How can eco-design be efficiently and effectively be ...

How can eco-design be efficiently and effectively be integrated in a product development process? Anders S.G Andrae1, Guizhen Xu2

1.

Huawei Technologies Sweden AB, Skalholtsgatan 9, 16494 Kista, Sweden;

e-mail: [email protected] 2.

Huawei Device Co., Ltd., Bantian, Longgang District Shenzhen 518129, China

Abstract. In product development in the industry, it is important to estimate the environmental impact of each product in a logical and applicable way. However, the quantity of requirements can act as a barrier to introducing eco-design. Few methods have been presented that clearly describes how eco-design can really become a part of the traditional product development process. Several existing eco-design methods do not seem to be intended for rapid product development process where the eco-design is not the main objective. Here an approach for rapid introduction of eco-design of electronics in the product development process of any company is presented. The cost-effective method makes use of seven eco-metrics and rapid LCA giving quantified results which are easily understood by designers. The proposed method captures the essence of eco-design of electronics in a cost-effective manner with enough precision for use as designer information. The actual implementation and verification of eco-design changes are solved and moreover the proposed eco-design method does not require specific customization prior to use. The presented method is successfully demonstrated for the development of a mobile phone. Keywords. eco-design; eco-environmental requirement; electronic equipment; life cycle assessment; mobile phone; product development

2 Highlights 

An approach for rapid introduction of eco-design of electronics in the product development process of any company is presented.



A cost-effective eco-design method which does not require specific customization prior to use is outlined.



The method is successfully demonstrated for a mobile phone.

1.

Introduction

Concretely today there are a few legal requirements on some toxic substances, whereas ―sustainability‖ and carbon are characterized by very vague requirements. Nevertheless, there is a growing interest of sustainability and methods to measure it as it leads to additional efficiency. Integrating environmental aspects in the design process is getting more and more covered by the actual scientific research. Based on various fields such as "eco-design", "design for sustainability", and "eco-innovation", several specific software programs and methods have been developed to tackle this issue [1],[2]. There are many reasons for the implementation of so called eco-design principles in the industry: from corporate identity to customers’ expectations, from voluntary agreements to mandatory regulations [1]-[26]. Concerning this last issue, for a few years, the European Community has been focusing on reducing the environmental impact of the waste disposal deriving, particularly, from automotive sector and electric and electronic equipment (EEE) [6]. Ecodesign is a part of the process of developing eco-efficient products because it explores opportunities to reduce environmental impacts throughout entire product life cycles by improved product design (whether these products are goods, services or processes). Since the whole product life cycle should be considered, representatives from development, design, production, recycling, marketing, purchasing, and project management should work together on the eco-design of existing or new products as well other stakeholders in the design and development process. Life cycle assessment (LCA) is used to support ecodesign by adding up all design measures into one score. However, the data collection for an LCA used within the design process cannot take longer time than other data collection, implying that simplified/rapid LCA methods are the most feasible. No literature could be found describing an easily applicable and apparently cost-effective method for integration of eco-design in the product development process for electronics in which the logic place of LCA is clarified. These previous methods are not necessarily wrong for the purpose of integration of ecodesign in the complex product development, but are they user-friendly and cost-effective enough? The present method moves away from complicated implementations as eco-design is not the main task of most companies. Still the proposed method is more sophisticated than checklist approaches and is useful for meeting eco-environmental requirements from the market. Philips’ Green Focal Area method [7],[12] has most similarities to the present method. However, the proposed method differs in several important aspects:  The process of how to use eco-metrics and rapid LCA in the high-level product

3

    

development is logically explained for non-environmental experts such as designers It does not introduce complicated analysis tools which would burden the designers It does not have high barriers for adoption for fast paced commercial companies easy and fast to implement fully transparent cost-effective

The present method is admittedly rather defensive and let the designers do their technical/performance oriented work without ―hindrance‖ of extra eco-environmental requirements beyond mandatory laws and regulations. In fact natural technical development such as miniaturisation often automatically leads to eco-environmental improvements, depending on the product at hand, without deliberate eco-environmental considerations [20]. Moreover, the Information Communication Technology (ICT) industry could occasionally benefit from eco-environmental measures which are based on the performance (capacity) of the product (system) as the system level efficiency has increased rapidly over the years [27],[28]. The challenge at hand is that per piece some products will exhibit an increased environmental impact from generation to generation, but decreased impact per performance (capacity). Moreover, for multifunctional products it is challenging to estimate a normalised environmental impact. The normalised impact should be investigated whenever appropriate, e.g., by counting the number of functions. Anyway, the absolute impact shall always be investigated. The problem addressed: Can a cost-efficient and logic eco-design method based on easy accessible metrics be demonstrated for electronic equipment and beyond? The examples and numbers in this papers are indicative and do not represent any real product. The sole purpose is to veraciously describe how eco-design can be integrated in product development.

2. Eco-design method Continuously every company investigates which features the customers want for next generation (NG) product. The features are translated into technical requirements including eco-environmental requirements, and later the designers come up with different concepts which satisfy these requirements. The proposed steps of the eco-design method are shown below in Fig. 1.

4 Targets： Eco-environmental Requirements Targets are documented for NG Product

Targets： 7 Eco-metrics and LCA scores for CG Product and same for NG Product Concepts

NG 1. CONCEPT Product Initial specification

2. PLAN

Targets： Fine-tune 7 Ecometrics and LCA score for Prototype of NG Product

Targets： Quantify 7 EcoTargets： metrics and LCA LCA score for NG for NG Product in Product in Use use

3. DEVELOPMENT 4. VALIDATION

5.CLOSING

Revised specification

Specification baseline

Final NG Product for sale

0.Requirements including ecoenvironmental requirements are collected and set Next NG 1. CONCEPT Product

2. PLAN

3. 4. VALIDATION 5. CLOSING DEVELOPMENT

Targets： 7 Eco-metrics and LCA score for NG Product from step 4 and same for Next NG Product Concepts Field Failure Rate： The Eco-metric Field Failure Rate is measured in Step 4 and estimated in Step 3

Fig. 1 Eco-design actions in product development The targets for all eco-metrics are set in step 1 (Concept) and baselined in step 2 (Plan). All eco-metrics are obtained, improved and fine-tuned in step 3 (Development), however, actual Field Failure Rate (FFR) values are obtained in step 4 (Validation). The proposed method suggests that the role of LCA in a PDCA (Plan, Do, Check, Act) cycle is to ―Check‖ environmental impacts holistically.

Eco-Metrics The proposed method includes seven eco-metrics and LCA score. 1.

Energy efficiency Energy efficiency is a rather broad concept defined as the quotient between the energy needed to do useful work and total energy actually used. The metric refers to the use stage energy and is product specific. Examples are charger efficiency, absorbed power, charging time, and receiver sensitivity.

2.

Packaging materials mass and volume This metric refers to the mass and volume of the packaging materials such as cardboard, paper, and plastics. The target is to reduce the volume and mass.

5 3.

Hazardous substances This metric refers to mass of hazardous substances which are not regulated or banned. It can also be qualitative measure such as elimination of substance usage.

4.

Precious metals This metric refers to mass of gold, silver, platinum, palladium and other valuable metals such as rhodium, ruthenium, osmium, and iridium.

5.

Total mass This metric refers to the total mass of the designed product including the accessories. The target is to reduce the mass.

6.

Recyclability This metric is typically defined as the amount of materials which can be recycled divided by the total mass. It is judged from case to case if energy recycling is to be included and which recyclability metrics are to be applied. Example of a recyclability metric is ―Total material mass of metals, plastics and glass with 99.9wt% purity which can be obtained after Disassembly/Dismantling/Shredding‖/―Total mass before Disassembly/Dismantling/Shredding‖. In 2012 European Union summarised several metrics for recycling such as reusability rate and post-consumer recycled content index [32]. The focus shall generally be on easy disassembly, material identification, less material types and less surface finish, etc which all help increase the recyclability.

7.

Lifetime reliability This metric usually refers to Field Failure Rate (FFR). FFR is defined as the frequency at which an engineered system fails.[33]. The mean time between failure (MTBF) scores can be determined by FFR data.

Life Cycle Assessment

The aforementioned eco-metrics are consolidated by the LCA score (e.g., GWP100 score, cumulative energy demand, or ReCiPe endpoint weighted score). This score refers to an overall calculation of the manufacturing, use and end-of-life phases for the design. LCA is useful for integrating the seven eco-metrics and numerous other design choices such as introducing renewable materials and energy. Based on seven eco-metrics and cost-effective LCA methods/tools (such as the free-ware Methodology for the Eco-design of Energy-related Products (MEErP) tool [29]) designers can be certain to implement eco-design in the product development process without hindrance of the ordinary design work or without being LCA experts. Naturally other LCA tools than MEErP can be used to such as e.g. GaBi, SimaPro, and iNEMI eco-impact emulator [30]. Eco-rating based LCA could also pose an alternative [31]. Anyway, the LCA tool should permit the calculation of the LCA result within the time frame of other

6 design activities. The confidence interval of the LCA score could be wide but bearable as the score is used for comparison and summary of the eco-metrics. LCA show the most important drivers i.e. which eco-metrics are relatively more important than others. Below the method is explained for the development of an electronic device (ED). 2.0 Collection of requirements The inputs for this stage are e.g. roadmaps for and LCA performance of similar products as ED. These inputs form the basis for the collection of technical/functional/performance requirements including eco-environmental requirements. The output is the initial specification. 2.1. Design step 1, Concept: drafting of design concepts In this step the most promising concepts and optional solutions are listed and drafted based on technical/functional/performance requirements and eco-environmental requirements. The eco-environmental requirement targets can be set based on findings in the customer surveys documented in the initial specification. Moreover, for the Current Generation ED (CGED), in use by the customer, the seven ecometrics and final LCA score are obtained. For Next Generation ED (NGED) concepts all eco-metrics are defined and preliminary LCA scores are obtained. The LCA score is calculated by cost-effective LCA methods such as MEErP or other LCA tools used by the organisation. For CGED the final LCA score and the real FFR value are possible to obtain as CGED is a final product used in the market. All eco-metrics are estimated and the preliminary LCA scores are calculated for the different NGED concepts which the designers propose. The output from Concept step is the revised specification. 2.2. Design Step 2, Plan In the Plan step the design is planned. Moreover the eco-environmental requirement targets in design are documented in the report from Plan. Revised specifications are developed into a specification baseline to be fine-tuned during the subsequent Development process. The output from Plan is the specification baseline for NGED. 2.3 Design Step 3, Development In the Development step the system architecture and the detailed design for NGED are formed. The detailed NGED design is based on the specification baseline for a NGED concept. Prototypes are created and then fine-tuned repeatedly to meet the technical/functional/performance and eco-environmental requirements. Meanwhile, verification and testing will be repeatedly conducted on Prototypes and their fine-tuning models including estimations of FFR values. Brainstorming, Theory of Inventive Problem Solving (TRIZ) [22], and guidelines can help generate ideas for fine-tuning. All eco-metrics are quantified and the preliminary LCA scores are calculated for the Prototype and its fine-tuning models of NGED. The designers find ways of fine-tuning

7 the applicable eco-metrics further for the NGED Prototypes resulting in Final product NGED. The new fine-tuned values of the eco-metrics and the LCA score for the Final product NGED design are quantified and calculated, respectively, and put into the report from Development. The Final product NGED is manufactured and goes for sale. The requirements from Step 2.2 Plan are checked (Check) to validate how the eco-metrics and the LCA score were investigated for NGED. It is also checked if the requirements from Step 2.2 Plan are fulfilled. The Development step is followed by the Customer Validation. 2.4 Design Step 4, Customer Validation This step validates data from the use of NGED. Here the final values of the eco-metrics and the LCA score for the final NGED design are quantified and calculated, respectively, and put into the report from Customer Validation. Here the FFR values are based on failure samples returned by customers. As shown in Figure 1 the eco-metrics values from this design step will be used as benchmark for the next NGED. 2.5 Design Step 5, Closing process. Another LCA score is calculated based on additional data about the life cycle of NGED and the design project for NGED is closed. The LCA score from this design step is usually very close to the previous from step 4. Design steps 0 to 5 are then repeated for next NGED e.g. starting with collecting new customer requirements (from e.g. roadmaps and LCAs). 3. Application of the eco-design method

Here follows an application of the eco-design method to a mobile phone (MP) within the smartphone segment. The accuracy of the absolute numbers given in the below example are of less importance than the logic of the eco-design methodology. The numbers used are nevertheless representative for smartphones designed in 2013. 3.0 Collection of requirements Based on the features obtained from customer surveys and analyses of voluntary trends, several technical/functional/performance requirement targets, and some ecoenvironmental requirement targets, were set for NGMP:  Reduce the overall power usage compared to CGMP  Introduce a biobased material  Have a reduced life cycle based environmental impact in absolute terms compared to CGMP Note that here eco-environmental requirements refer to customer requirements beyond mandatory legislation. Examples of eco-environmental requirement targets are

8

    

Reach a certain score for various Eco-Ratings, Fulfill Energy Star standards, Fulfill Code of Conducts for energy efficiency, Fulfill various eco-labels. Remove hazardous substances beyond legislation

There are several concept examples for NGMP which can fulfill the technical/functional/performance and cost requirements. Generally the designers moderate the display, integrated circuits, light emitting diodes, circuit design, battery charging & discharging, and printed circuit board assembly layout. In summary one of the NGMP concepts fulfilling the technical/functional/performance requirements, and highly likely meet the eco-design requirement targets, compared to CGMP: 

uses biobased plastics for the charger instead of petro-based plastics.



has lower packaging materials mass.



use higher integration of silicon dies.



has higher charger efficiency.



has lower power consumption.



has higher receiver sensitivity.



has longer talk time and stand-by time.



has shorter charging time.



has lower FFR.

3.1. Design step 1, Concept: drafting of design concepts for MP In Table 1 below shows eco-metrics for CGMP and a NGMP concept in step 2.1. Table 1 Eco-metrics for CGMP and a NGMP concept in Step 2.1 Eco-metric

1. Energy efficiency (Charger efficiency)

Value for CGMP

68

Target value for a NGMP concept

70

Unit

Comment

%

Charger efficiency is improved. Several other technical submetrics are possible for energy efficiency of mobile phones such as ―No-load power consumption by the charger‖ or ―Standby power consumption by the mobile‖

9 2.Packaging materials mass and volume

3.Hazardous substances

80 and 800

g and cm3

PVC eliminated

Qualitative.

0.33

0.29

g

220

210

g

Mass of phone, charger, battery, and accessories

130 and 840

Meet requirements laws regulations

4. Precious metals (Au, Ag, Pd) 5. Total mass

The packaging material could also be changed to made of 100% secondary material in order to lower the LCA score

the of and

6. Recyclability (metals and polymers)

75

80

%

Refers to amount of materials which can be obtained as 99.9wt% pure after Shredding. It does not include energy recycling.

7.Lifetime reliability

FFR=3.5%

3.0%

%

Can only be measured for NGMP when it has been used by customer.

6.0

5.8

points

ReCiPe Endpoint (H) weighing method. For Assembly of NGED a proxy value is used.

8.LCA score

3.2 Design Step 2, Plan of MP Here the sharp eco-environmental requirement targets in design are documented for NGMP: 

fine-tune and improve three of seven eco-metrics



uses biobased material for the charger



has >10% lower packaging material mass than CGMP



has at least 3% better charger efficiency than CGMP



has better absolute LCA score than CGMP

3.3 Design Step 3, Development of MP The Development step involves fine-tuning of eco-metrics making the Prototypes and Final design of NGMP. Table 2 shows the eco-metric values and LCA score which are put in the Development report.

10 Table 2 Eco-metrics for a NGMP Prototype and NGMP Final design in Step 2.3 Eco-metric

Value for a NGMP Prototype

Value for NGMP Final design

Unit

Comment


70

70

%

Charger efficiency

2.Packaging materials mass and volume

79 795

78 and 794

g and cm3


PVC eliminated

PVC eliminated

Qualitative.

4. Precious metals (Au, Ag, Pd)

0.29

0.29

g

5. Total mass

210

209

g


80

80

%


FFR=4.7%

FFR=1.6%

%

Estimations based on similar product to NGMP

5.7

5.7

points

ReCiPe Endpoint weighing method.

8.LCA score

and

(H)

These values correspond to CGMP values of Table 1. The final verification of all requirements is made. Moreover, the eco-environmental requirements for NGMP set in 3.2 Plan are checked. 

fine-tuned and improved three of seven eco-metrics. (Yes).



uses biobased material for the charger. (Yes).



has >10% lower packaging material mass than MP. (Yes).



has at least 3% better charger efficiency than CGMP. (Yes).

Next the final NGMP is sent for final assembly, assembled and its final LCA value, including the measured impact of the assembly process, is calculated as 5.7.

11 

NGMP has better absolute LCA score than CGMP. (Yes).

Next the NGMP is sold. 3.4 Design Step 4, Customer Validation of MP Here the final values of the eco-metrics and the LCA score (Table 3) for the final NGMP design are quantified and calculated, respectively, and put into the report from Customer Validation. These values for eco-metrics and LCA can be used in the design of the next generation NGMP. Table 3 Eco-metrics for a NGMP Final design in Step 2.4 Eco-metric

Value for NGMP Final design

Unit

Comment


70

%

Charger efficiency

2.Packaging materials mass and volume

78 794


PVC eliminated

Qualitative.

4. Precious metals (Au, Ag, Pd)

0.29

g

5. Total mass

209

g


80

%


FFR=1.9%

%

Measurement

5.7

points

ReCiPe Endpoint weighing method.

8.LCA score

and

g and cm3

(H)

Here FFR values are based on measured data for NGMP based on deficient products that consumers return to the shop, or products which need to be repaired. 3.5 Design Step 5, Closing the design NGMP project

12 The LCA score from step 4 is confirmed as 5.7 based on new data describing the NGMP life cycle, and next the design project for NGMP is closed. 4.Results The proposed eco-design method works for the design of a mobile phone. The method is logic and can be used for implementing eco-environmental requirements without hindering the actual design process. 5.Discussion The most important message from this paper is that eco-design cannot be allowed to be a complicated and isolated side task of the low cost/high performance driven design process. It is important to be able to estimate the environmental impact in an easily applicable and logic manner. Eco-design therefore is rather a check of the actual design and the ―eco‖ of the design can be monitored by eco-metrics and rapid LCA. Specific eco-metrics have been and can be developed for specific product groups based on detailed LCAs. This paper does not outline all possible sub-eco-metrics for all kinds of electronics. It is argued that improved design solutions cannot explicitly be deduced from LCA results. The eco-environmental improvements are rather driven by improvements of the ecometrics and checked and ranked holistically by LCA. Many previous papers suggest that the LCA is the tool to guide the designer in the right direction. Here it is argued that the designer is guided by customer based requirements. Besides most papers fail to show how the so called process of environmental innovation is done. It is very rare that the starting point for innovation is sustainability. The starting point is predominantly the features which the buyers of the products desire. These features can include low use phase energy consumption. In reality for most design cases we can just hope that the cost driven efficiency thinking also leads to lower absolute environmental impact scores. Few improvements are actually driven by green environmental factors. Energy efficiency is a border case but is mostly driven by lower electricity bills and convenience. It will be impossible to reduce a product’s absolute environmental impact to zero with continuous eco-design improvements. It will however be possible to reduce the environmental impact per function if the next generation product has more functions than the current generation. E.g. for storage devices such as universal serial bus (USB) it is apparent that the environmental impact per functional output decreases, but for multifunctional equipment such as smartphones the corresponding decrease is less apparent. The proposed method is limited to rather small product designs where a predecessor has a clear successor and the method is not suitable for design of complex industrial systems/solutions. Moreover, the proposed method does not tell much about system wide effects of the design changes. 6. Conclusions

13 Here a low-barrier eco-design method for convenient measurement of eco-metrics has been presented. The proposed method makes eco-design of electronics and beyond a natural part of the product development process without extra costs and hindrance of ordinary design work. A company can by using the eco-design method show systematic quantifications of the environmental impact from one product generation to the next. It has to be judged from case to case if the environmental impact has been decreased per functional capacity. The proposed method captures the essence of eco-design of electronic equipment and beyond in a straight-forward and cost-effective manner with enough precision for use as designer information. The actual implementation/verification of eco-design changes is solved and moreover the proposed eco-design method does not require specific customization prior to use. The shear diversity of pressures that come to bear during the product development process can also act as a barrier to adoption of eco-design. The present immediately applicable ecodesign approach overcomes such pressures. 7. Recommendations and perspectives Eco-design/Design For Environment (DFE) is a rather vague design discipline compared to other more explicit Design for X (X=cost, test, profit, recycling, logistics, assembly etc.) disciplines. It seems like eco-design is a part of the actual design work and not the main target for most products. There is not one method, tool, and strategy that work for all companies and the best approach is determined by the targeted market [2]. The present method shows how eco-metrics and rapid LCA can work practically in a design process. It is recommended to try the method in companies who perform development of electronic hardware and beyond. Acknowledgement Huawei Technologies CO. Ltd., Huawei Device CO. Ltd.

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