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

Natural: Systems Thinking

Industrial: Systems Thinking

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

EcoDesign Introduction Eco-Design Is a strategic design management approach incorporating l ife 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

Business Case
G reen standard isation for global development - On the green wave
T ransparency of product impacts will become commonplace - EPD
O pportunity for market leader ship - E xploit GreenEdge Technology
S et new standard s in each division - Influence Policy
Ecodesign promotes - Creativity, Innovation and active communication
Create commodity – Waste becomes valuable

KTP Project Approach
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 Objectives
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

Internal Influences Harman Bridgend Impacts
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 Customer Program
Tweeters
Mid Range
Sub Woofer
Total
2,262,040 798,400 285,240 3,345,680 BMW F10 Platform Program BMW Units pa HARMAN units per system F10 THF 28,350 X 16 373,600 F10 HF 72,370 X 12 868,440 F11 THF 5,300 X 14 72,200 F11 HF 10,600 X 12 127,200 F12 THF 9,100 X 12 109,200 F12 HF 3,900 X 10 39,000 F13 THF 9,100 X 14 127,400 F13 HF 3,900 X 10 39,000 TOTAL 3,345,680

Internal Influences Procurement 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 Material Selection 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 Component Transport Procurement Decisions

Internal Influences Component Travel Plans Component Tracking - Sub-Woofer
HARMAN Bridgend
Sea / Air Port Location
Supplier Location
Sea Travel
Land travel
Air Travel

Internal Influences Production Process
Over-Moulded components
Variety of materials
Adhesives used
Activators used
Unspecified adhesives
Over Specification
New product introduction

Internal Influences Waste Management Fiscal year 200 8 Tonnes - cost Fiscal year 2009 Tonnes - cost Using information from Envirowise the estimated cost of waste = Cost of Waste Management x 1 0 Total Waste Non Hazardous 47 2 .5 £43,120 Total Waste Hazardous 80.42 £48,150 £91,270 Total Waste Non Hazardous 315 . 9 £44,000 Total Waste Hazardous 76 . 08 £47,500 £91,500 Fiscal year 2010 Tonnes - cost Total Waste Non Hazardous 504 . 9 £ ………? Total Waste Hazardous 21 . 6 £ ………? £ ………?

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

ELV
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

Vehicle Material Content End Of Life Vehicle Directive ELV Recycled Vehicle Material Content

Current product life
Resource Depletion
Environmental and
S ocial degradation
Intensive energy use
VOC ’ s
Energy Use
Waste
Pollution
CO2 emissons
Energy Use
VOC ’ s
Landfill
Inceneration
Ecotoxicity
Waste
Pollution
CO2 Production
Cradle to Gate Cradle to Grave Raw Materials Production Distribution Product use End of life

Life Cycle Full Life Cycle Systems Thinking: Cradle to Cradle Raw Materials Production Distribution Product Use End of Life Raw Materials Use End of Life Distribution Production

Life Cycle 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 Recover y
ELV Directive
Recycle Waste
Reduce Pollution
Reduce CO2 Production
Raw Materials Use End of Life Distribution Production

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

Low Hanging Fruit Supplier Specification Waste Management Venders Internal Communication External Collaboration Supplier Collaboration Customer Specification ELV Directive Continued Communication EPD LCA

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

Market Movement Environmental Product Decloration – EPD ISO: 14001 ISO: 14006 ISO: 14062

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

Collaboration
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, Vienn a
Ellen MacArthur Foundation 10+1, Bradford
LCA Sustainable Product Design, London

5. EcoDesign Tools EcoDesign Workshop Impact Considerations Raw Materials Production Packaging & Distribution Use End of Life Materials Waste Components Adhesives Rubber Plastic Metals Cloths 1000kg of Adhesive per year Paper Foam 1 Speaker = 3 mtr of Copper wire 2.5m PC components 4m Neo Magnets Solder Consumables Cardboard Utilities Solvents VOC's H2S04 Waste Components Waste Assemblies Cardboard Plastic Foam Fuel VOC's VOC's Electricity Landfill Metal Recycling Energy Shellpot / Metal ware Magnet Plating Extraction Mining Transport Polymer Production Injection Moulding Anodising Magnet Cleaning Utilities Electricity Water Transport (forklift truck) Gas Air Conditioning Freight: sea, road, air 75% Ship, 25% Air Electricity 400 - 2kw Fuel Oil Gas Electricity Electricity Fuel Incineration Chemicals Solvents Phonolic Resin Polymer Production Plating process Impregnation Releasing Agents Acids Adhesive Accelerators Oil Water Solder (flux) Solvents Nitrogen Adhesives Anodising HCL H2S04 Tape Fuel Plastic Wrap (PP) Foam Paper Adhesive VOC ’ s Chemical Waste Effluent Waste Leaching Fire Retardants Other Chemical Contamination Leakage

5. EcoDesign Tools EcoDesign Workshop Impact Considerations Materials Production Transport & Packaging Use End of Life CON
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
PRO
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
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
Reuse of Materials
Design for Dis-assembly
ELV 2015
Government Policy

Knowledge Transfer amongst the Team
Procurement Location Supply Chain
Material Selection
Material Recyclability
Product Weight
Product Disposal
Quality, Reliability, Durability
Quality, Reliability
Energy Use (Air Conditioning) Shop Floor
Brand Identity& Quality
Direct Waste
Design for Manufacture & De-materialisation
Materials Processing
Product Efficiency in Use
Supplier Engagement
Manufacturing Cost & Waste
5. EcoDesign Tools EcoDesign Target Areas: Groups 1&2 EcoDesign Workshop

LCA 5. EcoDesign Tools Corporate Sustainability Management

Cradle to Cradle

To Finish
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

design

http://www.edcw.org	75
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http://edcw.hoffi.com	32
http://edcw.org	25
http://www.ecodesigncentre.org	17
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Harman Ecodesign shorter Knowledge Transfer Partnership (sKTP)

by E:DN Ecodesign Centre on Oct 13, 2011

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Harman Ecodesign shorter Knowledge Transfer Partnership (sKTP) — Presentation Transcript