1. Design for Disassembly (DFD) By Tyler Britten OISM 470 W

2. What will be covered: What is DFD?What is DFD? Why DFD?Why DFD? How does DFD work?How does DFD work? Who currently uses DFD?Who currently uses DFD? How can you use DFD?How can you use DFD? Resistance to DFDResistance to DFD SummarySummary

3. What is DFD? (1/3) Design for Disassembly(DFD) is: A type of green manufacturingA type of green manufacturing Products are designed to be taken apart, so that they can be used in later generations of products.Products are designed to be taken apart, so that they can be used in later generations of products. Also known as Design for Remanufacture or Reuse.Also known as Design for Remanufacture or Reuse.

4. What is DFD? (2/3) “The goal is to close the production loop, to conceive, develop, and build a product with a long-term view of how its components can be refurbished and reused--or disposed of safely--at the end of the product's life…..”

5. What is DFD? (3/3) “…In a world where the costs of disposal are rising, ease of destruction becomes as important as ease of construction.” -Gene Bylinsky, Fortune

6. Why DFD? Unlike other green business programs, DFD has financial benefits as well as environmental ones.Unlike other green business programs, DFD has financial benefits as well as environmental ones.

7. Why DFD? Why include recycling/reuse plans in the design process? Thinking problems through beforehand can lower recycling costs dramatically and reduce environmental hazards.Thinking problems through beforehand can lower recycling costs dramatically and reduce environmental hazards.

8. Why DFD? New laws across Europe will soon require manufacturers to take back used product.New laws across Europe will soon require manufacturers to take back used product. In Germany, manufacturers are already responsible for the final fate of their products' packaging.In Germany, manufacturers are already responsible for the final fate of their products' packaging. Similar legislation is expected in the US in the not-to-distant future.Similar legislation is expected in the US in the not-to-distant future.

9. Why DFD? “The Germans have established a de facto global manufacturing standard. U.S. companies wishing to compete globally must start making products that will comply with the green dictates of the huge European market” -Gene Bylinsky, Fortune

10. Green Product Design from a Environmental Perspective Design for Disassembly Slows the depletion of Natural Mineral ResourcesSlows the depletion of Natural Mineral Resources Lower Amounts of trash to already crowed landfillsLower Amounts of trash to already crowed landfills According to the National Academy of Sciences, 94% of the materials that are pulled out of the earth enter the waste stream within months.

11. Green Product Design from a Business Perspective The main principles of DFD and green manufacturing also fit into modern efforts to make assembly more efficient, such as concurrent engineering and total quality control.

12. Green Product Design from a Business Perspective (cont.) Used or refurbished parts sometimes work better than new ones. Among Integrated Circuits, 5% of new chips fail, but in comparison, used chips only fail 2% of the time

13. How Does DFD work? Design for Disassembly/Green Design: Emphasis on reducing partsEmphasis on reducing parts Rationalizing materialsRationalizing materials Reusing componentsReusing components Green Products more efficientGreen Products more efficient to build and distribute than conventional ones to build and distribute than conventional ones

14. How Does DFD work? Design for Disassembly/Green Design: DFD experts fit into Concurrent Engineering teams easilyDFD experts fit into Concurrent Engineering teams easily DFD reduces waste, which is an enemy of total quality managementDFD reduces waste, which is an enemy of total quality management

15. Examples of DFD Eastman-KodakEastman-Kodak Hewlett PackardHewlett Packard Vehicle Recycling Development CenterVehicle Recycling Development Center

16. Eastman-Kodak The Fling - first disposable cameraThe Fling - first disposable camera Angered EnvironmentalistsAngered Environmentalists Funsaver Panoramic - very popularFunsaver Panoramic - very popular Name Wastemaker of the YearName Wastemaker of the Year In 1990, Kodak had converted the disposable cameras to recyclable ones.In 1990, Kodak had converted the disposable cameras to recyclable ones. Now 87% of the Cameras are either reused or recycled.Now 87% of the Cameras are either reused or recycled.

17. Hewlett-Packard Depending on the model, hp is able to recycle up to 65% of the print cartridge by weight. The remaining parts that cannot be recycled are disposed of in an environmentally responsible manner.Depending on the model, hp is able to recycle up to 65% of the print cartridge by weight. The remaining parts that cannot be recycled are disposed of in an environmentally responsible manner.

18. Hewlett-Packard Each month, HP reuses or recycles more than 3.5 million pounds of material in their U.S. and European product-recovery centers.Each month, HP reuses or recycles more than 3.5 million pounds of material in their U.S. and European product-recovery centers. Recycled over 39 million hp LaserJet cartridges worldwide HP’s workstation designers’ new chassis reduces transport packaging by 30%, while disassembly time has been cut 90%.

19. Vehicle Recycling Development Center Established in 1994Established in 1994 Joint venture of GM, Chrysler, & FordJoint venture of GM, Chrysler, & Ford Goals of VRDC:Goals of VRDC: 1.Finding ways to recycle automobile "fluff"--the 25% or so of material remaining after recycling of the ferrous, nonferrous, and other readily recycled components. 2.Finding ways to more cost-effectively disassemble cars, including removal of fluids.

20. How to implement DFD DFD is easily implemented in most Quality StrategiesDFD is easily implemented in most Quality Strategies DFD involves considering the products’ entire life cycle.DFD involves considering the products’ entire life cycle.

21. How to implement DFD DFD includes looking at the impact of design decisions not only as they relate to a specific product attribute, but in the broader sense of environmental impact over the entire product life from procured parts to disposal.DFD includes looking at the impact of design decisions not only as they relate to a specific product attribute, but in the broader sense of environmental impact over the entire product life from procured parts to disposal.

22. Collecting Data for DFD 1.Cost in the form of complexity and time 2.Revenues provided in respect to the materials that can be liberated 3. Environmental impact in the form of residual material disposal 4.Technical difficulty in the form of special tools, material handling, material identification

23. Resistance to DFD Xerox is one of the companies meeting some resistance to selling refurbished products. Xerox is one of the companies meeting some resistance to selling refurbished products. “There are pockets in the consumer base that keep saying, 'We only want 100% new products.’” -Jack C. Azar, Xerox

24. Summary DFD involves examining a product’s entire life cycle DFD involves examining a product’s entire life cycle DFD’s benefit, both financial and ecological, outweigh the costs DFD’s benefit, both financial and ecological, outweigh the costs DFD is important part of a firm’s quality strategy. DFD is important part of a firm’s quality strategy.

25. Summary (cont.) Many European Countries will soon require DFD by law Many European Countries will soon require DFD by law Germany is the worldwide leader in DFD Germany is the worldwide leader in DFD There is a resistance to DFD by United States consumers who want 100% new products There is a resistance to DFD by United States consumers who want 100% new products

26. Bibliography S. Thomas Foster, Managing Quality (Prentice Hall 2001) Bylinski, G., “Manufacture for Reuse,” Fortune (Feb 6, 1995) Hewlett Packard (http://www.hp.com) http://www.hp.com Eastman-Kodak (http://www.kodak.com) http://www.kodak.com General Motors (http://www.gm.com) http://www.gm.com National Academy of Science (http://www4.nationalacademies.org/nas/) http://www4.nationalacademies.org/nas/