Sustainable Manufacturing: BITS Pilani

Sustainable Manufacturing
MM ZG534
BITS Pilani Lecture 10

Pilani Campus
BITS Pilani
Pilani Campus
Eco-innovation
Eco innovation
Eco-Innovation is the future development strategy

that companies adopt not only to develop new
products and processes that provide customer
and business value, but also to alter existing
ones so that they are more in harmony with the
environment
Eco-Innovation is the implementation of radical

ideas for environmentally friendly products and
processes that will meet future needs.
BITS Pilani, Pilani Campus

Eco innovation …
It involves organisational changes and any other

changes in economic activities from a product or
process design to its marketing strategy
Proactive companies use eco-innovation to exploit

further a market, while reactive ones develop
incremental improvements to comply with the
specific external demands

Eco-innovation Drivers

Eco-Innovation Procedure
1. Set outrageous goals; think outside of the box,

target the real market need to satisfy
customers.
2. Whole-like thinking; a product/service that adds
value and increases efficiency at the same
time.
3. Dematerialise; regard businesses as solution
providers rather than a product/service.
4. Make it fit; offer to customers what they really
need, no more or less.

BITS Pilani
Pilani Campus
Design for Environment

What is DFE
Ecodesign or Design for Environment, or DFE, covers any

design activity which aims at improving the
environmental performance of a product.

DFE…
DFE considers the environmental aspects in each

stage of the product development process,
striving to achieve products that have the lowest
possible environmental impact throughout their
entire life cycle
– An important DFE strategy aimed at minimising end of-life
impacts is remanufacturing; products need to be designed
to be viable for cost effective remanufacture, reuse and to
reduce the amount of waste going to landfills
• DFE studies focus on the end-of-life stage of the products. WEEE
thus requires a 75% recovery rate for cellular telephones, and
batteries, printed circuit boards and liquid crystal displays will be
required to be disassembled

DFE …
It is a combination of several design-related topics,

including disassembly, recovery, recyclability, regulatory
compliance, disposition, health and safety impact, and
hazardous material minimization.
Design for Environment is the systematic consideration of
design performance with respect to environmental,
health and safety objectives over the full product and
process life cycle
DFE covers all life cycle stages including material
extraction, manufacturing, transportation, usage and
end-of-life phases

DFE…
Design for Environment seeks to understand the life cycle

of the product and its impact on the environment at each
of its life stages and to make better decisions during
product design so that environmental attributes of the
product are kept at a desired level
Design for Environment must occur early in the design
phase to ensure that the environmental consequences of
a product’s life cycle are taken into account before any
manufacturing decisions are committed
DFE should be a component of the product definition and
creation cycle

DFE…
As a complex, multi-disciplinary, multi-functional activity, the

successful implementation of DFE calls for commitment
from upper and mid-level management as well as cross-
functional interaction (e.g., between design,
manufacturing, marketing, sales, accounting, etc.).
DFE requires the coordination of several design- and data-
based activities, such as environmental impact metrics;
data and data management; design optimization,
including cost assessments; and others.

Why DFE ?
The environmental impacts from our civilization can be

seen as a product of
– the size of the global population
– the economic activity per capita
– the eco-efficiency (the environmental impact per activity)
It follows from forecasts for the first two of these

parameters, that over the next 50 years, the third
parameter, the eco-efficiency, must increase by a
factor 10 or more to achieve sustainable
development
Role of developing countries will be strongest

10 rules of DFE by Lagerstedt
1. Do not use toxic substances, and use closed loops

when possible.
2. Minimize energy and material consumption in
production and transportation by striving for
efficiencies.
3. Minimize energy and resource consumption in the use
stage, especially for products with their most significant
environmental aspects in the use stage.
4. Promote maintenance, especially for system dependent
products .

10 rules of DFE …
5. Promote long life, especially for products with

their most significant environmental impacts
outside the use stage.
6. Use structural features and high quality
materials, to minimize weight; these should not
interfere with flexibility, impact strength or
functional properties.
7. Use better materials, surface treatments or
structural arrangements to protect products from
dirt, corrosion and wear.

10 rules of DFE …
8. Arrange in advance for upgrading, repair and

recycling, through good access, labeling, modules
and breakpoints, and provide good manuals.
9. Promote upgrading, repair and recycle by using few,
simple, recycled, unblended materials, and do not
use alloys.
10. Use the minimum joining elements possible, using
screws, adhesives, welding, snap fits, geometric
locking, etc. according to Life Cycle guidelines.

Design DfE in various stages

BITS Pilani
Pilani Campus
Design for Disassembly

Design for Disassembly (DfD)
DfD means developing products that are easy to

take apart.
This facilitates recycling, remanufacturing, reuse or
disposal
A key component of design for environment

Challenges in DfD
Product structure is optimized on the basis of functional

and assembly requirements resulting in many unwanted
disassembly steps
Joining methods are chosen for simple assembly and safe
joining
Materials are chosen from economic and performance
perspectives leading to different, often unrecyclable
materials with high disassembly and sorting costs
Difficult to get all the information for disassembly as the
products might get modified during repair
Wear and corrosion makes the joined parts difficult to
remove

Types of Disassembly
Non-destructive disassembly
Partially destructive disassembly
Completely destructive disassembly

Design Rules for DfD
Less disassembly work

Predictable product configuration
Easy disassembly
Easy separation
Easy handling
Variability reduction

Less disassembly work criteria
Combine elements
Limit material variability
Use compatible materials
Group harmful elements into sub assembly
Provide easy access for harmful, valuable and
reusable parts

Predictable product configuration
criteria
Avoid aging and corrosive material

combination
Protect subassemblies against corrosion

Easy disassembly criteria
Accessible drainage points

Use fasteners that are easy to remove or destroy
Minimize number of fasteners
Multiple fastening
Avoid complex movements in disassembly
Avoid metal inserts in plastic parts

Easy separation criteria
Avoid secondary finishing operations

Identify different materials by providing in
mould coding or bar coding or colour
coding or shredding suitability
Avoid parts made of materials that are likely
to damage shredder

Easy handling criteria
Provide surfaces for grasping

Avoid non-rigid parts
Enclose toxic substances in sealed units

Variability reduction criteria
Use standard subassemblies and parts

Minimize number of fastener types


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Sustainable Manufacturing

BITS Pilani Lecture 10

Eco-Innovation is the future development strategy

Eco-Innovation is the implementation of radical

BITS Pilani, Pilani Campus

It involves organisational changes and any other

Proactive companies use eco-innovation to exploit

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

1. Set outrageous goals; think outside of the box,

BITS Pilani, Pilani Campus

Design for Environment

Ecodesign or Design for Environment, or DFE, covers any

BITS Pilani, Pilani Campus

DFE considers the environmental aspects in each

BITS Pilani, Pilani Campus

It is a combination of several design-related topics,

BITS Pilani, Pilani Campus

Design for Environment seeks to understand the life cycle

BITS Pilani, Pilani Campus

As a complex, multi-disciplinary, multi-functional activity, the

BITS Pilani, Pilani Campus

The environmental impacts from our civilization can be

It follows from forecasts for the first two of these

BITS Pilani, Pilani Campus

1. Do not use toxic substances, and use closed loops

BITS Pilani, Pilani Campus

5. Promote long life, especially for products with

BITS Pilani, Pilani Campus

8. Arrange in advance for upgrading, repair and

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Design for Disassembly

DfD means developing products that are easy to

BITS Pilani, Pilani Campus

Product structure is optimized on the basis of functional

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Less disassembly work

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Avoid aging and corrosive material

BITS Pilani, Pilani Campus

Accessible drainage points

BITS Pilani, Pilani Campus

Avoid secondary finishing operations

BITS Pilani, Pilani Campus

Provide surfaces for grasping

BITS Pilani, Pilani Campus

Use standard subassemblies and parts

BITS Pilani, Pilani Campus

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