Transcript Design for Recycling - managementsupport.com

Design for Recycling
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A Product’s Life Cycle – From Cradle to Re-Incarnation
Manufacture
Material
processing
Mining
Environment:
air, sea, land
4
Disposal
Product
manuf acture
3
2
De m anufacture
Material demanuf acture
Product
demanuf acture
Clean f uel
Energy
recovery w ith production
via pyrolysis
incineration
Distribution
1
Use
Product
take-back
1 = Di rect reuse
2 = Remanufacture of reusab l e components
3 = Reprocessing of recycl ed materi
al
4 = Monomer / raw materi al regeneration
The term “demanufacture” is appearing more and more, especially in the electronics industry (DEC,
Motorola, AT&T, IBM), to characterize the process opposite to manufacturing involved in recycling
materials and products.
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Growing Importance of DFR



Dwindling resources

Landfill space, especially in (over) crowded Europe

Raw material (lesser short term importance)
For example:

Currently, around 80-90% of electronics are being sent to landfills!

The National Renewable Energy Laboratory estimates that 30 billion lbs. (14
billion kg) of plastics end up being landfilled each year, and only 1% of plastic
waste is recycled.
Social and political climate is changing

Big social and political push in Europe

Some states, US Congress and vice-president Gore may want to follow Europe
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European Take Back Legislation



European
“Take-Back
Law”
requires
automobile
(and
other)
manufacturers to take back all vehicles which were ever sold in that
country.
The German (draft) regulation on Electronic Waste obliges the retailer to
take back used electronic equipment from the end-user.
The
manufacturer/importer is obliged to take back the products from the
retailer.
Voluntary agreements have been widely accepted by industry and the
threat of legislation has subsided slightly.
Manufacturer
Manufactured goods
Take back of “retired” products
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Recovery Priorities
1) Re-Use
 Highest priority from environmental point of view
 All resources (material and energy) put into product during
manufacturing are preserved.
 Requires non-destructive disassembly.
2 ) Material recycling
 Most common.
 Only materials are preserved, all geometric details are lost.
 Allows for destructive disassembly.
 Also done for recovery of valuable material (e.g. gold in
electronics)
3) Energy recovery
 Only energy embodied in materials is preserved through
incineration or pyrolysis.
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Computer Recycling Processes



The large amount of ferrous metals, mainly steel, favors current recycling
practices of shredding the product and sorting with a simple magnet.
The printed circuit boards (PCB), plastic, and glass present the current
challenges.
 PCBs may contain valuable metals and reusable circuit components but
must undergo expensive and labor intensive disassembly.
 Plastics must be identified and sorted accurately to be recycled, and
there are huge varieties used in today’s products.
 In addition, many contain hazardous additives for flame retardation or
other purposes .
Finally, the last major portion of the computer is in glass, located in the
monitor.
 The obstacle here is finding a way to remove the lead, phosphorous,
and other hazardous additives from the glass so that it can be
recycled.
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Activity-Based Costing Dismantling Assessment
Fo rec as t: D ismantling Un it-profi tabi lity
Fr equ en cy Cha rt
C ell F41 5
Sens itivity C har t
99 6 Tria ls Show n
.034
34
Target Fore cas t: D ismantling Unit-p rofitability
.02
25.5
.01
17
.00
8.5
.00
0
-9. 50
-8. 38
-7. 25
[$/unit ]
-6. 12
-5. 00
Truck Infor ma tion
Other Depart ments
EPA S tor age
Requir ements
Fork lift
Information
No. 7 Time [ sec]
-.53
Mi crophone Pay-back Price […
-.41
A311 Direct Labor [$/ h]
-.17
Business days per week
.16
Mi crophone Total Vol ume [ft^…
.14
Recycling Revenue
.08
Super-Duty Impact Wrench
.08
Al uminum[$/kg]
Reuse Revenue
ABC Cost Mode l
with Uncer tainty
S hredder
Information
-.12
Fuel Consumption int ensit y […
Reusables V olume [f t^3]
Cos ti ng Depart ment
Equipme nt Information
-.66
No. 19 Time [sec]
Tra nsporta tion Infor mation
Legal
Informa tion
A13 Volume [$/f t^3]
-.08
.07
No. 44 Keypad RcE
-.07
No. 38 Time [sec]
-.07
-1
-0. 5
0
0.5
1
Measured by Rank Correlation
Assumptions
Tools

Disma ntling
Information
Product Da tabase
Recycling & Reuse
Efficiencies
Action Cha rt for
Each Product
Des ign Department
In any “detailed” assessment,
uncertainty should be taken into
account!
Process Department
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