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SustainableSustainable Product DevelopmentProduct DevelopmentSustainable Sustainable Product Development Product Development with with
Green DesignGreen Design WorkbenchWorkbenchTMTM**Green Design Green Design WorkbenchWorkbench
Agenda
Section 1
Section 2
Green Business Drivers & Sustainability Challenges
Green Design WorkBench™ Introduction
Environmental Regulatory Compliance Management SolutionSection 3
Section 4
GDW Benefits Summary
Global Compliance Solution Case study – Hi-Tech Giant
Section 5
2
Business Drivers & Challenges in Green / Sustainability
Business Drivers in Sustainability
Cost of non-compliance to Green
Business Challenges
Lack of collaboration among globally spreadCost of non compliance to Green
Cost of in-action on Green initiatives –impact on Carbon Credit
Increased consumer preference for
Lack of collaboration among globally spread R&D teams
High cost of green product development
Lack of visibility on ROI for green initiatives
energy efficient products/ solutions
Increased organizational drive for efficient products and processes
E i i t f
Lack of comprehensive/ in-built framework facilitating easy compliance to RoHS/ REACH/ WEEE/ JEDEC during the product development
Linking Carbon credit to product & it’s easy tracking Ever increasing cost of energy
Alternate technologies such as renewable energy sources, composite materials
g p y gat the global level
IT Challenges
Sustainability of the available natural resources
Corporate social responsibility
Defining, Implementing and Monitoring GPIs
Determining Cost of Conformance, Cost ofnon-conformance and Efficiency Benefits
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End-of-Life Reverse manufacturing challenges
Organizational Challenges in Implementing GREEN
GREEN Definition for a Global Manufacturing Enterprise
Green Portfolio
Green Product Design
Green Drivers
Standards ComplianceMaterial characteristics – reuse, recycle, decompose, performanceProduct Efficiency – energy, water, gas, other consumablesEnvironment, Health and Safety – Emission, heat, radiation,
pCost of non-conformanceCost of ConformanceEfficiency Benefits
GREEN PERFORMANCE
, y , , ,waste, etc
Green ManufacturingConsumables characteristics – reuse, recycle, decompose, performance
TARGETS (GPT)
GREEN PERFORMANCE INDICATORS(GPI)
performanceOperating Efficiency – energy, water, gas, other consumablesEnvironment, Health and Safety – Effluents, emission, heat, radiation, waste, etcManufacturing performance Rework/ scrap/ wasteINDICATORS(GPI) Manufacturing performance – Rework/ scrap/ wasteManufacturing Process Automation
Green End-Of-Life – Reverse ManufacturingReverse Supply chain and logistics performance
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CONTINUOUS IMPROVEMENT
Reclaim profile & performanceReuse/ Reduce/ Recycle performance – Bin/ Scrap/ Waste
Green Design Workbench (GDW™*)
HCL’s Green Design Workbench (GDW™) is an enterprise class framework & solutions to enable sustainability, environmental compliance and other green processes during the product design,
development operation and EOL managementdevelopment, operation and EOL management.
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GDW Solutions Map
Part Regulatory
Data
Audit Trail/ Traceability
Global Regulations Database
Compliance enabled
Workflows
Compliance Documenta
tion
BOM/ Product
Compliance
Compliance Reporting
Environment Compliance Regulations Data Database Workflows tionComplianceRegulations
Supplier Qualification
Workflows/ Data
Logistics Performance/
Reverse SupplyDeclaration Standards
Automatic Error Checking Green
Procurement Qualification Requisition Reverse Supply Chain
Standards Tracking/ ReportingProcurement
Design products composed of recycled or
Benchmarking with Global Database/
Recycle/Reuse performance - EOL BOM Recycle/
DisposalRRR composed of recycled or reclaimed materials
Global Database/ Reporting
performance Bin/Scrap/Waste Design Disposal
EfficiencyRRR
Design energy ManufacturingMonitor/ ReportingResources/ Energy Green Performance
Resources or E
Green Product GREEN
Design energy efficient products
Manufacturing Simulation
Resources/ Energy consumptionand emissions
Green Performance ReportingEnergy
Consumption
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Green Design Green Operation EOLDevelopment/ Manufacturing
GREENFoundation
GDW - HCL’s Environmental Regulatory Compliance Management Solution
Business ChallengesLack of comprehensive /in-built framework facilitating easy compliance to RoHS, REACH, WEEE, JEDEC during the product developmentComplexities in involved in development of products to meet multiple Complexities in involved in development of products to meet multiple regulationsLack of streamlined processes to support changes in compliance definition, history and tracking across product life cycleNeed for systematic automated processes to identify alternate complaint Need for systematic automated processes to identify alternate complaint components in the product development
The Solution helpsTo proactively address sustainability / compliance during product design to
Features Compliance Data Management To proactively address sustainability / compliance during product design to
o Avoid after-the-fact redesigns, o Avoid physical prototyping & enabling virtual analysiso Measure green index of the product during designo Product design with environment friendly materials
Data Collection – MDR, Supplier qualification & integrationEnvironmental Regulatory Standards – EU RoHS, REACH, ELV, WEEE, JIG, China RoHS, GASDL
To manage compliance with REACH, RoHS, WEEE etc. during product development To create the product development IT framework for future compliance standardsTo measure supplier characteristics/performance for sourced components to GREEN conformance
Information Exchange Standards – IPC, IMDSCompliance Analysis & Reporting – Internal, ExternalIntegrate & Analyze External BOMs
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To support product compliance tracking at the substance, material, part and product levelsTo improve data collection, analysis and reporting from the beginning of product design to final disposal and recycling
Compliance Definition Change ManagementRoHS Component ReplacementSystem Integration – PLM, ERP, Legacy Systems
GDW Framework – Logical Architecture
Green Solutions SuitePLM
Global Databases / Repository
Compliance Regulations IMDS
Global / StandardonGreen
Reporting
Template MgtIndustry / Standard /
Resources and Energy
tiRRR
MPMERP
Global / Standard Templates / Declarations
Green Standards & Industry Standards
XML / SOA
A In
tegr
atio
BIReporting
Benchmarks
Green Templates
Green Solution Componentsconsumption
Environmental Compliance
Green Procurement
MES / Shop floor apps
SCM XM
L/S
OA
Green Foundation / SchemaExternal Databases
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Compliance Management – Process Details
Compliance Definition
Compliance Definition
Identify Regulatory
Requirements
Identify Regulatory
Requirements
Define Compliance standards
Define Compliance standards
Compliance Definition Changes
Compliance Definition Changes
Identify Products /
P t
Identify Products /
P t
Identify products and demanding
standards
Identify products and demanding
standards
Initial compliance
analysis
Initial compliance
analysis
Roll-ups / compare
with targets
Roll-ups / compare
with targets
Capture unreported
parts, update exemptions
Capture unreported
parts, update exemptionsPartsParts
Integrate S l Ch i
Integrate S l Ch i
standardsstandards analysisanalysis with targetswith targets
Notify Suppliers for unreported
Notify Suppliers for unreported
exemptionsexemptions
Follow-up and collect
i f ti f
Follow-up and collect
i f ti f
Validate the informationValidate the information
Update the compliance
i f ti i
Update the compliance
i f ti iSupply ChainSupply Chain
Impact Impact
for unreported parts
for unreported parts information from
suppliersinformation from
suppliersinformation
receivedinformation
received information in system
information in system
Impact analysis Impact analysis Customer or Customer or Remediation ( t
Remediation ( tpac
Analysispac
Analysis on the identified assemblies
on the identified assemblies
Region specific Analysis
Region specific Analysis
(component replacement / design
changes)
(component replacement / design
changes)
A l i /A l i / S b i iS b i i
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ReportingReportingAnalysis / Internal Reports
Analysis / Internal Reports
Customer Reports
Customer Reports
Submission to
Customers
Submission to
Customers
Supplier Collaboration for Compliance Management
Material Structure/ Substances MasterCompliances – RoHS, REACH, IPC, ELV, JAMA
Host Org
Standard Formats-IPC 1752
Product StructureBill Of Materials
Part Composition Requests
IPC 1752, Compliance Connect
S b it t S li
Multiple Composition Requests
Submit to Suppliers
IPC 1752, Compliance Connect
Completed Composition DataDistributed to applicable parts/products
Declaration with Multiple Compositions Returned
Suppliers
System Validates InputsApprove/Reject
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Compliance Definition Change Management (CDCM)
Business Challenge –Compliance definition standards changes are coming into force due tonew regulation or changes in existing regulation from governmentnew regulation or changes in existing regulation from governmentstatuary bodies.
Compliance Definition Change Management (CDCM) –CDCM process facilitates maintaining the complete history of theCDCM process facilitates maintaining the complete history of theCompliance Definitions in the system like:Details of the changes, Reason for change, Impact analysis, Compliance status of the affected parts and products & Traceability of the compliance data
Key AdvantagesApply changes in compliance definitionRecording the reason for the change, Change g g , gdescription, Approval & Effectivity datesImpact analysis and reporting after applying the changes Implementation of the changes (if needed)
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p g ( )Compliance HistoryCompliance Traceability
RoHS Component Replacement Processes
Business Challenge –Shorter lifecycle of Hi-Tech products need to address changes in products, new product development identification of alternate parts and changes innew product development, identification of alternate parts and changes incompliance definitions require ability to identify suitable alternate parts to meetthe environmental compliance for the final product.
RoHS Component Replacement processes –p p pEnables component replacement in an integratedPLM environment to meet compliance regulations.Process/ workflow automation for capturing compliance data, validation and approval
Key Advantages
Faster identification of suitable alternate component/component replacement for compliance
Enhanced collaboration with the suppliers to shorten the cycle time to improve productivity
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Green Procurement – Supplier Qualification for Green
Business Challenge –Developing green products requires collaborating working with vendors & suppliers todevelop greener products/components Identifying these green suppliers and ensuringdevelop greener products/components. Identifying these green suppliers and ensuringprocess compliance for green is a major challenges in developing green products
Supplier Qualification for Green –Process based on weighted scorecard of greenProcess based on weighted scorecard of greenprocess complianceWorks as additional qualification to identify green suppliersEncourage/ award vendors to adhere to green processesfor providing quality & reliable components/ parts meeting compliancesfor providing quality & reliable components/ parts meeting compliances
Key Advantages
Quick identification of competent suppliers, who can develop and supply components meeting regulatory compliances
Reduced cost of the green components
Green process compliance & traceability
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Green process compliance & traceability
Helps in third party Green certification of vendors
Green Procurement – Green RFQ Process
Business Challenge –Procuring a green part within a given timeframe and at a competitive costis a challengeis a challenge.Vendor selection based on the complex criteria involving cost, response time,green process compliance & reliability etc.
Green RFQ Process –Green RFQ Process –A RFQ process designed to capture applicable greenparameters for the suppliers Calculates weighted scorecard on relativegreen compliance parametersgreen compliance parametersAwards contract based on green capabilities, green index ofthe product, green supply-chain cost, quality reliability and
cost of the developed part..
Key AdvantagesKey Advantages
Faster procurement of green parts/components
Reducing cost of green procurement
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Encouraging suppliers- embracing green processes
REACH Analysis
• Analyze Part ,Product Structures
For all Enterprise Parts • For all the Products in all the
Product Lines,• MEPs, Supplier data• Collate Reference /absolute
Weight • Substance Concentration
Analysis
• Aggregate substance weight, concentration levels at the Product Level
• Arrive at the Total Mass of SVHC shipped with Product
,• Aggregate mass of
concentration to arrive at Annual Shipped Quantity
• If Annual Shipped Quantity > 1 Tonne, Report ExcessAnalysis
For Every SVHC at Part Level
SVHC shipped with Product Level Concentration and EU Shipment Volume
, p
EU REACH limit analysis
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REACH Content Report
Choose REACH Compliance DefinitionCompliance Definition
REACH Substance Usage Details
REACH Detailed Report16
Compliance Dashboard
Rollup Options:• All MEPs Compliant• At Least One MEP Compliant• Preferred MEP Compliant
Compliance Report for the Computer Assembly Option to Override
Compliance Scope At Assembly Level
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Compliance Roll-Up Reports
Roll Up Report of typePreferred MEP Compliance
Roll Up Report of typeAt Least One Part is
Compliant
Roll Up Report of type All MEPs are Compliant
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Global Compliance Solution Case study – Hi-Tech Giant
• Analysis of global compliance requirements for RoHS and REACH
• Supplier Central / portal integration with green procurement on MCC
• AML/ASL synchronization between PLM and ERP
• Global Compliance Implementation
• Business Analysis and solution definition of compliance practices
• Integration with ERP and other CAD systems for the green indices
• Mapping of business requirements into identified PLM solutions
• Modularized implementation for Scaling
• Business Process Analysis, Solution Architecting, Detailed Design and custom implementation on PLM
• Centralized Compliance reports
• Global roll –out
• Adhere to RoHS (EU, China, California), EU REACH, JIG A & B regulatory compliances f ll P d t hi d
• Standardized processes across the globe for compliance definition and management
Si l t f li d th l tifor all Products shipped.
• Manage compliance definition changes, improve green indices on Products and manage green audit trail for Regulatory Agencies and customers across all Product li
• Single system for compliance reduces the cycle time
• Product information including compliance enables quicker reporting
• Process standardization
• Upgraded system to minimize customization leveragelines
• Lack of robust change management process
• Product structure streamlining
• Upgraded system to minimize customization, leverage pre‐built processes and reduced maintenance cost
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GDW™ – Business Benefits
Green Portfolio
Enable Sustainability beyond just compliance
Ability to driving Sustainability as continuous improvement program
Sustainable reporting, data collection, analysis, Audit & traceability
Address sustainability during product design to:Address sustainability during product design to:Avoid after-the-fact redesigns, Avoid physical prototyping & enabling virtual analysisMeasure green index of the product during designProduct design with environmental friendly materials
Enable Design manufacturing process for greener product manufacturing
Enable measurement of supplier characteristics/performance to GREENEnable measurement of supplier characteristics/performance to GREEN conformance
EOL management facilitating Reuse, Reduce, Recycle (RRR)
Integrate the sustainable solution with other enterprise PLM and other apps
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Integrate the sustainable solution with other enterprise PLM and other apps
HCL Sustainability Solutions & Services
ng
Sustainable Product Development:Green Design Workbench (GDW™) is a framework & a setof solutions to enable sustainability, environmentalcompliance and other green processes during the productdesign, development, operation and EOL.
Green Products Development G
reen
M
anuf
actu
rin
Sustainable Operations
Solar Power system monitoring:Solar Power Data Analysis, Inference, Intervention andImprovement system is a web based monitoring and dataanalysis framework for power plants and cell/modulemanufacturers. SP DAIS provides customizabledashboards, issue management, automated alerts,statistical inference, parts obsolescence management,REC reporting and ROI analysisM REC reporting, and ROI analysis.
Emission Management:RtEMS is a solution providing real-time monitoring of Emissions and compliance reporting for manufacturing industry, focusing on ‘Direct Emissions’ or ‘Fugitive Emissions’.It interfaces with the Plant floor systems and Data Historians providing real-time environmental compliance
Green Product Design
Value Engineering
Ob l
End-of-Life reverse
manufacturing
RtEMSFrameEAD
SPC/APC implementation
Plant Automation
Emission Management
Renewable Energy
Energy Management
Historians providing real time environmental compliance data trends and rolling averages for the process manufacturing industry.
Manage Carbon is a real time Green House Gas emissionsmanagement framework complaint with GHGP protocol. Itenables to calculate the accurate emissions and variousanalytics using the emissions data and helps to measurethe effectiveness of the green initiatives taken by theObsolescence
ManagementAutomation
RtEMSGDW
GDW
the effectiveness of the green initiatives taken by theenterprise.
Energy Management :Integrated smart energy analytics dashboard (iSEAD), isan intelligent analytics solution focusing on the energyefficiency at the demand side of energy business spectrumaugmented with domain specific knowledgebase to form astrategic Decision Support System & an Intelligent Control
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strategic Decision Support System & an Intelligent ControlSystem. It supports most of the Open Standards (iLON &BACnet etc).
Thank you
For more information on our Engineering and R&D services for sustainability:
Visit us at www.hcltech.com
h h lWrite to me at [email protected]
HOW CAN I HELP YOU?
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