30
40
50
60
70
Current appliance Peltier + cold store Absorption cooling Vapour compression
Impa
ct (E
i-99
Poi
nts)
USE: 82% reduction
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5. Getting Started
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Start Simple and Build Eco-Design Capability
Consider eco-impact at the design stage using basic guides and checklists
Focus on energy efficiency – 9/10 products which consume energy have most eco-impact during the use phase
Make products that have recycling value (easy to dis-assemble, good yield)
Benchmark using simple lifecycle analysis
– Existing products and competitors
– Identify biggest opportunities for improvement
Consider increasing product lifetime and re-define commercial models:
– Upgradeable platforms
– Services versus products
Getting Started
Commercially Confidential 31 11 June 2010 S3908-P-090 v1.0
Contact details:
Cambridge Consultants Ltd Cambridge Consultants IncScience Park, Milton Road 101 Main StreetCambridge, CB4 0DW Cambridge MA 02142England USA
Tel: +44(0)1223 420024 Tel: +1 617 532 4700Fax: +44(0)1223 423373 Fax: +1 617 737 9889
Registered No. 1036298 England
info@CambridgeConsultants.comwww.CambridgeConsultants.com
Commercially Confidential This Presentation contains ideas and information which are proprietary to Cambridge Consultants Limited and/or Cambridge Consultants Inc: it is given to you in confidence. You are authorised to open and view any electronic copy we send you of this document within your organisation and to print a single copy. Otherwise the material may not in whole or in part be copied, stored electronically or communicated to third parties without the prior written agreement of Cambridge Consultants Limited and/or Cambridge Consultants Inc.
© 2009 Cambridge Consultants Ltd, Cambridge Consultants Inc. All rights reserved.
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