Design For Recycling

Transcription

1 Design For Recycling A Product s Life Cycle From Cradle to to Re-Incarnation Manufacture Mining Material processing Product manufacture Distribution Environment: air, sea, land Demanufacture 1 Use Disposal Material demanufacture Product demanufacture Product take-back Energy recovery with incineration Clean fuel production via pyrolysis 1 = Direct reuse 2 = Remanufacture of reusable components 3 = Reprocessing of recycled material 4 = Monomer / raw material 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. DFR (1) - 1

2 Growing Importance of 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 president may want to follow Europe s lead. 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. German 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 DFR (1) - 2

3 European Commission --Automobiles Objectives Avoidance of waste Reduction of landfill demand Reduction of toxicity Recycling Targets Maximum of 15% of car weight can be landfilled or incinerated without energy recovery. For models beginning in 2002, maximum of 10% disposal. Maximum of 5% of car weight disposal in From 1995, cars must be depolluted before shredding. From 1998, 100% of all wrecks to be collected. A dream for politicians and a nightmare for car manufacturers? Maybe, but: In Europe, people are VERY serious about cleaning up the environment. The US is generally expected to follow European successes. Cooperation in in Automobile Industry Legislation has caused closer collaboration among vehicle manufacturers. In Europe, several (international) collaborative projects are underway. Daimler-Chrysler is the only company in US in EURHEKAR which is a consortium of non-german car manufacturers. BMW and Volvo seem to be leading in Europe In the US, largest companies formed the Vehicle Recycling Partnership and the Vehicle Recycling and Dismantling Center in Highland Park to look at recycling issues. 10 million vehicles are already recycled in the US annually. DFR (1) - 3

4 Definitions Recycle: A series of activities, including collection, separation, and processing, by which products or other materials are recovered from or otherwise diverted from the solid waste stream for use in the form of raw materials in the manufacture of new products.» Materials which are diverted for use as an energy source should be documented separately under the category of energy recovery» US EPA uses the same definition. Re-use: The series of activities, including collection, separation, and in some cases processing, by which products are recovered from the waste stream for use in their original intended manner.» Remanufactured components fall under the classification of re-use.» (Germans refer to this as product recycling.) Definitions (continuation) Recyclable (recyclability) Refers to products or materials that can be diverted from the waste stream and returned to use as functioning part or a raw material for the manufacture or assembly of a new product through a process that is currently and widely available.» If the infrastructure to recycle the product or material is limited, the claim should be so qualified.» Recyclability claims should be qualified on a weight basis or in terms of which portions of a product or package are recyclable. In Europe, incineration with energy recovery ( energy recycling ) is also considered an option for recycling. DFR (1) - 4

5 Common Errors and Mistakes Do not make unqualified claims! Always justify! this product is recyclable (misleading; how much, what process?) 90% of this vehicle by weight is recylable (prove it!!) parts are marked for recyclability (justify implication that recycling is possible). Post and Pre-Consumer Materials Post-Consumer Materials Those products or materials generated by a business or consumer that have served their intended end uses and that have been recovered from or otherwise diverted from the waste stream for the purpose of recycling. Pre-Consumer Materials Those materials generated during any step in the production of a material or product that have been recovered or otherwise diverted from the waste stream for the purpose of recycling.» This does not include home scrap.» Pre-consumer materials are also referred to as rework, post-industrial, and post-process materials. DFR (1) - 5

6 Home Scrap Home Scrap Those scrap materials, virgin material scrap, or by-products generated from and commonly reused by the industry within an original manufacturing process.» This cannot be claimed as recycled content.» Plastic regrind is an example of home scrap. Because you cannot claim it as recycled content does not mean you should not recycle it! Recycled Content Recycled Content The portion of a material s or product s weight that is composed of materials that have been recovered from or otherwise diverted from the waste stream either during the manufacturing process (pre-consumer) or after consumer use (post-consumer).» Distinctions should be made between pre- and post-consumer materials.» Unqualified claims can only be made if the entire product or package is made of recycled materials.» The term recyclate may be used to refer to a material that contains at least 25% post-consumer recycled content by weight. Not needed when recycled content is specified. We want to maximize recycled content as much as possible. DFR (1) - 6

7 Recycling Rate Recycling rate The percentage by weight of a given product or material category that is recycled. We want to maximize the recycling rate as much as possible. Dismantling and Recycling Strategies and Processes DFR (1) - 7

8 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. Basic Processes Disassembly is not the only process For remanufacture and re-use, the following processes are typically considered: Non-destructive disassembly down to module level cleaning inspection and sorting part upgrading or renewal re-assembly. For material recycling: material separation (disassembly, destructive or not), sorting, reprocessing. DFR (1) - 8

9 Shredding (destructive disassembly) Arguably, vehicle recycling became economically feasible with shredder technology. Shredders reduce vehicles to small fragments which may be sorted magnetically into ferrous and non-ferrous materials. Electronics industry is also using shredder technology. Typical values for for vehicles according to to to to AAMA brochure: Automotive Automotive Shredder Shredder Residue Residue 24%: 24%: Plastic Plastic 34% 34% Fluids Fluids 17% 17% Non-Ferrous Rubber Rubber 12% Non-Ferrous Metals Metals 5.6%: 5.6%: 12% Aluminum Glass Glass 16% Aluminum Ferrous 16% Copper Ferrous Metals Metals 70.4%: 70.4%: Other Other 21% Copper Iron 21% Lead Iron Lead steel Zinc steel Zinc Note: Note: Validity Validity of of some some numbers numbers has has been been questioned. questioned. Ex., Ex., fluid fluidpercentage is is too too high high Computer Material Composition and Recyclability A Carnegie Mellon University study estimates that up to 150 million used computers will be piled in US landfills in 2005 Feasibility of recycling computers: Also, about 50 percent of today's personal computers are plastics, which can be returned to their original makers for recycling. About 30 percent of a personal computer is steel, which fetches about 1.5 cents a pound. 10 percent is aluminum, worth 11 to 23 cents a pound. 10 percent is boards and miscellaneous wire, including 1 percent of gold worth about 90 cents a pound. Thus, effectively recycled, only about 0.5% of an entire computer system will actually have to go to landfill. DFR (1) - 9

10 Basic Shredder Process Vehicle Dismantler Hammer Mill or other Shredder Magnet Eddy Current Separator Automotive Shredder Residue Reusable/Remanufacturable Parts Easily Accessible Pure Materials Ferrous Metals Non-ferrous metals Density separation Some polymers A.S.R. Expected Future Viability Currently, all metals (ferrous and non-ferrous) can be recycled. Although high in value, plastics are unattractive to recyclers because of the difficulties in separation and identification of the various types, the contaminants used in most plastics. The challenge of using mechanical shredding (instead of dismantling) is that these products contain a variety of contaminants that threaten the purity of the plastics: acoustical foam, metal inserts, paint, brackets, coatings, and labels. Semi-Automated Disassembly Line and Center (De Mosselaar BV) DFR (1) - 10

11 Advanced Automated (Mechanical) Separation Techniques Many believe that manual separation is too expensive and will not be economically feasible. There is a need for cheap, reliable separation methods Promising separation techniques are primarily based on material properties, for example: E.g., density-based float-sink separation techniques, Froth-floatation (based on surface properties), air classification, electro-static and magnetic separation. Also, more reliable identification techniques than human inspection are needed and being developed E.g., FT-IR (Fourier Transform - Infrared), FT-NIR (same but uses Near Infrared light), FT-Raman (uses a YAG laser) However, there will always be a need for non-destructive disassembly if substances of concern have been used in the product. Classic examples are batteries in electronic products. Robotic Disassembly Robotic disassembly is being investigated, but requires much study and experimentation The robot must be highly sensorized, flexible, and intelligent. Disassembly cannot be regarded as reverse assembly because of the variety of products to be recycled and the uncertain state they come in. Some investigations conclude that robotic disassembly is possible, even if product conditions are uncertain. The main problems encountered are: Fasteners that require high forces, such as glue Accessibility to parts that are very close together Jamming and wedging of parts Uncertain object conditions Error detection and recovery needs to be looked into for the future. Also, robot systems need to be optimized for specific electronic product types DFR (1) - 11

12 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. Procedures for Electronic Recycling (from Resource Concepts Enviro) 1 Separate, segregate and track, by customer order, all incoming product. 2 Examine, identify and separate all incoming material into one of the following classifications: A. Non-proprietary product that» Can be refurbished and remarketed;» Has no resale value and must be disposed of in its entirety;» Has no resale value and contains hazardous materials B. Proprietary product that (at customer discretion)» Can be refurbished and remarketed with customer concurrence;» Must be disassembled and only the non-proprietary components refurbished and remarketed;» Must be destroyed beyond all recognition. 3 Repackage all hazardous material for shipment to EPA registered recyclers 4 Return all ferrous and non-ferrous metal, plastic, wire, and cable to reuse through their respective closed-loop recyclers. 5 Ship de-populated Printed Wiring Assemblies to precious metal refiners for the metal recovery 6 Ship CRT s to an EPA registered smelter for recycling lead and glass. 7 Ship batteries to approved EPA sites for reuse or disposal. 8 Provide a Certificate of Destruction to our customers for all material disposed of or destroyed beyond recognition. DFR (1) - 12

13 Developing an End-Of-Life System for Product Demanufacture Basic Questions to Ask Developing an an End-of-Life System Draw up a profile of the product s current end-of-life system Who owns the product? What kind of ownership is involved? What is the price? How big is the product? What is the average life of the product? What is the weight of the product? Analyse the main reasons why users dispose of the product Is the product disposed of because of technical failure? Is the product sensitive to trends? Are there new products on the market which offer more features? DFR (1) - 13

14 Developing an an End-of-Life System (cont.) Determine what legislation and regulations affect the end-oflife system To what extent is the manufacturer responsible for the end-of-life phase? Does a take-back obligation already exist for discarded products? How can the costs of returning an processing the product be financed? What rules and prices apply with regard to product reuse, material recycling, incineration and dumpin of residual wastes? Contact the suppliers Due to specialized expertise, suppliers can usually achieve sub-assembly reuse, recycling more efficiently than the OEM Establish how the product can be collected Consumer return system via recycling center Pick-up from last user Return system via retailers Developing an an End-of-Life System (cont.) Determine who is going to recycle or process the product Should the product be processed in house? Should the product be processed by a third party? Select the most efficient end-of-life system Use the answers to the preceding to establish a end-of-life scenario Due to the uncertain nature, consider establishing several scenarios Some trends to keep in mind: Users will think twice before discarding products Governments will develop more regulations The processing industry will become more effective Technological options will be expanded, especially in mechanical waste processing Market for recycled materials will improve Incineration and burial of waste will be subjected to more regulations and become more expensive DFR (1) - 14

15 Basic Cost Factors in Recycling Profitability of of Recycling We want to make recycling profitable: Profit = Revenue Cost Revenues are obtained from: High value (high demand), undamaged recovered reusable components. Additional processing (cleaning, inspection, upgrading, reassembly, and redistribution) adds to costs. High value, uncontaminated scrap materials. Any contamination which reduces material properties depreciates the material value. Energy recovered and sold from incineration or pyrolysis. Lowest revenue of all. DFR (1) - 15

16 Common Cost Factors Buy back of product ($/product) Dependent on condition and value of product type. Transportation costs ($/km) May also dependent on weight and damage tolerated. Tip/storage fees ($/product), also for landfilled residue. Strongly influenced by location of facility and local legislation. Labor cost ($/hour) Dependent on level of skills required and location. Equipment investment cost ($) Influenced by need for special (expensive) equipment. Equipment operating cost ($/car, $/hr) Time necessary to recover parts and materials (hr/product) STRONGLY INFLUENCED BY PRODUCT DESIGN! A Quick Costing Example Recovery of a dashboard: Removal of dashboard from car = 35 min. Removal of dash components = 35 min. At $20/hour, labor cost - $23 In order to break even with material recycling, more than 10 kg of copper (most valuable scrap material in table) would have to be recovered Or, dash components (gauges, etc) would have to be sold for re-use. Big questions: What is the market willing to pay for recovered dashboard components? How much value would remanufacture add to recovered components? Material Mass Virgin price Scrap pric [ kg ] [ % ] [ $ / kg ] [ $ / kg ] Steel / Iron Aluminum Zinc Copper Lead Polyurethane foam Polypropylene Poly Vinyl Chloride ABS Nylon Polycarbonate Polyurethane Polyethylene Polyester Rubber Other polymers Gasoline Oil Antifreeze Other hazardous fluids Glass Plastic Reinforced Fibers Plastic Composite Fillers Miscellaneous Total weight of car Typical 1990 vehicle material mix Re-Design of dash is desirable! (Any suggestions how?) DFR (1) - 16

17 Design for Recycling Approach DFR Guidelines Common complaint : I have to satisfy my customer demands, my boss, get the product out on time, meet all the deadlines, do DFMA, TQM, etc., and now I also have to worry about RECYCLING? DFR (1) - 17

18 DFR and DFE Most DFR and Design for Environment (DFE) guidelines also have other benefits (technical, economical, quality). It is argued that the biggest advantage of doing DFE is that it forces more creative thinking. Some good examples of this can be found in automotive industry. How to to do do DFX? Key to success in Design for X (DFX): Know the process(es) you are designing for. Know the critical technical and economic factors in these processes. If you are aware of the preceding issues, design guidelines are easy to postulate. Knowledge of corporate goals (and constraints) is also very useful. DFR (1) - 18

19 Recycling Loop according to to GE Plastics Question: What would be important design attributes and corresponding design guidelines to ease each of the stages listed in this figure? Also, what trade-offs do they require? German Engineering Standard VDI 2243 Designing Technical Products for for ease of of recycling: Fundamentals and rules for for design Effort from German engineering society (VDI) to standardize notions about recycling. The purpose of VDI 2243 is to provide engineers a quick and relatively complete overview of useful issues to be considered in modern design for recycling. The 35 page long VDI 2243 guideline contains the following: An introduction to recycling motivation, application, terminology and definitions, and the general life cycle and design processes. A short discussion on production waste recycling waste streams in production and rules for the designer. A discussion on product recycling (during a product s useful life) goals, processes involved, and rules for the designer. A discussion on material and waste recycling (after a product s useful life) goals, processes involved, and rules for the designer. A short discussion on the application of design for recycling rules. It contains a wealth of information and illustrates the state of the art in design for recycling in Germany. Needless to say it incorporates a lengthy bibliography of publications, however, mostly in German. DFR (1) - 19

20 Recycling Loops according to to VDI 2243 VDI 2243 makes distinctions between primary and secondary re-use and recycling. Resource Raw material collection and processing Please note that the German use slightly different definitions (after translation). Stick to AAMA definitions! Secondary reuse Primary reuse Production Recycling of production waste Waste from production being reprocessed Secondary reuse Primary reuse Use of product and / or consumption Recycling during the use of the product Reprocessing repair etc. Material recycling Material reprocessing = Disposal = Inciniration A General Design for Recycling Approach Recyclability and Recycled Content Assessment and Improvement Tasks 1 Assessment and Planning Obtain initial targets Assess existing design Identify planned changes affecting recyclability and recycled content R ecyclability is 100% or close and recycled content exceeds targets? No 2 - Product and Process Improvement Obtain detailed information Distribute information to suppliers (if needed) Yes Approach is very similar to DFE approach. Three phases: Assessment and planning Improvement Implementation and documentation Identify and prioritize limiting factors Major improvements needed Minor improvements needed Identify design alternatives Select design changes Reevaluate new design Minor or major? Yes I mprovements needed? 3 - Implementation and Documentation No Implement proposed design Document recyclability and recycled content of new design Provide feedback DFR (1) - 20

21 Recyclability Assessment US Vehicle Recycling Partnership Approach The US Vehicle Recycling Partnership is one of the few (if not the only one) industry organizations who have identified and recommended an industry wide recyclability assessment method To make a recyclability assessment, a four step approach should be followed: 1) Data collection (identify the components, materials, and fastening mechanism in the assembly to be rated). 2) Rate the components according to the rating scheme. 3) Calculate the percentage recyclability by weight. 4) Identify areas for improvement. Step 1 is an inventory step, but helpful in ensuring a complete and correct assessment. The identification of materials) is also needed to determine whether any substances of concern have been used. DFR (1) - 21

22 Step 1 --Data Collection General: Most, if not all, of the information can be obtained from the Bill of Materials. Materials: A proper identification of the materials used in a component is essential because these materials define its recyclability. Surface treatments (like paints, varnishes) and bonding agents (glues) must also be identified because of their potential to contaminate materials (especially plastics) to be recycled. In some cases, one percent contamination is enough to ruin a batch of high grade plastics for recycling. Fasteners: A proper identification of fastening mechanisms is important because these largely define the separation process needed in case two components need to be separated for recycling. Permanent connections (like welds, heat stakes) almost always require some form of mechanical separation. Non-permanent mechanical connections (like bolted joints, screws) allow for manual as well as mechanical separation. The fastener material and coatings need to be evaluated as well, because it may need separation to avoid contamination. Step 2 Rate the Components The calculation used to evaluate vehicle recyclability is based on two ratings for each component: a recyclability rating, and a material separation rating Rating Scales: A rating of 1 is the best. A rating of 1, 2, or 3 for both recyclability and separability is considered acceptable for the European market and should be strived for. Ratings of 4, 5, and 6 are considered poor. In contrast, the United States Federal Trade Commission (FTC) rules are stricter. At the moment, the FTC only considers products/component with a recyclability rating of 2 to be called recyclable. DFR (1) - 22

23 Material Recyclability and Part Remanufacture Categories Category 1 Part is remanufacturable Example: starter, transmission 2 Recyclable infrastructure and technology are clearly defined. Part is completely recyclable, infrastructure clearly defined and functioning. Example: Body sheet metal. + 3 Technically Feasible, infrastructure not available. Collection network not defined or organized, technology for material recycling has been established. Example: Plastic interior trim. 4 Technically feasible, but further process or material development is required. Technology has not been commercialized. Example: Backlite glass. - 5 Organic material for energy recovery, that cannot be recycled. Known technology/capacity to produce energy with economic value. Example: Tires, rubber in hoses. 6 Inorganic material with no known technology for recycling. Recycling technology not known. Category 3 is a prediction of materials that are technically feasible to recycle. Categories for Ease of of Disassembly for Material Separation in in a Component 1 Can be disassembled easily, manually. Approximate disassembly time is one minute or less. Example: A pillar trim cover 2 Can be disassembled with effort, manually. Component may contain compatible coatings or adhesives. Approximate disassembly time is one to three minutes. Example: fan shroud. 3 Disassembled with effort, requires some mechanical separation or shredding to separate component materials and parts. Component may contain non-compatible coatings or adhesives. The process has been fully proven. Example: seat assembly, windshield glass. 4 Disassembled with effort, requires some mechanical separation or shredding to separate component materials and parts. Component may contain non-compatible coatings or adhesives. The process is currently under development. Example: instrument panel. - 5 Cannot be disassembled. No know technology for separation. Example: heated backlite glass. Note: Note: It It is is assumed that that the the assembly or or part part being being rated rated has has already already been been removed from from the the vehicle. vehicle. + DFR (1) - 23

24 Rules of of Thumb for Recyclability Ratings Component/assembly material R.R. Reason 1 Single metal 2 Technology and recycling infrastructure in place. 2 Single thermo-plastic 3 Technology available, but no infrastructure in place. 3 Single thermoset 4, 5 Some technology under development. Incineration may be possible. 4 Multiple metals 2 Technology and recycling infrastructure in place. 5 Single or multiple metals with single thermoplastic 3, 4 Shredding and magnetic separation allow for separation of metals, depending on number and types. Resulting residue consists of a single plastic which may be recyclable. 6 Multiple thermo-plastics: All compatible 3, 4 Technology is available or under development to recycle this plastic mix, but no infrastructure exist. 7 Multiple thermo-plastics: Incompatible 4, 5, 6 8 Multiple thermosets 4, 5, 6 At best, technology is under development to recycle/separate this mixture. Incineration may be possible, dependent on composition. At best, some technology is under development to recycle/separate part of this mixture. Incineration may be possible, dependent on composition. Rules of of Thumb for Separability Ratings Situation S.R. Reason 1 Fasteners are made of same material as parts being joined. 2 Fasteners are made of material compatible with material of parts being joined. 3 Fasteners are incompatible with parts being joined, but easily removable. 4 Fasteners are incompatible with parts being joined, but removable by force (e.g. rivets or heatstakes). 5 Fasteners are made of ferrous material and easily removable and parts being joined are made of compatible or same plastic. 6 Fasteners are non - removable/permanent/molded in, but made of ferrous material and parts being joined are made of compatible or same plastic. 7 Fasteners are non - removable/permanent/molded in, but made of ferrous material and parts being joined are made of incompatible plastics. 8 Fasteners and part materials are incompatible and fasteners are absolutely non-removable (e.g. adhesives). 9 Part materials are same or compatible, but incompatible with fastener. However, fastener mass is so small that realistically no contamination will occur. 1 No disassembly required. All can be recycled as a single part. Preferred situation. 1 No disassembly required. All can be recycled as a single part. 1, 2 Fasteners can be removed manually. Part material can be separated manually. 3, 4, 5 1, 2, 3 Fasteners can be removed manually. Part material can be separated manually or mechanically if material properties allow. Fasteners can be removed manually or by shredding and magnetic separation. Choice depends on time required. Plastic parts are recycled as a mix. 3 Fasteners can be removed by shredding and magnetic separation. Plastic parts are recycled as a mix. 3, 4, 5 Fasteners can be removed by shredding and magnetic separation. Plastics may be separated through density separation, number and densities allow. 4, 5 No separation possible and fastener will cause part material contamination if shredded. In limited cases, (chemical) separation technologies are under development. 1 All can be recycled as a single part. Advice from Materials Engineering should be sought, because 1% contamination is already unacceptable in some cases. if DFR (1) - 24

25 Step 3 Calculating Percent Recyclability by by Weight The recyclability for an entire assembly is calculated on a percent recyclability by weight basis. The weights of all components with a recyclability rating of 1-3 and a separation rating of 1-3 are summed. The resulting weight number is then divided by the total weight of all components in the assembly. The subsequent number represents the percentage (by weight) of the assembly that is technically feasible to recycle. The calculation provides a quantitative value, but the additional discussion of the good and bad points of the system and/or components is, in general, much more informative than this value (Total weight of components with ands.r. R.R. of 1-3) Percent recyclability by weight = (Total weight of all components in assembly) Step 4 Identify Areas of of Improvement In general, any components with recyclability and/or separability ratings of 4 are immediate candidates for improvement, especially if a component s recyclability rating is 3 but its separability rating is 4. Furthermore, components with a relatively large weight should be investigated first since they provide the (potential) highest increase in percent recyclability by weight. This step is a precursor to Task 2.c (Identify and Prioritize Limiting Factors) if improvements are needed. DFR (1) - 25

26 Product Example Motorola Display/Keypad Microphone ITEM NO. DESCRIPTION 1 SCREW 2 WASHER (2 req d) 3 SCREW 4 LABEL 5 LEVER, PTT (part of item 6) 6 ASSEMBLY, Housing (includes item 5) 7 STRAIN RELIEF 8 CLAMP 9 SCREW (2 req d) 10 CORD, Coil 11 HOUSING, Header 12 WIRE, Receptacle 13 WIRE, Receptacle 14 PRINTED CIRCUIT BOARD, PTT 15 CONTACT, Snap 16 SEAL, Dome 17 FRAME 18 MICROPHONE 19 BOOT, Microphone 20 WIRE, Receptacle 21 WIRE, Receptacle 22 PAD 23 ASSEMBLY, Display Cover 24 LABEL, Nameplate 25 O-RING 26 WASHER, Insulator 27 INSULATOR 10 VRP DFR Assessment Disassembly activity Disassemblability Material recyclability Comments No. Name Quantity Type Access Tool Force Time Rating Material Mass Rating Rating Marked CE/SP/SA [sec.] [1-5] [1-4] (1-6) [y/n] 1 Disconnect mic. from base 1 CE N Microphone Disassembly 2 Remove screws #1 phillips 2 CE 3 #1 PS Stainless Steel N 3 From No. 2 Washer 2 SP Plastic PP N 4 From No. 2 Washer 2 SP Plastic PP N 5 Remove keypad subassembly 1 SUB 4 Pliers Mix N 6 From No. 5 Gasket 1 SP Rubber N 7 From No. 5 Break H-S Tabs 8 CE 1 Knife N 8 From No. 5 Keypad PCB/LCD 1 SUB 4 Pry Mix Y 9 From No. 8 Undo metal tabs 6 CE 3 Pliers N 10 From No. 8 Remove. Disp. Sub. 1 SUB Mix Y 11 From No. 10 LCD Cover 1 SP Plastic HDPE Y 12 From No. 10 LCD 1 SP Mix Y 13 From No. 10 Conductor 2 SP Mix Y 14 From No. 10 LCD Base 1 SP Aluminum Y 15 From No. 8 PCB 1 SP Mix Cu, Au Y 16 From No. 5 Keypad 1 SP Rubber Y 17 From No. 5 LCD Prot. Scrn. 1 SP 1 Pry out Plastic HDPE N 18 From No. 5 Foam 1 SP 2 Knife Foam N 19 From No. 5 Inserts 2 SP 1 Saw Brass N 20 From No. 5 Keypad base 1 SP Plastic ABS Y pin connector housing 1 CE 2 pin Plastic HDPE Y 22 Microphone subassembly 1 SUB 3 Pliers Mix Y 23 From 22 Mic. & wires 1 SP Mix Cu, Al Y 24 From 22 Microphone boot 1 SP Rubber N 25 PTT Contact & wires 1 SUB 1 Pliers Mix Cu, Au Y 26 Screw - mic. cord/bracket 1 CE 4 #1 PS Steel N 27 Mic. cord bracket 1 SP 3 Pliers Stainless Steel Y 28 Microphone cord 1 SUB Mix Cu, AU, Pl Y 29 Mic. cord boot 1 SP Rubber N 30 Spacer 2 SP Plastic PP N 31 Screw - mic./ptt lever mount 1 CE 4 #1 PS Steel N 32 Microphone/PTT mount bracket 1 SP 3 Pliers Plastic ABS Y 33 Rubber pad 1 SP Rubber N 34 Motorola label 1 SP PLastic HDPE N 35 PTT lever 1 SP 1 Pliers Plastic ABS Y 36 PTT bezel 1 SP 2 Pliers Plastic ABS Y 37 PTT actuator 1 SP Rubber Y 38 Microphone Hanger 1 SP 4 Drill Stainless Steel N 39 Microphone base 1 SP Plastic ABS Y Percent Recyclability by Weight DFR (1) - 26

27 Activity-Based Costing Dismantling Assessment Cell F Forecast: Dismantling Unit-profitability Frequency Chart 996 Trials Shown 34 Sensitivity Chart Target Forecast: Dismantling Unit-profitability [$/unit] Equipment Information Transportation Information Fork lift Truck Information Information Legal Other Departments Information Costing Department EPA Storage Requirements Recycling Revenue Reuse Revenue ABC Cost Model with Uncertainty A13 Volume [$/ft^3] -.66 No. 7 Time [sec] -.53 Microphone Pay-back Price [ -.41 A311 Direct Labor [$/h] -.17 Business days per week.16 Microphone Total Volume [ft^.14 No. 19 Time [sec] -.12 Fuel Consumption intensity [.08 Super-Duty Impact Wrench.08 Reusables Volume [ft^3] -.08 Aluminum [$/kg].07 No. 44 Keypad RcE -.07 No. 38 Time [sec] -.07 Shredder Information Tools Dismantling Information Recycling & Reuse Efficiencies Process Department Assumptions Product Database Design Department Action Chart for Each Product Measured by Rank Correlation In any detailed assessment, uncertainty should be taken into account! Activity-Based Costing Shredding Assessment Cell F Forecast: Shredding Unit-profitability Frequency Chart [$/unit] 1,994 Trials Shredding cost less than manual dismantling in this case, which is not surprising. Note the sensitivity of the cost with respect to the product pay-back price Sensitivity Chart Target Forecast: Shredding Unit-profitability Microphone Pay-back Price [ A51 Direct Labor [h/batch] -.07 A51 Tooling Time [h/batch].06 No. 25 Time [sec.].06 Microphone Total Volume [ft^.06 Business days per week.05 Operation hours per day -.05 Plastic Shredder Price [$/un.05 Maintenance cost [$/year].05 A1e21 Direct Labor [h/batch] -.05 A612 Direct Labor [h/batch] -.05 Concrete [Yard^3].05 Inspection Fee [$/year] Measured by Rank Correlation DFR (1) - 27

28 Involving the Suppliers Suppliers need to be involved as well because of outsourcing in modern companies. Big issue: How to get not only the products from the supplier, but also the necessary information? Supplier Regulated Substance and Recyclability Data Collection and Reporting System To avoid mistakes and costly errors down the road, a computer-based Supplier Regulated Substance and Recyclability Data Collection and Reporting System is being developed. The idea is that suppliers will answer questions and fill out forms in the software. DaimlerChrysler is using it. DFR (1) - 28

29 Supplier Regulated Substance and and Recyclability Data Collection and and Reporting System Entry Screen Flow Diagram * * * * DFR (1) - 29