Sustainable Development of Coffeemaker Using Design for Environment (DFE) Methodology.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Sustainable Development of Coffeemaker
Using Design for Environment (DFE)
Methodology
Thesis submitted in accordance with the requirements of the Universiti
Teknikal Malaysia Melaka for the Bachelor of Manufacturing
Engineering (Manufacturing Design) with Honours
By
Shivarajh A/L Egambaram
Faculty of Manufacturing Engineering
May 2008
2
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:
SUSTAINABLE DEVELOPMENT OF COFFEEMAKER USING DESIGN FOR
ENVIRONMENT (DFE) METHODOLOGY
SESI PENGAJIAN:
Semester 2 2007/ 2008
Saya Shivaraj h A/ L Egambaram mengaku membenarkan laporan PSM / t esis
(Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia
Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1.
2.
3.
4.
Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan
penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
*Sila t andakan ( √)
√
SULIT
(Mengandungi maklumat yang berdarj ah keselamat an at au
kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA
RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh
organisasi/ badan di mana penyelidikan di j alankan)
TIDAK TERHAD
(TANDATANGAN PENULIS)
Alamat Tet ap:
311, Taman Muhibbah Dua,
32000 Sit iawan,
Perak Darul Ridzuan.
(TANDATANGAN PENYELIA)
15 May 2008
Tarikh: _______________________
Tarikh: _______________________
Cop Rasmi:
* Jika laporan PSM ini SULIT at au TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
3
ABSTRACT
Engineers are in an essential position to affect the environmental aspects of the
product they design. Role of a design engineer has become increasingly vital not
only to produce product to meet customers needs of quality and cost but also to
produce products with as low environmental impact as possible. This report is about
sustainable development of a coffeemaker by applying the Design for Environment
(DFE) approach which aims to protect human health and preserve environment. In
recent years, DFE has become an important approach since the world is facing
problems of limited resources and serious environmental effects. DFE is an approach
implemented at product design and development stage to avoid or minimize
significant environmental impacts and increase resource efficiency at all phase of a
product life cycle ranging from extraction of its material, manufacturing, packaging,
transportation, product usage and finally to recycling or deposition of the used
product. The methodology used in this report is by developing Philips’ coffeemaker
as a benchmark and implement DFE tools and guidelines to produce a sustainable
coffeemaker. From the result obtained, the evaluation and comparison of
environmental impact and effect on human health of the Philips coffeemaker and
sustainable coffeemaker is carried out with life cycle assessment (LCA) method.
LCA software, SimaPro is used to carry out the assessment. By adopting DFE, a
certain company can achieve the ISO 14001 international specification for
Environmental Management System (EMS) beside other benefits such as
encouraging the customers to accept its product, reduce environmental effect and
conserve energy or natural resources.
4
ABSTRAK
Peranan jurutera menjadi semakin penting bukan sahaja untuk merekebentuk produk
yang memenuhi kehendak pelangan tetapi juga memastikan bahawa produk yang
dihasilkan itu tidak memberi kesan buruk terhadap alam sekitar. Laporan ini adalah
tentang memajukan produk yang mampan melalui aplikasi pendekatan rekabentuk
untuk alam sekitar untuk melindungi kesihatan manusia dan memelihara alam
sekitar. Pengamalam konsep ini menjadi semakin penting sejak kebelakangan ini
kerana dunia kini menghadapan dengan masalah sumber terhad dan kesan
persekitaran yang serius. Pendekatan rekabentuk untuk persekitaran diaplikasi pada
peringkat rekabentuk produk dan mengembangkan sesuatu produk untuk
mengelakkan atau mengurangkan kesan negatif terhadap persekitaran serta
meningkatkan kecekapan sumber asli pada setiap peringkat jangka hayat produk
bermula
dengan
melombong
bahan
mentah,
pembuatan,
pembungkusan,
pengangkutan, pengunaan produk sehingga ke kitar semula atau pelupusan produk
tersebut. Kaedah yang digunakan dalam laporan ini adalah dengan memajukan mesin
pembancuh kopi Philips yang berperanan sebagai penanda aras serta mengaplikasi
alat bantu dan garis panduan untuk pendekatan rekabentuk untuk persekitaran untuk
menghasilkan mesin pembancuh kopi yang mampan. Daripada keputusan yang
diperoehi, penilaian dan perbandingan kesan kedua-dua produk ini terhadap alam
sekitar dan kesihatan manusia dilakukan dengan menggunakan kaedah penilaian
jangka hayat produk. Perisian yang digunakan untuk mengendalikan tugas ini ialah
perisian SimaPro. Melalui pengamalan kaedah rekabentuk untuk persekitaran,
sesuatu syarikat boleh mendapatkan penganugerahan ISO 14001 yang merupakan
piawaian pengurusan persekitaran selain menggalakkan pengguna menerima produk
pengeluar, mengurangkan kesan buruk terhadap alam sekitar dan memelihara tenaga
atau sumber asli.
5
DEDICATION
To My beloved mum
6
ACKNOWLEDGEMENTS
It gives me utmost pleasure to express my gratitude to who have directly or indirectly
contributed to the fruition of the project compilation. They include;
My supervisor, Mr. Shajahan Bin Maidin of which we had an excellent working
relationship, and who offered tremendous help and encouragement,
My family, who inspired me through the hardship,
and last but not least all
lecturers, friends and relevant personnel who helped in one way or another.
Thank you.
7
TABLE OF CONTENTS
Abstract………..……………………………………..……………………...………...i
Abstrak…………………………………………………………………..…………....ii
Dedication………………………………………………………………….……...…iii
Acknowledgements……………………………………………………………….….iv
Table of Contents………………………………………………………………...…...v
List of Figures…………………………………………………………………..……ix
List of Tables………………………………………………………..………...……..xi
List of Abbreviations, Symbols, Specialized Nomenclature………………..………xii
Definition of Terms……………………………………..……………..………...…xiii
1. INTRODUCTION………………………………….………………………….....1
1.1 Background……………….………........……………………….....……………1
1.2 Statement of the Problem……………………..………………………………...3
1.3 Objective………….....………………………….………………………………3
1.4 Scope…………………………………...…….…………………………………4
2. LITERATURE REVIEW……………….………………………….……………5
2.1 Introduction…….…………………………………..…………………………...5
2.2 Background of Design for Environment (DFE)…..……………..……………...5
2.2.1
Definition for DFE……….….…………………………………….……...6
2.2.2
Aims and Benefits of DFE……………………………………………......7
2.2.3
Product Life Cycle…………..……………………………………………8
2.2.4
DFE Guidelines, Techniques and Rules…..…………………………….11
2.2.5
DFE Tools…………...……..……………………………………...…….15
2.2.6
Life Cycle Assessment (LCA)…………………………………...……...19
2.3 Background of Product Design and Development……….……………...…….20
2.3.1
Process of Product Design and Development………….………………..21
8
2.4 Introduction to Sustainable Product Design and Development….……...…….24
2.4.1 Methodology of Sustainable Product Development……...……………..25
2.5 Summary……………………………………...……………………………….28
3. METHODOLOGY……...….……………………………………….…………..29
3.1 Introduction…….…………..………………………………………………….29
3.2 Methodology Flow Chart………………….………..…………………………29
3.3 Detail Description of Methodology Flow Chart…...………………………….31
3.3.1
Literature Review.………..….…….…………………………………….31
3.3.2
Benchmarking of Competitors’ Product.…...…………………………...31
3.3.3 Competitors’ Product Review....…...…………….….………….……….32
3.3.4 Benchmark Performance….......…………….……….………….……….34
3.3.5 DFA Analysis…………..…..….…………………….………….……….35
3.3.6 Customer Survey…………..….……….…………….………….……….36
3.3.7 Environmentally Conscious Quality Function Deployment (ECQFD) /
System-Level Design………………….…………...……………………37
3.3.8 Detailed Design…...……....…………….……………………………….39
3.3.9
Assessment and Comparison of Environmental Performance…….…….40
3.3.10 Result & Discussion …………………………………………………….42
3.3.11 Conclusion & Recommendation……………..………….....………….42
3.4 Summary.…………………………………………………….……….……….42
4. RESULT AND DISCUSSION..…………………………………….…………..43
4.1 Introduction…….…………………………..………………………………….43
4.2 Benchmarking…………..…………………………..…………………………44
4.2.1
Product Specification….….….………………………………………….45
4.2.2
Product View Structure.….….……………….………………………….46
4.2.3
Product System-Level Design.……………….………………………….47
4.2.4
Product Tree Structure……....……………….………………………….49
4.2.5
DFA Analysis of Benchmark Product……….………………………….55
9
4.3 Sustainable Product Development…………………………….………………62
4.3.1
Customer Survey…...….….….………………………………………….62
4.3.2
Environmentally Conscious Quality Function Deployment (ECQFD)…64
4.3.3
Sustainable Coffeemaker System-Level Design.………………….…….66
4.3.4
Sustainable Coffeemaker Target Specification………………………….67
4.3.5
Detailed Design of Sustainable Coffeemaker.……….………………….68
4.3.5.1
Detailed Design of the Base.……………..…….………………….68
4.3.5.2
Detailed Design of the Jug...……………..…….………………….69
4.3.5.3
Detailed Design of the Jug Lid…………..…….………………….70
4.3.5.4
Detailed Design of the Filter……………..…….………………….71
4.3.5.5
Detailed Design of the Rod Mounting…...…….………………….72
4.3.5.6 Detailed Design of the Rod Holder…………..……..…………….73
4.3.5.7
Detailed Design of the Valve Ball……..…...….………………….74
4.3.5.8 Detailed Design of the Valve Piston……..……….……………….75
4.3.5.9
Product Information for the Heating Element…….…..………….76
4.3.5.10 Assembly of the Sustainable Coffeemaker…….....……………….77
4.3.5.11 Sustainable Coffeemaker Tree Structure…..….……………….81
4.3.5.12 Technical Comparison……...……………………….…………….82
4.3.6
Life Cycle Assessment…...………………….……….………………….84
4.3.6.1
Life Cycle Assessment of Philips Coffeemaker.………………….84
4.3.6.2
Life Cycle Assessment of Sustainable Coffeemaker.…….……….87
4.3.6.3
Comparison of Life Cycle Assessment…….…………..………….89
5. CONCLUSION AND RECOMMENDATION…...……………….…………..93
5.2 Conclusion …………………..……………………..…………………………93
5.3 Recommendation…………………………..……..…………………………...94
REFERENCES…..……………………..…………………………………………..95
10
APPENDICES
A
Gantt chart for PSM I
B
Gantt chart for PSM II
C
Shape generation capability of process and compatibility table between
process and material
D
Customer survey questions
E
Environmental VOC and environmental EM
F
Heat-o-Matic part specification
G
Detailed drawing of the sustainable coffeemaker of the Product
11
LIST OF FIGURES
2.1
Typical product life cycle representations
9
2.2
DFE benchmarking for environmental performance
14
2.3
Product development and required DFE tools
15
2.4
Product development phase diagram
21
2.5
Flow diagrams for sustainable product development
26
2.6
Dimensions of ECQFD
27
2.7
Predetermination and generation of environmental impacts at
28
various stages of product life cycle
3.1
Methodology flowcharts
30
3.2
Measuring environmental performances
34
3.3
Customer Survey
36
3.4
Structure of ECQFD
37
3.5
Example of assessment and comparison using SimaPro
40
3.6
Measurement of mass with electronic weigh
41
3.7
Generation of mass from SolidWork design
41
4.1
Philips coffeemaker
44
4.2
Overall structure of the Philips coffeemaker
46
4.3
System-level design of Philips coffeemaker
47
4.4
Main tree structure of Philips coffeemaker
49
4.5
Main body unit structure of Philips coffeemaker
49
4.6
Electrical unit structure of Philips coffeemaker
50
4.7
Electrical circuit diagram of Philips coffeemaker
51
4.8
Water circulating unit structure of Philips coffeemaker
52
4.9
Filtering unit structure of Philips coffeemaker
53
4.10
Jug unit structure of Philips coffeemaker
54
4.11
System-level diagram of sustainable coffeemaker
66
4.12
Isometric view of the base
68
4.13
Isometric view of the jug
69
4.14
Isometric view of the jug lid
70
12
4.15
Isometric view of the filter
71
4.16
Isometric view of the rod mounting
72
4.17
Isometric view of the rod holder
73
4.18
Isometric view of the valve ball
74
4.19
Isometric view of the valve piston
75
4.20
Immersion heaters
76
4.21
Isometric view of the sustainable coffeemaker
77
4.22
Sectional view of the sustainable coffeemaker
78
4.23
Exploded view of the sustainable coffeemaker
79
4.24
Tree structure the sustainable coffeemaker
81
4.25
SimaPro software tree structure wizards for the Philips
85
coffeemaker
4.26
SimaPro impact assessments for Philips coffeemaker
86
4.27
SimaPro software tree structure wizards for the sustainable
87
coffeemaker
4.28
SimaPro impact assessments for sustainable coffeemaker
88
4.29
SimaPro impact comparisons (weighting)
90
4.30
SimaPro impact comparisons (single score)
91
4.31
SimaPro impact comparisons (damage assessment)
92
13
LIST OF TABLES
2.1
Functions of DFE Tools
16
4.1
Application of DFA criteria to Philips coffeemaker parts
55
4.2
Boothroyd Dewhurst material identification
58
4.3
DFA analysis of product Philips coffeemaker parts
59
4.4
Summary for the customer survey
63
4.5
Environmentally conscious quality function deployment
65
4.6
Technical comparison of Philips coffeemaker and sustainable
82
coffeemaker
14
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CAD
-
Computer-Aided Design
CAE
-
Computer-Aided Engineering
CR
-
Customer Requirements
DFA
-
Design for Assembly
DFD
-
Design for Disassembly
DFE
-
Design for Environment
DFMA
-
Design for manufacturing and Assembly
ECQFD
-
Environmentally Conscious Quality Function Deployment
EM
-
Engineering Matrices
EMS
-
Environmental Management System
EPD
-
Environmental Product Declaration
EPI
-
Environmental Performance Indicator
ERA
-
Environmental Risk Assessment
FEM
-
Finite Element Analysis
ISO
-
International Standards Organization
LCA
-
Life Cycle Assessment
LCC
-
Life Cycle Cost Assessment
LCD
-
Life Cycle Design
SDS
-
Safety Data Sheet
SPI
-
Sustainability Performance Indicator
Std
-
Standard
TR
-
Technical Requirement
UTeM
-
Universiti Teknikal Malaysia Melaka
VOC
-
Voice of Customers
QFD
-
Quality Function Deployment
WEEE
-
Waste Electronic and Electronic Equipments
15
DEFINITION OF TERMS
The following are the terms that frequently used in this report so it is
important to understand their definitions.
I)
Sustainable product ~ product which will give as little impact on the
environment as possible during its life cycle (Ljungberg, 2007);
II)
DFE ~ systematic way of incorporating environmental consideration
into the design of a product (Manuilova et al., 2005);
III)
Product life cycle ~ product phases ranging from extraction of raw
material, product manufacturing, packaging, usage and final disposal
(Kurk and Eagan, 2008);
IV)
LCA ~ DFE tool to evaluate environmental performance of a certain
product (Rebitzer et al., 2004).
16
CHAPTER 1
INTRODUCTION
1.1
Background
The world is facing problem with the limited resources and serious
environmental impacts, so it is important to live a more sustainable life style. It is not
only designers’ but also responsibility for every inhabitant to overcome these
environmental problems. During the last century, the environmental problem faced at
the end of life cycle of certain product during its disposal or recycling. But today the
environmental performances of a product are taken into consideration in very early
stages of product design and development.
Basically, there are four environmental challenges need to be faced and
overcome by the mankind which are over-consumption, resource utilization,
pollution and over-population (Ljungberg, 2007). Over consumption refers to use of
many different materials which demands for transportation. Thus, increases the
energy consumption around the world. Resource utilization requires a product not to
be “over-designed” or having unnecessary parts. Pollution is a common challenge in
industry resulting from emissions. Over-population refers to ever increasing world
inhabitants that demand for less consumption for resources or energy otherwise the
mankind will face an exhaustion of those resources and energy.
17
Besides meeting the customers’ need for better quality and price demands and
employees demand for economic competitiveness, the design engineers also have to
take into consideration the environmental impact during designing phase of a product
(Schvaneveldt, 2003). Fundamentally, it is impossible to design a product which has
zero impact on environment and human health (Kurk and Eagan, 2008). However,
this drawback can be solved by implementing DFE at early stages of product design
and development.
Design of the product according to DFE enables companies or firms to
be recognized according to International Standards Organization 14001 for
Environmental Management System. Adopting DFE into their product
actually benefits the companies in many areas such as broadening market
access, reducing liability, expediting permits, improve public acceptance of
the product, decreasing pollution and conserve energy or natural resources
(DeMendonça and Baxter, 2001).
In this project, a non ISO 14001 certified product will be chosen and the
products’ performance will be analyzed as a benchmark. The product then will be
developed using DFE tools to obtain a sustainable product status. Finally, the
performance of both products will be analyzed with LCA method.
The sustainable product will be designed to reduce a product’s energy
consumption, material usage, recycle-ability or toxicity compared to its
originally designed performance level by the implementation of DFE. The
expected outcome for this project is the sustainable product will have less
impact than the benchmark on human health, resource usage and environment.
18
1.2
Statement of the Problem
When a product is designed and introduced to the market, the environmental
value of the product is given less priority and this has led to lack of sustainable
products in market. These products will face the risk of disposal difficulties at the
end of products’ life cycle (Kurk and Eagan, 2008). Thus, the overall cost of the
product will be raised due to the disposal difficulties. The emissions and waste
produced during the manufacturing phase and service of the product eventually harm
the environment and human health. Besides the issue of disposal, emission and
waste, another crucial issue is the ever decreasing resources for the natural resources
and material urging the necessity to produce a sustainable product. This project will
look into implementation of DFE method and tools to obtain a sustainable product
that will have less impact to environment, resource and human health than
benchmark product of same kind.
1.3
Objectives
The objectives of this project are:
(a) to identify a non ISO 14001 certified, carry out study and analysis about
the product necessary for sustainable development;
(b) to integrate design for environment (DFE) tools into product design and
development process;
(c) to carry out customer survey and develop an environmentally conscious
quality function deployment (ECQFD);
(d) to produce a detailed design of the product with a computer-aided design
(CAD) software;
(e) to carry out assessment and comparison of environmental impact of
benchmark product and sustainable product designed with
assessment (LCA) method.
19
life cycle
1.4
Scope
The product design and development is based on the DFE guidelines,
method and tools obtained through the literature studies. Tools such as DFA,
ECQFD and The Ten Golden Rules are integrated during different phases of
product design and development. The environmental performance of the
products is evaluated with SimaPro which is software for LCA studies. CAD
software SolidWork will be used for designing the detailed design for the
product.
20
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
A literature search was performed to study, implement, design and analyze
the sustainable product through implementation of Design for Environment (DFE).
This study also includes the areas of product design and development of a sustainable
product.
2.2
Background of Design for Environment (DFE)
DFE is a concept originated from industry’s effort to incorporate
environmental consideration during the product development stage (Sroufe et al.,
2000). It is also known as eco-design and life cycle design (LCD). According to ISO
14062, the aim of integrating environmental aspects into product development stage
is to reduce the total amount of environmental impact of products during its life cycle
(Lindahl, 2006).
The objective of DFE is to produce sustainable product which satisfy human
needs and requirement for the product which will increase the positive value and
decrease the negative values of a certain product pose on the environment (Karlsson
and Luttropp, 2006). In order to achieve these goals, there are necessary methods and
21
tools to systematically implement DFE into products such as the LCA tool to
quantify and compare environmental impacts (Rebitzer et al., 2004).
2.2.1
Definition for DFE
Since DFE is a new term in product design and development, there are many
definitions to describe the concept of DFE. One of the sources define DFE as
integrating environmental aspect at every product design criteria including the
function-ability, cost, aesthetics, safety, reliability and ergonomics (Kurk and Eagan,
2008).
Another source states that DFE is an integral part of a product development
phase that taken into account by the designers to understand and reduce a products’
impact on the environment during its life cycle from material selection,
manufacturing, usage and deposition (Schvaneveldt, 2003).
DFE is an attempt taken to minimize the environmental impact of a product
during its life cycle ranging from extraction of raw material through processing,
manufacturing and transportation to reuse, recycling and final disposal. This is
important to decrease the consumption of raw materials and energy, reduce cost and
make the process environment friendly (Manuilova et al., 2005).
DFE can be concluded as an approach implemented during the design and
development of a product to minimize its environmental impacts during a products’
life cycle.
22
2.2.2 Aims and Benefits of DFE
At early stage of DFE implementation in product development, it is often
causes problems to companies rather than benefits as environmental assessment tools
are very complex, time consuming and need expertise to perform the task
(Manuilova et al., 2005). After further improvement made on DFE tools and
techniques, the benefits of DFE is seen through good reputation among the customers
and better saving by using recycled material (Ljungberg, 2007).
Manufacturing firms now are beginning to benefit from DFE which provides
opportunity for cost saving and reduced responsibility to for environmental and
human health protection (Kurk and Eagan, 2008). The application of DFE during the
product development stage has proved beneficial by reducing manufacturing cycle
time and distinguishes products with added value of environmental feature to provide
competitive advantage in the market (Kurk and Eagan, 2008). Apart from that, DFE
is giving an opportunity to design or develop sustainable products without
influencing the products market competitiveness and profitability (DeMendonça and
Baxter, 2001).
Practicing DFE actually benefits the industry itself by widening the market
access as well as customer base and expediting permits. This is done through good
reputation to preserve nature. Thus, improves customer acceptance of the product.
Beside that implementation of DFE reduces record keeping and less inspection. DFE
also decreases emission or pollution, conserve energy or natural resource. All of this
will contribute to economical advantage and reducing control cost to a manufacturer
(DeMendonça and Baxter, 2001).
23
Sustainable Development of Coffeemaker
Using Design for Environment (DFE)
Methodology
Thesis submitted in accordance with the requirements of the Universiti
Teknikal Malaysia Melaka for the Bachelor of Manufacturing
Engineering (Manufacturing Design) with Honours
By
Shivarajh A/L Egambaram
Faculty of Manufacturing Engineering
May 2008
2
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:
SUSTAINABLE DEVELOPMENT OF COFFEEMAKER USING DESIGN FOR
ENVIRONMENT (DFE) METHODOLOGY
SESI PENGAJIAN:
Semester 2 2007/ 2008
Saya Shivaraj h A/ L Egambaram mengaku membenarkan laporan PSM / t esis
(Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia
Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1.
2.
3.
4.
Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan
penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
*Sila t andakan ( √)
√
SULIT
(Mengandungi maklumat yang berdarj ah keselamat an at au
kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA
RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh
organisasi/ badan di mana penyelidikan di j alankan)
TIDAK TERHAD
(TANDATANGAN PENULIS)
Alamat Tet ap:
311, Taman Muhibbah Dua,
32000 Sit iawan,
Perak Darul Ridzuan.
(TANDATANGAN PENYELIA)
15 May 2008
Tarikh: _______________________
Tarikh: _______________________
Cop Rasmi:
* Jika laporan PSM ini SULIT at au TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
3
ABSTRACT
Engineers are in an essential position to affect the environmental aspects of the
product they design. Role of a design engineer has become increasingly vital not
only to produce product to meet customers needs of quality and cost but also to
produce products with as low environmental impact as possible. This report is about
sustainable development of a coffeemaker by applying the Design for Environment
(DFE) approach which aims to protect human health and preserve environment. In
recent years, DFE has become an important approach since the world is facing
problems of limited resources and serious environmental effects. DFE is an approach
implemented at product design and development stage to avoid or minimize
significant environmental impacts and increase resource efficiency at all phase of a
product life cycle ranging from extraction of its material, manufacturing, packaging,
transportation, product usage and finally to recycling or deposition of the used
product. The methodology used in this report is by developing Philips’ coffeemaker
as a benchmark and implement DFE tools and guidelines to produce a sustainable
coffeemaker. From the result obtained, the evaluation and comparison of
environmental impact and effect on human health of the Philips coffeemaker and
sustainable coffeemaker is carried out with life cycle assessment (LCA) method.
LCA software, SimaPro is used to carry out the assessment. By adopting DFE, a
certain company can achieve the ISO 14001 international specification for
Environmental Management System (EMS) beside other benefits such as
encouraging the customers to accept its product, reduce environmental effect and
conserve energy or natural resources.
4
ABSTRAK
Peranan jurutera menjadi semakin penting bukan sahaja untuk merekebentuk produk
yang memenuhi kehendak pelangan tetapi juga memastikan bahawa produk yang
dihasilkan itu tidak memberi kesan buruk terhadap alam sekitar. Laporan ini adalah
tentang memajukan produk yang mampan melalui aplikasi pendekatan rekabentuk
untuk alam sekitar untuk melindungi kesihatan manusia dan memelihara alam
sekitar. Pengamalam konsep ini menjadi semakin penting sejak kebelakangan ini
kerana dunia kini menghadapan dengan masalah sumber terhad dan kesan
persekitaran yang serius. Pendekatan rekabentuk untuk persekitaran diaplikasi pada
peringkat rekabentuk produk dan mengembangkan sesuatu produk untuk
mengelakkan atau mengurangkan kesan negatif terhadap persekitaran serta
meningkatkan kecekapan sumber asli pada setiap peringkat jangka hayat produk
bermula
dengan
melombong
bahan
mentah,
pembuatan,
pembungkusan,
pengangkutan, pengunaan produk sehingga ke kitar semula atau pelupusan produk
tersebut. Kaedah yang digunakan dalam laporan ini adalah dengan memajukan mesin
pembancuh kopi Philips yang berperanan sebagai penanda aras serta mengaplikasi
alat bantu dan garis panduan untuk pendekatan rekabentuk untuk persekitaran untuk
menghasilkan mesin pembancuh kopi yang mampan. Daripada keputusan yang
diperoehi, penilaian dan perbandingan kesan kedua-dua produk ini terhadap alam
sekitar dan kesihatan manusia dilakukan dengan menggunakan kaedah penilaian
jangka hayat produk. Perisian yang digunakan untuk mengendalikan tugas ini ialah
perisian SimaPro. Melalui pengamalan kaedah rekabentuk untuk persekitaran,
sesuatu syarikat boleh mendapatkan penganugerahan ISO 14001 yang merupakan
piawaian pengurusan persekitaran selain menggalakkan pengguna menerima produk
pengeluar, mengurangkan kesan buruk terhadap alam sekitar dan memelihara tenaga
atau sumber asli.
5
DEDICATION
To My beloved mum
6
ACKNOWLEDGEMENTS
It gives me utmost pleasure to express my gratitude to who have directly or indirectly
contributed to the fruition of the project compilation. They include;
My supervisor, Mr. Shajahan Bin Maidin of which we had an excellent working
relationship, and who offered tremendous help and encouragement,
My family, who inspired me through the hardship,
and last but not least all
lecturers, friends and relevant personnel who helped in one way or another.
Thank you.
7
TABLE OF CONTENTS
Abstract………..……………………………………..……………………...………...i
Abstrak…………………………………………………………………..…………....ii
Dedication………………………………………………………………….……...…iii
Acknowledgements……………………………………………………………….….iv
Table of Contents………………………………………………………………...…...v
List of Figures…………………………………………………………………..……ix
List of Tables………………………………………………………..………...……..xi
List of Abbreviations, Symbols, Specialized Nomenclature………………..………xii
Definition of Terms……………………………………..……………..………...…xiii
1. INTRODUCTION………………………………….………………………….....1
1.1 Background……………….………........……………………….....……………1
1.2 Statement of the Problem……………………..………………………………...3
1.3 Objective………….....………………………….………………………………3
1.4 Scope…………………………………...…….…………………………………4
2. LITERATURE REVIEW……………….………………………….……………5
2.1 Introduction…….…………………………………..…………………………...5
2.2 Background of Design for Environment (DFE)…..……………..……………...5
2.2.1
Definition for DFE……….….…………………………………….……...6
2.2.2
Aims and Benefits of DFE……………………………………………......7
2.2.3
Product Life Cycle…………..……………………………………………8
2.2.4
DFE Guidelines, Techniques and Rules…..…………………………….11
2.2.5
DFE Tools…………...……..……………………………………...…….15
2.2.6
Life Cycle Assessment (LCA)…………………………………...……...19
2.3 Background of Product Design and Development……….……………...…….20
2.3.1
Process of Product Design and Development………….………………..21
8
2.4 Introduction to Sustainable Product Design and Development….……...…….24
2.4.1 Methodology of Sustainable Product Development……...……………..25
2.5 Summary……………………………………...……………………………….28
3. METHODOLOGY……...….……………………………………….…………..29
3.1 Introduction…….…………..………………………………………………….29
3.2 Methodology Flow Chart………………….………..…………………………29
3.3 Detail Description of Methodology Flow Chart…...………………………….31
3.3.1
Literature Review.………..….…….…………………………………….31
3.3.2
Benchmarking of Competitors’ Product.…...…………………………...31
3.3.3 Competitors’ Product Review....…...…………….….………….……….32
3.3.4 Benchmark Performance….......…………….……….………….……….34
3.3.5 DFA Analysis…………..…..….…………………….………….……….35
3.3.6 Customer Survey…………..….……….…………….………….……….36
3.3.7 Environmentally Conscious Quality Function Deployment (ECQFD) /
System-Level Design………………….…………...……………………37
3.3.8 Detailed Design…...……....…………….……………………………….39
3.3.9
Assessment and Comparison of Environmental Performance…….…….40
3.3.10 Result & Discussion …………………………………………………….42
3.3.11 Conclusion & Recommendation……………..………….....………….42
3.4 Summary.…………………………………………………….……….……….42
4. RESULT AND DISCUSSION..…………………………………….…………..43
4.1 Introduction…….…………………………..………………………………….43
4.2 Benchmarking…………..…………………………..…………………………44
4.2.1
Product Specification….….….………………………………………….45
4.2.2
Product View Structure.….….……………….………………………….46
4.2.3
Product System-Level Design.……………….………………………….47
4.2.4
Product Tree Structure……....……………….………………………….49
4.2.5
DFA Analysis of Benchmark Product……….………………………….55
9
4.3 Sustainable Product Development…………………………….………………62
4.3.1
Customer Survey…...….….….………………………………………….62
4.3.2
Environmentally Conscious Quality Function Deployment (ECQFD)…64
4.3.3
Sustainable Coffeemaker System-Level Design.………………….…….66
4.3.4
Sustainable Coffeemaker Target Specification………………………….67
4.3.5
Detailed Design of Sustainable Coffeemaker.……….………………….68
4.3.5.1
Detailed Design of the Base.……………..…….………………….68
4.3.5.2
Detailed Design of the Jug...……………..…….………………….69
4.3.5.3
Detailed Design of the Jug Lid…………..…….………………….70
4.3.5.4
Detailed Design of the Filter……………..…….………………….71
4.3.5.5
Detailed Design of the Rod Mounting…...…….………………….72
4.3.5.6 Detailed Design of the Rod Holder…………..……..…………….73
4.3.5.7
Detailed Design of the Valve Ball……..…...….………………….74
4.3.5.8 Detailed Design of the Valve Piston……..……….……………….75
4.3.5.9
Product Information for the Heating Element…….…..………….76
4.3.5.10 Assembly of the Sustainable Coffeemaker…….....……………….77
4.3.5.11 Sustainable Coffeemaker Tree Structure…..….……………….81
4.3.5.12 Technical Comparison……...……………………….…………….82
4.3.6
Life Cycle Assessment…...………………….……….………………….84
4.3.6.1
Life Cycle Assessment of Philips Coffeemaker.………………….84
4.3.6.2
Life Cycle Assessment of Sustainable Coffeemaker.…….……….87
4.3.6.3
Comparison of Life Cycle Assessment…….…………..………….89
5. CONCLUSION AND RECOMMENDATION…...……………….…………..93
5.2 Conclusion …………………..……………………..…………………………93
5.3 Recommendation…………………………..……..…………………………...94
REFERENCES…..……………………..…………………………………………..95
10
APPENDICES
A
Gantt chart for PSM I
B
Gantt chart for PSM II
C
Shape generation capability of process and compatibility table between
process and material
D
Customer survey questions
E
Environmental VOC and environmental EM
F
Heat-o-Matic part specification
G
Detailed drawing of the sustainable coffeemaker of the Product
11
LIST OF FIGURES
2.1
Typical product life cycle representations
9
2.2
DFE benchmarking for environmental performance
14
2.3
Product development and required DFE tools
15
2.4
Product development phase diagram
21
2.5
Flow diagrams for sustainable product development
26
2.6
Dimensions of ECQFD
27
2.7
Predetermination and generation of environmental impacts at
28
various stages of product life cycle
3.1
Methodology flowcharts
30
3.2
Measuring environmental performances
34
3.3
Customer Survey
36
3.4
Structure of ECQFD
37
3.5
Example of assessment and comparison using SimaPro
40
3.6
Measurement of mass with electronic weigh
41
3.7
Generation of mass from SolidWork design
41
4.1
Philips coffeemaker
44
4.2
Overall structure of the Philips coffeemaker
46
4.3
System-level design of Philips coffeemaker
47
4.4
Main tree structure of Philips coffeemaker
49
4.5
Main body unit structure of Philips coffeemaker
49
4.6
Electrical unit structure of Philips coffeemaker
50
4.7
Electrical circuit diagram of Philips coffeemaker
51
4.8
Water circulating unit structure of Philips coffeemaker
52
4.9
Filtering unit structure of Philips coffeemaker
53
4.10
Jug unit structure of Philips coffeemaker
54
4.11
System-level diagram of sustainable coffeemaker
66
4.12
Isometric view of the base
68
4.13
Isometric view of the jug
69
4.14
Isometric view of the jug lid
70
12
4.15
Isometric view of the filter
71
4.16
Isometric view of the rod mounting
72
4.17
Isometric view of the rod holder
73
4.18
Isometric view of the valve ball
74
4.19
Isometric view of the valve piston
75
4.20
Immersion heaters
76
4.21
Isometric view of the sustainable coffeemaker
77
4.22
Sectional view of the sustainable coffeemaker
78
4.23
Exploded view of the sustainable coffeemaker
79
4.24
Tree structure the sustainable coffeemaker
81
4.25
SimaPro software tree structure wizards for the Philips
85
coffeemaker
4.26
SimaPro impact assessments for Philips coffeemaker
86
4.27
SimaPro software tree structure wizards for the sustainable
87
coffeemaker
4.28
SimaPro impact assessments for sustainable coffeemaker
88
4.29
SimaPro impact comparisons (weighting)
90
4.30
SimaPro impact comparisons (single score)
91
4.31
SimaPro impact comparisons (damage assessment)
92
13
LIST OF TABLES
2.1
Functions of DFE Tools
16
4.1
Application of DFA criteria to Philips coffeemaker parts
55
4.2
Boothroyd Dewhurst material identification
58
4.3
DFA analysis of product Philips coffeemaker parts
59
4.4
Summary for the customer survey
63
4.5
Environmentally conscious quality function deployment
65
4.6
Technical comparison of Philips coffeemaker and sustainable
82
coffeemaker
14
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CAD
-
Computer-Aided Design
CAE
-
Computer-Aided Engineering
CR
-
Customer Requirements
DFA
-
Design for Assembly
DFD
-
Design for Disassembly
DFE
-
Design for Environment
DFMA
-
Design for manufacturing and Assembly
ECQFD
-
Environmentally Conscious Quality Function Deployment
EM
-
Engineering Matrices
EMS
-
Environmental Management System
EPD
-
Environmental Product Declaration
EPI
-
Environmental Performance Indicator
ERA
-
Environmental Risk Assessment
FEM
-
Finite Element Analysis
ISO
-
International Standards Organization
LCA
-
Life Cycle Assessment
LCC
-
Life Cycle Cost Assessment
LCD
-
Life Cycle Design
SDS
-
Safety Data Sheet
SPI
-
Sustainability Performance Indicator
Std
-
Standard
TR
-
Technical Requirement
UTeM
-
Universiti Teknikal Malaysia Melaka
VOC
-
Voice of Customers
QFD
-
Quality Function Deployment
WEEE
-
Waste Electronic and Electronic Equipments
15
DEFINITION OF TERMS
The following are the terms that frequently used in this report so it is
important to understand their definitions.
I)
Sustainable product ~ product which will give as little impact on the
environment as possible during its life cycle (Ljungberg, 2007);
II)
DFE ~ systematic way of incorporating environmental consideration
into the design of a product (Manuilova et al., 2005);
III)
Product life cycle ~ product phases ranging from extraction of raw
material, product manufacturing, packaging, usage and final disposal
(Kurk and Eagan, 2008);
IV)
LCA ~ DFE tool to evaluate environmental performance of a certain
product (Rebitzer et al., 2004).
16
CHAPTER 1
INTRODUCTION
1.1
Background
The world is facing problem with the limited resources and serious
environmental impacts, so it is important to live a more sustainable life style. It is not
only designers’ but also responsibility for every inhabitant to overcome these
environmental problems. During the last century, the environmental problem faced at
the end of life cycle of certain product during its disposal or recycling. But today the
environmental performances of a product are taken into consideration in very early
stages of product design and development.
Basically, there are four environmental challenges need to be faced and
overcome by the mankind which are over-consumption, resource utilization,
pollution and over-population (Ljungberg, 2007). Over consumption refers to use of
many different materials which demands for transportation. Thus, increases the
energy consumption around the world. Resource utilization requires a product not to
be “over-designed” or having unnecessary parts. Pollution is a common challenge in
industry resulting from emissions. Over-population refers to ever increasing world
inhabitants that demand for less consumption for resources or energy otherwise the
mankind will face an exhaustion of those resources and energy.
17
Besides meeting the customers’ need for better quality and price demands and
employees demand for economic competitiveness, the design engineers also have to
take into consideration the environmental impact during designing phase of a product
(Schvaneveldt, 2003). Fundamentally, it is impossible to design a product which has
zero impact on environment and human health (Kurk and Eagan, 2008). However,
this drawback can be solved by implementing DFE at early stages of product design
and development.
Design of the product according to DFE enables companies or firms to
be recognized according to International Standards Organization 14001 for
Environmental Management System. Adopting DFE into their product
actually benefits the companies in many areas such as broadening market
access, reducing liability, expediting permits, improve public acceptance of
the product, decreasing pollution and conserve energy or natural resources
(DeMendonça and Baxter, 2001).
In this project, a non ISO 14001 certified product will be chosen and the
products’ performance will be analyzed as a benchmark. The product then will be
developed using DFE tools to obtain a sustainable product status. Finally, the
performance of both products will be analyzed with LCA method.
The sustainable product will be designed to reduce a product’s energy
consumption, material usage, recycle-ability or toxicity compared to its
originally designed performance level by the implementation of DFE. The
expected outcome for this project is the sustainable product will have less
impact than the benchmark on human health, resource usage and environment.
18
1.2
Statement of the Problem
When a product is designed and introduced to the market, the environmental
value of the product is given less priority and this has led to lack of sustainable
products in market. These products will face the risk of disposal difficulties at the
end of products’ life cycle (Kurk and Eagan, 2008). Thus, the overall cost of the
product will be raised due to the disposal difficulties. The emissions and waste
produced during the manufacturing phase and service of the product eventually harm
the environment and human health. Besides the issue of disposal, emission and
waste, another crucial issue is the ever decreasing resources for the natural resources
and material urging the necessity to produce a sustainable product. This project will
look into implementation of DFE method and tools to obtain a sustainable product
that will have less impact to environment, resource and human health than
benchmark product of same kind.
1.3
Objectives
The objectives of this project are:
(a) to identify a non ISO 14001 certified, carry out study and analysis about
the product necessary for sustainable development;
(b) to integrate design for environment (DFE) tools into product design and
development process;
(c) to carry out customer survey and develop an environmentally conscious
quality function deployment (ECQFD);
(d) to produce a detailed design of the product with a computer-aided design
(CAD) software;
(e) to carry out assessment and comparison of environmental impact of
benchmark product and sustainable product designed with
assessment (LCA) method.
19
life cycle
1.4
Scope
The product design and development is based on the DFE guidelines,
method and tools obtained through the literature studies. Tools such as DFA,
ECQFD and The Ten Golden Rules are integrated during different phases of
product design and development. The environmental performance of the
products is evaluated with SimaPro which is software for LCA studies. CAD
software SolidWork will be used for designing the detailed design for the
product.
20
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
A literature search was performed to study, implement, design and analyze
the sustainable product through implementation of Design for Environment (DFE).
This study also includes the areas of product design and development of a sustainable
product.
2.2
Background of Design for Environment (DFE)
DFE is a concept originated from industry’s effort to incorporate
environmental consideration during the product development stage (Sroufe et al.,
2000). It is also known as eco-design and life cycle design (LCD). According to ISO
14062, the aim of integrating environmental aspects into product development stage
is to reduce the total amount of environmental impact of products during its life cycle
(Lindahl, 2006).
The objective of DFE is to produce sustainable product which satisfy human
needs and requirement for the product which will increase the positive value and
decrease the negative values of a certain product pose on the environment (Karlsson
and Luttropp, 2006). In order to achieve these goals, there are necessary methods and
21
tools to systematically implement DFE into products such as the LCA tool to
quantify and compare environmental impacts (Rebitzer et al., 2004).
2.2.1
Definition for DFE
Since DFE is a new term in product design and development, there are many
definitions to describe the concept of DFE. One of the sources define DFE as
integrating environmental aspect at every product design criteria including the
function-ability, cost, aesthetics, safety, reliability and ergonomics (Kurk and Eagan,
2008).
Another source states that DFE is an integral part of a product development
phase that taken into account by the designers to understand and reduce a products’
impact on the environment during its life cycle from material selection,
manufacturing, usage and deposition (Schvaneveldt, 2003).
DFE is an attempt taken to minimize the environmental impact of a product
during its life cycle ranging from extraction of raw material through processing,
manufacturing and transportation to reuse, recycling and final disposal. This is
important to decrease the consumption of raw materials and energy, reduce cost and
make the process environment friendly (Manuilova et al., 2005).
DFE can be concluded as an approach implemented during the design and
development of a product to minimize its environmental impacts during a products’
life cycle.
22
2.2.2 Aims and Benefits of DFE
At early stage of DFE implementation in product development, it is often
causes problems to companies rather than benefits as environmental assessment tools
are very complex, time consuming and need expertise to perform the task
(Manuilova et al., 2005). After further improvement made on DFE tools and
techniques, the benefits of DFE is seen through good reputation among the customers
and better saving by using recycled material (Ljungberg, 2007).
Manufacturing firms now are beginning to benefit from DFE which provides
opportunity for cost saving and reduced responsibility to for environmental and
human health protection (Kurk and Eagan, 2008). The application of DFE during the
product development stage has proved beneficial by reducing manufacturing cycle
time and distinguishes products with added value of environmental feature to provide
competitive advantage in the market (Kurk and Eagan, 2008). Apart from that, DFE
is giving an opportunity to design or develop sustainable products without
influencing the products market competitiveness and profitability (DeMendonça and
Baxter, 2001).
Practicing DFE actually benefits the industry itself by widening the market
access as well as customer base and expediting permits. This is done through good
reputation to preserve nature. Thus, improves customer acceptance of the product.
Beside that implementation of DFE reduces record keeping and less inspection. DFE
also decreases emission or pollution, conserve energy or natural resource. All of this
will contribute to economical advantage and reducing control cost to a manufacturer
(DeMendonça and Baxter, 2001).
23