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METHODOLOGY TO SUPPORT ENVIRONMENTALLT AWARE PRODUCT DESIGN USING AXIOMATIC DESIGN: eAD+

IDETC/CIE 2010 DETC2010/VIB-29171 . METHODOLOGY TO SUPPORT ENVIRONMENTALLT AWARE PRODUCT DESIGN USING AXIOMATIC DESIGN: eAD+. KAIST, Industrial and Systems Engineering Mijeong Shin, James Morrison and Hyo Won Suh. CONTENTS. Background Necessity and Trend of Eco-Design

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METHODOLOGY TO SUPPORT ENVIRONMENTALLT AWARE PRODUCT DESIGN USING AXIOMATIC DESIGN: eAD+

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  1. IDETC/CIE 2010 • DETC2010/VIB-29171 METHODOLOGY TO SUPPORT ENVIRONMENTALLT AWARE PRODUCT DESIGN USING AXIOMATIC DESIGN: eAD+ KAIST, Industrial and Systems Engineering Mijeong Shin, James Morrison and Hyo Won Suh

  2. CONTENTS • Background • Necessity and Trend of Eco-Design • Previous Approaches • Proposed Approach (eAD+) • Methodology Flow diagram • Comparisons to Other Methodologies • Methodologies • Axiomatic Design Based Methodology • Structured Eco-FR & Eco-DP • Feedback Mechanism from Environmental Analysis • Augmented Design Matrix • Example (Case Studies : Mobile phone, Stapler, Flash light) • Concluding remarks

  3. Necessity and trend of eco-design [1] [1] Jovane, F., Yoshikawa, H., Alting, L., Boer, C. R., Westkamper, E., Williams, D., Tseng, M., Seliger, G. and Paci, A. M., 2008, “The Incoming Global Technological and Industrial Revolution towards Competitive Sustainable Manufacturing”, CIRP Annals, pp. 641-659 World’s development paradigms are rapidly changing Sustainability becomes main driver of new paradigm

  4. Necessity and trend of eco-design Consumer sophistication regarding environmental issues has increased International regulations for environmental emissions have become more strict Need for product designs that satisfy international regulations and meet consumer’s environmental expectations

  5. Previous approaches ( Reactive redesign ) For proactive eco-design, eco-factors should be considered early in the design process

  6. Previous approaches ( Reactive redesign ) Proactive eco-design - Eco Needs Formal Method - LCT/LCA

  7. Proposed Approach: eAD+ • eAD+ methodology follows the essentials of Axiomatic Design • To manage couplings between eco-factors and product design parameters : Axiomatic design theory -> Supporting domain of design -> Encouraging innovative alternatives -> Insensitive to iterative design changes • However, it has some different points: • Pre-made and structured eco-FRs and eco-DPs : Eco-FRs and Eco-DPs libraries • Using feedback mechanism, design can be affected by eco-analysis result directly : LCT/LCA to Re-design • Environmental effects of each DP are quantitatively estimated : Augmented Design Matrix

  8. Comparisons to other methodologies [1] [1] Integration of Sustainability Into Early Design Through the Function Impact Matrix, Devanathan S, Ramanujan D, Bernstein WZ, Zhao F, Ramani K, 2010, Journal of Mechanical Design

  9. eAD+ methodology flow Eco-Factors & Axiomatic Design LCA LCA LCT/LCA AD+ (Aug DM)

  10. Axiomatic design theory • -> Supporting domain of design • -> Encouraging innovative alternatives • -> Insensitive to iterative design changes • “Axiomatic Design (AD) theory is a systems design methodology using matrix methods to systematically analyze the transformation of CN into FR, DP and PV”[1] • Customer Needs (CN): Voice of the customer (all stakeholders including eco-stakeholder) • Functional Requirement (FR): Functions that a design must provide - goals • Design Parameter (DP): Solution for each FRs (e.g. concept, component, process…) - methods • Constraints & Selection Criteria • Axiom 1: Maintain independence of the FRs • There is only one DP for each FR [1] Axiomatic Design, N. P. Suh, 2002

  11. Eco-FR and Eco-DP list • Eco-customer needs were collected from literature survey • Y. Zhang, H. –P. Wang, C. Zhang, “Green QFD-II-: a life cycle approach for environmentally conscious manufacturing by integrating LCA and LCC into QFD matrices”, International Journal of Production Research, 1999, vol. 37, No. 5, 1075-1091 • K. Masui, T. Sakao, A. Inaba, “Quality function deployment for environment QFDE”, IEEE, 2001, 852-857 • T. Hur, J. Lee, J. Ryu, E. Kwon, “Simplified LCA and matrix methods identifying the environmental aspects of a product system”, Journal of Environmental Management, 2005, 229-237 • P. Park, K. Lee, “Development of an ecodesign method for electronics products and application to mobile phone”, Journal of Korean Institute of Industrial Engineering, 2004, Vol. 26 • 17 companies’ web pages and environmental reports

  12. Eco-FR and Eco-DP list • 2004 OECD key environmental indicators • Climate change: CO2 and greenhouse has emission intensities • Ozone layer: Ozone depleting substances • Air quality: SOx and NOx emission intensities • Waste generation: municipal waste generation intensities • Freshwater quality: waste water treatment connection rates • Freshwater resources: intensity of use of water resources • Forest resources: intensity of use of forest resources • Fish resources: intensity of use of fish resources • Energy resources: Intensity of energy use • Biodiversity: Threatened species

  13. Eco-FR and Eco-DP list Environmental benchmarking parameters Ecodesign strategies for electronic products • Source: P. Park, K. Lee, “Development of an ecodesign method for electronics products and application to mobile phone”, Journal of Korean Institute of Industrial Engineering, 2004, Vol. 26

  14. Eco-FR and Eco-DP list ~100 eco-CNs for the eco-stakeholders • CNs are simply things the stakeholder-thinks they want • NOTE: There is generally little/no structure to CNs - They can include goals, methods, constraints, feelings, contradictions - unstructured • Preserve material • Design for disassembly • Reduce weight • Save Energy • Improve logistics • Battery-free product • Reduce amount of liquid residues • Eliminate cleaning process • Reduce emission • …

  15. Eco-FR and Eco-DP list - Less amount of liquid residues - Less emission Eco-CNs may be categorized in 3 classes FRs are goals DPs are methods What goals can we find to satisfy the eco-stakeholder?

  16. Eco-FR and Eco-DP list

  17. Eco-FR and Eco-DP list Life Cycle * * * * * * * * * * FRs which are directly related with LCA index

  18. Eco-FR and Eco-DP list FRs Possible DPs - - Eco-FR and eco-DP are intended to serve as a reference for the designer They can be readily incorporated into the design process

  19. Feedback mechanism from eco-analysis Direct feedback mechanism from eco-analysis result to the design process Using relationships between LCT/LCA index and Eco-FR, LCT/LCA result can be linked with augmented design matrix

  20. Feedback mechanism from eco-analysis LCT/LCA Values DPs FRs

  21. Augmented design matrix Augmented DM • Using weighted DP, critical coupling can be defined • Effective and efficientdesign process is possible • * Augmented Design Matrix is inspired by House of Quality in Quality Function Deployment (QFD) methodology A design might have several couplings Each coupling has different effects on customer/eco satisfaction In practice, eliminating all couplings might be very difficult due to technology, time or resource limitation

  22. Augmented design matrix Critical coupling is identified! Environmental analysis results are mapped to FR and FR weight are mapped to DP Finally, critical DP which has the worse effect on the environment will be identified

  23. Augmented design matrix

  24. Augmented design matrix (ADM) Normally, whether there is a coupling or not is indicated on the design matrix (not the magnitude of coupling) In ADM, specific numbers are used to express magnitude of couplings Using those numbers, result of environmental analysis can be mapped to FR and each DP’s environmental effects are quantitatively calculated Designer can easily see which part has the worst effect on the environment

  25. Case Study 1 – mobile phone Samsung Electronics SPH-C2300 Objective: design eco-friendly mobile phone Start with existing mobile phone design, modify the design specifications using eAD+ methodology Using this activity, we can verify the effectiveness of eAD+ methodology for designing eco-friendly product

  26. eAD+ methodology flow LCA LCA

  27. LCA (Life Cycle Assessemt) 4. Interpret result 3. Evaluate effect 2. Analyze inventory Methane SO2 GW AD 1. Set objective and range LCA(Life Cycle Assessment)

  28. LCI DB (PASS, Korean Government)

  29. Upstream process From raw material acquisition to part manufacturing

  30. Upstream process From raw material acquisition to part manufacturing

  31. Upstream LCA Result

  32. Downstream process

  33. Characterization

  34. Normalization • Reference • Year : 1995 • Global population : 5,675,675,676 • Regional population (East china region) : 45,093,000

  35. Total LCA Result

  36. Redesigned LCA Result • Reference • Year : 1995 • Global population : 5,675,675,676 • Regional population (East china region) : 45,093,000

  37. Redesigned LCA Result Initial Design Redesign

  38. Example – mobile phone LCD PCB 1 PCB 2 FRT panel Bolts & Plastics Battery PCB 2 plate Inner Panel Key Pad Number Pad Slide UPR Panel Back Panel Slide LWR Slide UPR

  39. Example – mobile phone Samsung Electronics SPH-C2300

  40. Example – mobile phone Samsung Electronics SPH-C2300

  41. Example – mobile phone Eco-FR

  42. Example – mobile phone Eco-FR

  43. Example – mobile phone • GW value is mapped to FR 4.1 • ARD value is mapped to FR 5.1

  44. Example – mobile phone • In the detailed design, augmented design matrix looks exactly same as LCA • However, in the conceptual design, we cannot get LCA value because of lack of detailed design specifications • In the conceptual level, we can get DP’s environmental effect by assuming coupling magnitude

  45. Example – mobile phone • Calculate each DP’s environmental effect score • E.g. DP32 = (FR41) X 2 + (FR51) X 1 = (3.27E-04) X 2 + (5.04E-04) X 1 = 1.16E-03

  46. Example – mobile phone • Housing • Slide structure → Bar type structure • Some parts are used only to maintain slide structure, so these parts can be removed by changing to bar type structure • Reduce amount of material Slide LWR Slide UPR Slide UPR Panel

  47. Example – mobile phone • Battery • Li-ion battery → Hybrid energy system (solar cell + Li-ion battery) • Solar energy is infinite energy source • Reduce energy-providing material consumption • Display system • LCD display → LED display • LED display consumes less energy that LCD display • Reduce energy-providing material consumption

  48. Example – mobile phone Couplings were Eliminated Average of couplingsignificantly reduced (2.73→1.64)

  49. Case Study 2 – stapler Objective: design eco-friendly stapler Conducting design process by another person, we can find out what is missing in the eAD+ methodology Using this activity, we could make modified and detailed eAD+ methodology flow

  50. eAD+ methodology flow LCA LCA

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