harman ecodesign shorter knowledge transfer partnership (sktp)

Environmental Economics

Investigation into Eco-Design practices within Harman product development to reduce environmental impact and increase profit.

sKTP EcoDesign

eoin bailey DEC 2010

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Natural: Systems Thinking

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Industrial: Systems Thinking

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Contents

• EcoDesign• Project Brief• Harman Impact Understanding• Linier Systems• Think Logically• Ecodesign Tools

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EcoDesign Introduction

Eco-Design

Is a strategic design management approach incorporating life cycle thinking of product development and services.

Ecodesign takes into account social, economic and environmental impacts in the production and consumption of products and services.

Ecodesign = good design

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• Green standardisation for global development - On the green wave

• Transparency of product impacts will become commonplace - EPD

• Opportunity for market leadership - Exploit GreenEdge Technology

• Set new standards in each division - Influence Policy

• Ecodesign promotes - Creativity, Innovation and active communication • Create commodity – Waste becomes valuable

Business Case

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• A shorter KTP (Knowledge Transfer Partnership) grant • Under the framework of the Wales Assembly Government,• Administered by UWIC• Facilitated by The EcoDesign Centre, Cardiff• A project champion• A multi-disciplinary Harman team

KTP

Project Approach

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• Initial investigation into the environmental impacts of Harman Speaker products throughout the life cycle.

• To facilitate implementation of Ecodesign principles into product development, with a view to:

Lower production costs. Improve product functionality and quality Eliminate waste to landfill Increase market share Improve environmental performance Compliance with legislation Increase potential for recycling Increase marketability of Brand profile

KTP Project Objectives

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• 4 Production Lines

• 6,000 Units Produced Per Line Per Day

• 227 Working Days Per Year

• 5,448,000 Speaker Produced Per Year

Internal Influences Harman Bridgend Impacts

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Internal Influences Customer Program

ProgramBMW Units

paHARMAN units per system

F10 THF 28,350 X16 373,600

F10 HF 72,370 X12 868,440

F11 THF 5,300 X14 72,200

F11 HF 10,600 X12 127,200

F12 THF 9,100 X12 109,200

F12 HF 3,900 X10 39,000

F13 THF 9,100 X14 127,400

F13 HF 3,900 X10 39,000

TOTAL 3,345,680

• Tweeters• Mid Range• Sub Woofer

Total

2,262,040798,400285,240

3,345,680

BMW F10 Platform

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Material Selection

• Low Carbon Steel• Mild Steel• Neodymium Iron Boron• Copper• Polyamide (Nylon)• Dried Paper Pulp• Rubber• Phenolic Resin (Formaldehyde)• Brass• Polyethylene• Polypropylene• Polycarbonate (Bisphenol)

Internal Influences Procurement

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Material Concerns

• Bisphenol A: (Monomer)• Polycarbonate (PC)• Polystyrene• PVC• Epoxy Resins• ABS

Health Concerns:• Endocrine disruptor• Foetal and neonatal development defects• Obesity• Neurological issues• Dopaminergic system defects• Thyroid function defects• Breast cancer• Prostate cancer• Reproductive systems defects• DNA methylation

Internal Influences Material Selection

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Procurement Decisions

Internal Influences Component Transport

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Component Tracking - Sub-Woofer • HARMAN Bridgend• Sea / Air Port Location• Supplier Location

Sea TravelLand travelAir Travel

Internal Influences Component Travel Plans

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• Over-Moulded components• Variety of materials• Adhesives used• Activators used• Unspecified adhesives• Over Specification• New product introduction

Internal Influences Production Process

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Fiscal year 2008 Tonnes - cost

Fiscal year 2009 Tonnes - cost

Using information from Envirowise the estimated cost of waste= Cost of Waste Management x 10

Total Waste Non Hazardous 472.5 £43,120Total Waste Hazardous 80.42 £48,150

£91,270

Total Waste Non Hazardous 315.9 £44,000Total Waste Hazardous 76.08 £47,500

£91,500

Internal Influences Waste Management

Fiscal year 2010 Tonnes - cost

Total Waste Non Hazardous 504.9 £………?Total Waste Hazardous 21.6 £………?

£………?

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• Customer Specification• Customer Design Tolerances• Government Directives: ELV, REACH.• Standards: ISO, TS• Industry Directives: IMDS compliance• International markets: Neo export

External Influences

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Current ELV Directive:• Deploy airbags.• Remove all liquids.• Remove wheels and tyres.• Crush all remaining vehicle parts.• Vehicle shredding.• Defragmentation.• 85% of the Vehicle weight Recycled

2015 ELV Directive:• 95% of the Vehicle Weight Recycled• Details not specified??

Automotive Value Chain

ELV

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Vehicle Material Content

End Of Life Vehicle Directive

ELV

Recycled Vehicle Material Content

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• Resource Depletion• Environmental and• Social degradation• Intensive energy use• VOC’s

• Energy Use• Waste• Pollution• CO2 emissons

• Energy Use• VOC’s

• Landfill• Inceneration• Ecotoxicity

• Waste• Pollution• CO2 Production

Raw Materials Production Distribution Product use End of life

Current product life

Cradle to Gate

Cradle to Grave

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Raw Materials

Use

End of Life

Distribution

Production

Full Life Cycle Systems Thinking:

Cradle to Cradle

Raw Materials

Production

Distribution

Product Use

End of Life

Life Cycle

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Raw Materials

Use

End of Life

Distribution

Production

Benefits of EcoDesign to a Product-Life-Cycle

Raw Materials

Production

Distribution

Product Use

End of Life

• Reduce Materials• Use of Technical Nutrients• Material Selection• Responsible development

• Eliminate Waste• Reduce Energy Use• Eliminate Pollution• Reduce CO2 Production• Design for Disassembly• Eliminate Hazardous Materials

• Eliminate VOC• Reduce Energy Use

• 0% Waste to Landfill• Recycle Waste• Technical Nutrients• Resource Recovery• ELV Directive

• Recycle Waste• Reduce Pollution• Reduce CO2 Production

Life Cycle

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• No over-moulded components• Material selection• Design for disassembly• Adhesive decision• Mechanical fix• Specify every item with suppliers• Review specs with customers• Communication

Suggested Paths

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Low Hanging Fruit

Supplier Specification

Waste Management Venders

Internal Communication

External Collaboration

Supplier Collaboration Customer

Specification

ELV DirectiveContinuedCommunication

EPD

LCA

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Financial• 0% Waste to Landfill = £0 Landfill Tax.• Material Recycling from Waste.• Resale of Recovered Material (Technical Nutrients).• Recovery of Rare earth Material.• Recovery of material from ELV products

Market• Green is the new black.• Be the market leader.

Brand Image• Truly sustainable brand image• GreenEdge Technology

Legislation• ELV Directive 2015• WEEE• REACH• RoHS

Standards• ISO:14001

EcoDesign Drivers

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Environmental Product Decloration – EPDISO: 14001ISO: 14006ISO: 14062

Market Movement

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EcoDesign Tools

• Communication• Collaboration• EcoDesign Workshop• Cradle to Cradle • Systems Thinking• LCA

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• Adhesive Suppliers – • Henkel.• 3M

• Plastic Suppliers –• Bayer Material Science

• Recycling Companies – • Axion.• MBA Polymers

• LCA Providers – • GaBi.• Sustainable Minds. • SAP Sustainability.• PTC Insight.• Wipro SMART• Granta design

• Waste Management Providers – • Broughshire. • Enviroquip.

• Neo Magnets Recyclers – • Birmingham Uni.

• Harman International – • Harman Professional• Harman Automotive Germany• Harman Corporate US

• Customer Collaboration• VW Sustainability• BMW DesignWorks, Sustainability

• ELV Experts – • Dr. Paul Nieuwenhuis, Cardiff Uni. • Nick Morley, Oakdene Hollins. • Jon Mayton, BIS. • Dr Shahin Rahimifard, Loughborough Uni.

• Government Departments – • WAF.• WRAP.• Carbon Trust.• Envirowise.• KTN

• Seminars, Workshops and Conferences – • EcoDesign Centre workshop, Harman• New Frontiers, Manchester • E:DN, Cardiff• BIC, Bridgend.• CARE Innovation Conference, Vienna• Ellen MacArthur Foundation 10+1, Bradford• LCA Sustainable Product Design, London

Collaboration

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5. EcoDesign Tools

Raw Materials Production Packaging &

Distribution

Use End of Life

Materials Waste ComponentsAdhesivesRubberPlasticMetalsCloths1000kg of Adhesive per yearPaperFoam1 Speaker = 3 mtr of Copper wire2.5m PC components4m Neo Magnets

SolderConsumablesCardboardUtilitiesSolventsVOC'sH2S04Waste ComponentsWaste Assemblies

CardboardPlasticFoamFuelVOC's

VOC's Electricity

LandfillMetal Recycling

Energy Shellpot / Metal wareMagnetPlatingExtractionMiningTransportPolymer Production

Injection MouldingAnodisingMagnet CleaningUtilitiesElectricityWaterTransport (forklift truck)GasAir Conditioning

Freight: sea, road, air75% Ship, 25% AirElectricity

400 - 2kwFuelOilGasElectricity

ElectricityFuelIncineration

Chemicals SolventsPhonolic ResinPolymer ProductionPlating processImpregnationReleasing Agents

AcidsAdhesive AcceleratorsOilWaterSolder (flux)SolventsNitrogenAdhesivesAnodisingHCLH2S04

TapeFuelPlastic Wrap (PP)FoamPaperAdhesive

VOC’s Chemical WasteEffluent WasteLeachingFire Retardants

Other Chemical ContaminationLeakage

EcoDesign Workshop Impact Considerations

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5. EcoDesign Tools

Materials Production Transport &

Packaging

Use End of Life

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•Virgin Materials•Source away from Use•Time•Cost•Reach•Down Cycling•Crude Oil•Transport Far East•Carbon Footprint•Communication•Inventory•Non-Recyclable Materials•Packaging•Human Social Costs•Unethical working conditions•Unfairly Traded•Excessive use of natural resources•Warehouse & storage costs•Mining of Neodymium

•Fuel Costs•Gas & Electricity Costs•Waste via Scrap•Packaging Waste•Cost•No design for disassembly•VOC’s•Production Waste•Harm to workforce•Sulphuric acid•Insurance Costs•Unethical working conditions•Non returnable Packaging•Response time

•Energy•Cost•Trade route destructive to wildlife•Location of Manufacturing to end-user•Ship lots of air•Emissions•CO2 Footprint•Packaging energy in production•Oil residue in the Sea

• CO2• Toxins• VOC’s• Health impact end-user• Warranty• Durability

• VOC’s• Government Policy• Leaching• Methane Production• Shipping waste back to China• Waste removable Costs• Landfill Tax• Impact to ecosystems• Acidification• Waste• Eutrophication• Land Value goes down• Speakers go to Landfill• Methane Production

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•Local Suppliers•Use of ELV materials•Induce good work practices at Suppliers•Packaging Technology improvements•Up Cycling•Repeat Recycling•Returnable Packaging

•Right first time•Employment•Reduced Packaging•0% Waste to Landfill•Design for Manufacture DfM•Workforce Eco Aware•Skills Base•Adhesive-less assembly•Eco-Factory

•Reusable packaging•Local suppliers•Efficient packaging•Right first time project management•Packaging Materials selection

• Green Edge Technology• Product Life Cycle• Product service systems• User Satisfaction sound quality & other factors• Warranty• Durability• Entertainment• Pleasure

•0% Waste to Landfill• Reuse of Materials• Design for Dis-assembly• ELV 2015• Government Policy

EcoDesign Workshop Impact Considerations

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1. Knowledge Transfer amongst the Team

2. Procurement Location Supply Chain

1. Material Selection2. Material Recyclability

1. Product Weight2. Product Disposal

1. Quality, Reliability, Durability

2. Quality, Reliability

1. Energy Use (Air Conditioning) Shop Floor

2. Brand Identity& Quality1. Direct Waste2. Design for Manufacture & De-materialisation

1. Materials Processing2. Product Efficiency in Use

1. Supplier Engagement2. Manufacturing Cost &

Waste

5. EcoDesign ToolsEcoDesign Target Areas: Groups 1&2

EcoDesign Workshop

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LCA

5. EcoDesign Tools

Corporate Sustainability Management

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Cradle to Cradle

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• Always look at the bigger picture• Collaborate with as many people as possible• Never be afraid to ask difficult questions• Promote Creativity• View challenges as avenues for creativity• View design as an evolution without an end date

To Finish

design