Design for the Environment Felicia Kaminsky ESM 595F 2 November 2000

2 Outline u History and Definitions u EPA Cooperative Industry Projects  Printing  Garment Care u Corporate Environmental Policy  Xerox  Lucent u Conclusions & Discussion

3 Defining “DfE” u Concept pioneered by industry u US EPA Program  Office of Pollution Prevention and Toxics u Over the past decade – created from several voluntary initiatives  Safer chemicals  Comparative risk analysis  Alternative technology u Voluntary, partnership program that works directly with industries and other partners to integrate health and environmental considerations in business decisions DfE

4 Goals u New approaches to risk reduction through pollution prevention  Balancing business needs and environmental concerns  Encourages front-end innovations through the redesign of formulations and manufacturing and disposal processes DFE

5 Design for the Environment Integrated Product Development Pollution Prevention Environmental Stewardship Total Quality Management Sustainable Development DFE Enterprise Integration

6 Scope of DfE u Occupational health and safety u Consumer health and safety u Ecological integrity and resource protection u Pollution prevention and toxic use reduction u Transportability (safety and energy use) u Waste reduction and minimization u Disassembly and disposability u Recycle-able and remanufacture-able DFE

7 Cooperative Industry Projects u Premise: companies do not want to pollute, but often lack information u Information needed  Environmental impacts and consequences u Trade one product or process for another u Aim to provide current information needed to practice DfE

EPA DfE Cooperative Industry Projects

9 u Entire industry sector  Industry leaders  Trade associations u Printing u Printed Wiring Board u Computer Display u Garment and Textile Care EPA DfE Partnerships u Industrial/Institutional Cleaning Formulations u Auto Refinishing u Adhesives in Foam Furniture and Sleep Products u Supplier Initiative DfE

10 Printing Projects u 1992 Printing Industries of America approached DfE u Screen printing  Evaluated 18 screen reclamation technologies u Lithography  Assessed 40 blanket wash formulations u Flexography  Comparing solvent, water, and ultraviolet ink technologies printing

11 Flexography Project u Printing from a raised image on a printing plate made from rubber or photopolymers u Printing on paper, corrugated paperboard, or plastic consumer packages and labels u Inks – highly fluid and quick drying  Contain solvents or water  Selection = performance requirements

12 Flexography Project, continued u Traditionally solvents from VOCs  Regulated air pollutants u Alternatives to conventional ink formulations  Waterborne  UV-cured  Hazardous materials  Disposal u DfE seeks to provide info:  Technical and environmental advantages and disadvantages  Implementation Studies – research and applied  Outreach

13 Garment and Textile Care Program u Following a 1992 roundtable on drycleaning, industry leaders paired with DfE u Technical studies  Cleaner Technologies Substitutes Assessment (CTSA) u Implementation  Demonstration shops; Training u Outreach

DfE as Corporate Environmental Policy

15 DfE Guidelines u Design for:  recovery and reuse  disassembly  waste minimization  energy conservation  material conservation  chronic risk reduction  accident prevention

16 Interrelationships

17 Driving Forces Design for Environment Sustainable Development Risk Management Product Stewardship Regulatory Constraints Customer Satisfaction International Standards Competitive Pressures Enterprise Integration

18 DfE at Xerox u Waste-free products and factories  Minimize waste to landfill and releases to the environment at every step of a product life cycle u 1993 – began training design engineers in DFE principles  Objective to incorporate into new and existing products u Copy cartridges  new copiers, printers, and multifunction products Xerox

19 Implementation u Develop and environmental plan for each product  Environmental impacts  Product life cycle costs u Limit production materials  Recyclable  Recycled thermoplastics and metals u Recycling symbols Xerox

20 Design for Reuse u 1995 – Mark engineering drawings with remanufacturing codes u Snap-together designs  Facilitate assembly and disassembly processes u Copy cartridges u Asset Recovery Center  One million parts in 1993 Xerox

21 Goals (1998); Results (1994) u Decrease waste 90% u Air emissions -90% u Water discharges -90% u Post-consumer +25% u Energy efficiency +10% u Recycled >75% u Air emissions -75% u  Use of recycled materials Xerox

22 DfE at Lucent u Part of Corporate Environmental Strategy  “Committed to ‘design for the environment’” u Established cross-functional DfE team u Product Lifecycle Team u Integrated into product realization process  Aims to develop and apply DfE criteria for all operating units by 2000 Lucent

23 Lucent Program Highlights u Equipment reuse and refurbishment u Repair and refurbishment of business telephones u Battery-return program u Packaging u Material Reclamation Center

24 Conclusions & Discussion u Public awareness – is this necessary? u Fully integrated to environmental management practices? u What about small companies?

25 Additional Information u EPA DfE Homepage u Design for Environment: Creating Eco-Efficient Products and Processes, Joseph Fiksel, editor