redesigning the office chair – part 2cushman/courses/engs171/officechair.pdf · label plastics...
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Redesigning the Office Redesigning the Office Chair Chair –– Part 2Part 2
ENGS 171ENGS 171
May 27, 2004May 27, 2004
by Brian by Brian HenthornHenthorn
and Charles Pahland Charles Pahl
PREVIOUS ENVIRONMENTAL PREVIOUS ENVIRONMENTAL ASSESSMENTASSESSMENT
�Average Office Chair weight: 20.53kg*
�Our chair Royal Blue Global Armless Task Chair, carried by Staples Inc, and of which there are over 20 at the Thayer School: 11.4kg
�2.2kg of packaging on average
*US Environmental Protection Agency, Solid Waste and Emergency Response, Municipal Waste Reduction Branch, Waste Wise Update: The Measure of Success Calculating Weight Reduction (Washington, DC: 1999) 11. <http://www.epa.gov/wastewise/pubs/wwupda11.pdf>.
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PREVIOUS ENVIRONMENTAL PREVIOUS ENVIRONMENTAL ASSESSMENTASSESSMENT
333,987.001,004,778.0411.40Total
9,632.009,632.00--60,200.000.16Hydraulic Oil
8,587.4915,083.9442,300.0074,300.000.20Fabrics (Olefin, PP)
160,682.74259,758.4344,600.0072,100.003.60Plastics (polyurethane)
6,573.8221,912.7415,900.0053,000.000.41Zinc
73,205.34532,146.4926,000.00189,000.002.82Aluminum
75,225.61166,244.4418,100.0040,000.004.16Steel
Chair Energy (Recycled) (kJ)
Chair Energy (Virgin) (kJ)
Energy Required -Recycled (kJ/kg)
Energy Required -Virgin (kJ/kg)
Our Office Chair (kg)Material
Replace table with newer one
PREVIOUS ENVIRONMENTAL PREVIOUS ENVIRONMENTAL ASSESSMENTASSESSMENT
12,254,387.0536,875,354418.38Total
353,494.40353,494.40--60,200.005.87Hydraulic Oil
315,160.96553,580.6042,300.0074,300.007.45Fabrics (Olefin, PP)
5,897,056.719,533,134.2844,600.0072,100.00132.22Plastics (polyurethane)
241,259.22804,197.4015,900.0053,000.0015.17Zinc
2,686,635.9019,529,776.326,000.00189,000.00103.33Aluminum
2,760,779.856,101,170.9418,100.0040,000.00152.53Steel
Total Energy (Recycled) (kJ)
Total Energy (Virgin) (kJ)
Energy Required -Recycled (kJ/kg)
Energy Required -Virgin (kJ/kg)
Annual Quantities (million kg)Material
Replace table with newer one
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Energy HierarchyEnergy Hierarchy
Making Materials
Transport Assembly Disassembly
EnergyEnergy
�� Annual Values range between 12.3Annual Values range between 12.3--
36.9 GJ36.9 GJ
�� Total Energy to produce one chair Total Energy to produce one chair
ranges: ~334ranges: ~334--1005 MJ1005 MJ
(recycled or not)(recycled or not)
��Calculated assembly: 14,500kJCalculated assembly: 14,500kJ
–– Agreeing with hierarchy of energyAgreeing with hierarchy of energy
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TRANSPORTATION COSTSTRANSPORTATION COSTS
�� Plays a significant Plays a significant
part to part to
environmental environmental
impactsimpacts
TRANSPORTATION COSTSTRANSPORTATION COSTS
Shipment Characteristics by Mode of Transportation, US (percent of total tonnage)
Truck
Rail
Water
Air
Pipeline
69.1%
By the American Trucking Institute
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Truck 7622257 65.9
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TRANSPORTATION COSTSTRANSPORTATION COSTS
�� 7.6 Billion Tons = 6,895Tg7.6 Billion Tons = 6,895Tg
�� Lower Bound:Lower Bound:
13.68kg/chair * 36.7Mchairs = 502Gg13.68kg/chair * 36.7Mchairs = 502Gg
��Upper Bound:Upper Bound:
22.75kg/chair * 36.7Mchairs = 835Gg22.75kg/chair * 36.7Mchairs = 835Gg
��US Truck Shipment: 0.0073US Truck Shipment: 0.0073--0.012% 0.012%
Transportation PollutionTransportation Pollution
0.04780.40930.47670.00150.002135.350
Office chairs (upper bound, Gg)
0.02880.24610.28660.00090.001221.252
Office chairs (lower bound, Gg)
0.05730.49020.57080.00170.002542.335
g emission per kg shipped
3953,3803,9361217291,900Total (Gg)
NMVOCCONOxN2OCH4CO2
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Transportation PollutionTransportation Pollution
�� Difficult to compare Difficult to compare
energy to emissionsenergy to emissions
�� Study of Power plant Study of Power plant
guidelines set NOx guidelines set NOx
emissions at 86emissions at 86--
260ng/J260ng/J
�� Pie chart compares Pie chart compares
using this using this
conversion between conversion between
energy & pollutantenergy & pollutant
Percentage of Estimated Total NOx emissions (Gg)(Using the Upper Bounds)
Production
Assembly
Transportation
REDESIGN PROCESSREDESIGN PROCESS�� DeepDeep
�� Moderate/DeepModerate/Deep
Product change Benches/couches
Product change No need for height adjustments -several chairs w/ different heights
Transport reduction Localized production/sale
Product change Integrating chair into desk - no separate chair unit
TYPETYPEALTERNATIVESALTERNATIVES
Product change Air hockey table floor - no need for wheels
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REDESIGN PROCESSREDESIGN PROCESS�� ModerateModerate
Dematerialization Replace foam with air
Design for disassembly/extend product lifetime
Detachable fabric - wears out quickest
Transport reduction Fleets use alternative fuels
Design for disassembly Alternative height adjustment (pin/notch, springs, screw)
Dematerialization Redesign wheel-system
Design for reuse Service-lease chairs or components
REDESIGN PROCESSREDESIGN PROCESS�� Shallow/ModerateShallow/Moderate
�� ShallowShallow
Dematerialization Honey comb plastic
Design for Recycling Plastics identification
Design for Disassembly Plastic clips instead of staples and screws
Design for RecyclingEnvironmental friendly fabric
Design for Disassembly Replaceable wheels
Using a uniform plastic/nylon for entire chair
Design for Recycling
DematerializationMolded butt and back together
Design for recyclingLabeling each type of material
DematerializationReducing materials (cardboard) by stamping info on plastic
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REDESIGN PROCESSREDESIGN PROCESS
�� Deep Solutions are infeasible & Deep Solutions are infeasible &
need societal changeneed societal change
�� Lease possible with companiesLease possible with companies
�� Redesign wheelsRedesign wheels
�� AlternativelyAlternatively--fueled fleetsfueled fleets
Selected AlternativesSelected Alternatives
Dematerializationshallow/moderateMolded butt and back together
DematerializationmoderateReplace foam with air
Design for disassembly/extend product lifetimemoderate
Detachable fabric - wears out quickest
Design for recyclingshallow/moderateLabeling each type of material
Design for recyclingshallowPlastics identification
Design for disassemblymoderateAlternative height adjustment -nylon screw
Design for disassemblyshallowNylon screws for fasteners instead of steel screws
Dematerializationshallow/moderateReducing materials (cardboard) by stamping info on plastic
Design for recyclingshallowUsing a uniform plastic/nylon for entire chair
TYPESCOPEALTERNATIVES
Maybe insert highlight above for what investigated
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ImplementationImplementation
�� Eliminating Cardboard PanelingEliminating Cardboard Paneling
–– Though already use 100% recycled, can Though already use 100% recycled, can
stamp information into plastic insteadstamp information into plastic instead
Height Adjustment RedesignHeight Adjustment Redesign
�� Seat HeightSeat Height
–– PinPin--Notch Notch
SystemSystem
��Requires difficult Requires difficult
removal of loadremoval of load--
bearing pinbearing pin
–– SpringsSprings
��Height controlled Height controlled
by user weight by user weight
–– ScrewScrew
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Seat Height Seat Height ImplementationImplementation
�� ScrewScrew
––Have the support rod be a Have the support rod be a
large screw that winds into the large screw that winds into the
base for height adjustmentbase for height adjustment
Air CushioningAir Cushioning��Uses air as a Uses air as a
substitute for foamsubstitute for foam
�� Encasing plastic is Encasing plastic is
PolyPoly--Vinyl Chloride Vinyl Chloride
(PVC)(PVC)
--Create different pockets Create different pockets
for ergonomicsfor ergonomics
Plastic Frame
Air Cushion
Fabric Cover
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Molded Seat and BackMolded Seat and Back
�� Eliminates need for steel connecting Eliminates need for steel connecting
barbar
Alternative FastenersAlternative Fasteners
�� Replace metal screws inlaid into plastic frame Replace metal screws inlaid into plastic frame with nylon screws into nylon framewith nylon screws into nylon frame–– Allows for easier recyclability and disassemblyAllows for easier recyclability and disassembly
�� Replace staples connecting fabric and plastic Replace staples connecting fabric and plastic frame with elastic band on edge of fabricframe with elastic band on edge of fabric–– Allows for easy detachment of fabric backing for Allows for easy detachment of fabric backing for recycling/disposal/replacementrecycling/disposal/replacement
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Design for RecyclingDesign for Recycling
�� Use uniform plastics throughout chair Use uniform plastics throughout chair (Nylon or alternative)(Nylon or alternative)
�� Label plastics with corresponding number Label plastics with corresponding number to aid recyclingto aid recycling
�� Label composition of all materialsLabel composition of all materials–– may have proprietary issuesmay have proprietary issues
Recalculated Material CompositionRecalculated Material Composition
5.5011.40Total
0.250.25Other
5.243603.001.003.60Plastics (polyurethane)
0.0059.007.000.41Zinc
0.001042.962.702.82Aluminum
0.00539.508.004.32Steel
Redesigned Office Chair
(kg)Volume (cc)Densities
(g/cc)
Original Office Chair
(kg)Material
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Recalculated Production EnergyRecalculated Production Energy(per chair)(per chair)
359,143.5581,7938.11Total (upper bound)
242,291.5392,8885.49Total (lower bound)
8,587.515,08442,30074,3000.203Fabrics (Olefin, PP)
350,556566,70944,60072,1007.86
Plastics upper bound (polyurethane)
233,704377,80444,60072,1005.24
Plastics lower bound (polyurethane)
Chair Energy (Recycled) (kJ)
Chair Energy (Virgin) (kJ)
Energy Required -
Recycled (kJ/kg)
Energy Required -
Virgin (kJ/kg)
Redesigned Office
Chair (kg)Material
Recalculated Production EnergyRecalculated Production Energy(Annually)(Annually)
13,180,566.1621,351,690.8295.913Total (upper bound)
8,892,097.76314,418,987.4199.759Total (lower bound)
315,160.9627553,580.60442,30074,3007.451Fabrics (Olefin, PP)
12,865,405.220,798,110.244,60072,100288.462
Plastics upper bound (polyurethane)
8,576,936.813,865,406.844,60072,100192.308
Plastics lower bound (polyurethane)
Total Energy (Recycled)
(GJ)
Total Energy (Virgin)
(GJ)
Energy Required -Recycled (kJ/kg)
Energy Required -
Virgin (kJ/kg)
Annual Quantities
(million kg)Material
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Energy ConsumptionEnergy Consumption(Before and After Redesign)(Before and After Redesign)
Energy Consumption per Chair
0
0.2
0.4
0.6
0.8
1
1.2
Per Chair(low er bound)
Per Chair(upper bound)
En
erg
y (G
J)
Energy (original)
Energy (redesign)
Energy Consumption Annually
0
5
10
15
20
25
30
35
40
Annual (low erbound)
Annual (upperbound)
En
erg
y (m
illio
n G
J)
Energy (or iginal)
Energy (redesign)
Transportation Emissions Transportation Emissions ReductionsReductions
0.15590.18150.00060.000813.4625
Office chairs (upper bound, Gg)
0.13970.16270.00050.000712.0655
Office chairs (lower bound, Gg)
0.24610.28660.00090.001221.2522
Office chairs (pre-redesign, Gg)
0.49020.57080.00170.002542.3350g emission per kg shipped
3,3803,9361217291,900Total (Gg)
CONOxN2OCH4CO2
Overall, a 57-63% reduction in all emissions from original design!
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CONCLUSIONSCONCLUSIONS
�� Production energy savings = between 3.1 Production energy savings = between 3.1 and 15.4 million GJand 15.4 million GJ–– Equivalent to:Equivalent to:
�� a 5.9a 5.9--6.1 magnitude earthquake6.1 magnitude earthquake
�� 775,000 to 3.85M tons of TNT775,000 to 3.85M tons of TNT
�� power 310,000power 310,000--1.54M homes per year 1.54M homes per year
�� Transportation emission savings = Transportation emission savings = between 8 and 9 thousand metric tons of between 8 and 9 thousand metric tons of COCO22 annuallyannually–– However, annual US COHowever, annual US CO22 = 1,547 million = 1,547 million metric tonsmetric tons
CONCLUSIONSCONCLUSIONS
�� Significant opportunity for energy Significant opportunity for energy
and emissions reductions in office and emissions reductions in office
chair industrychair industry
�� Similar reductions could be achieved Similar reductions could be achieved
in other commonly used, mass in other commonly used, mass
produced productsproduced products
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Questions?Questions?
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