INNOVATION IN LIFE CYCLE ENGINEERING AND SUSTAINABLE DEVELOPMENT

INNOVATION IN LIFE CYCLE ENGINEERING AND SUSTAINABLE DEVELOPMENT

Innovation in Life Cycle Engineering and Sustainable Development Edited by DANIEL BRISSAUD Université de Grenoble, France SERGE TICHKIEWITCH Université de Grenoble, France and PEGGY ZWOLINSKI Université de Grenoble, France

A C.I.P. Catalogue record for this book is available from the Library of Congress. ISBN-10 1-4020-4601-4 (HB) ISBN-13 978-1-4020-4601-8 (HB) ISBN-10 1-4020-4617-0 ( e-book) ISBN-13 978-1-4020-4617-9 (e-book) Published by Springer, P.O. Box 17, 3300 AA Dordrecht, The Netherlands. www.springer.com Printed on acid-free paper All Rights Reserved 2006 Springer No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written permission from the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work. Printed in the Netherlands.

Contents Introduction to Innovation in Life Cycle Engineering and Sustainable Development by D. Brissaud, S. Tichkiewitch and P. Zwolinski...ix Integrated Design Centre, 3S Laboratory, University of Grenoble, France...xi Eco-development of products and sustainable manufacturing strategies: The key interests of the Integrated Design Centre by D. Brissaud and P. Zwolinski... xiii Business Models Feasibility and scope of life cycle approaches to sustainable consumption E.G. Hertwich and G.P. Peters...3 A business-oriented approach to the product life cycle G. Molcho and M. Shpitalni...17 Meeting the Climate Change Challenge C. Rynikiewicz...33 Assessing product life cycle strategies in the Japanese market Y. Ogushi, M. Kandlikar and H. Dowlatabadi...49 Applications of service engineering methods and tool to industries T. Sakao, Y. Shimomura, M. Lindahl and E. Sundin...65 End-of-Life Strategies Towards self-disassembling products J.R. Duflou, B. Willems and W. Dewulf...87 Indicators to measure sustainability of an industrial manufacturing E. Raizer Neto, M.T.Mariotte and R.T.P.Hinz...111

vi Contents Concepts and definitions for product recovery M. Lindahl, E. Sundin, J. Östlin and M. Björkman...123 Remanufacturing of flat screen monitors C. Franke, S. Kernbaum and G. Seliger...139 Improving product recovery decisions through product information A.K. Parlikad, D.C. McFarlane and A.G. Kulkarni...153 Photocopier remanufacturing at Xerox UK A. King, J. Miemczyk and D. Bufton...173 Dynamic process and operation planning for hybrid disassembly H.-J. Kim...187 Clean technologies for recycling H.V. de Medina...199 Identifying availability contribution of lifecycle-adapted services J. Fleischer and D. Nesges...209 Product Development for Sustainability Designing products that are never discarded P. Zwolinski and D. Brissaud...225 Guidelines in ecodesign: a case study from railway industry J. Lagerstedt and C. Luttropp...245 Identifying and assessing environmentally benign modules M. Voß and H. Birkhofer...255 Strategies and material flow in ecodesign C. Luttropp...271 Screening life cycle modelling for sustainable product design M. Fargnoli and F. Kimura...281 Using design for environment for redesigning a household appliance S. Kara, H. Kaebernick and S. Ibbotson...293 Modular design of technical product-service systems J.C. Aurich, C. Fuchs and C. Wagenknecht...303

Contents vii Estimating the environmental profile of early design concepts W. Dewulf, B. Willems and J.R. Duflou...321 Product Life Cycle Management Design for environment by target life cycle costing D. Janz, M. Hornberger and E. Westkämper...337 PLM to support hazard identification in chemical plant design F. Giannini, M. Monti, S. Ansaldi and P. Bragatto...349 Smart machining systems: issues and research trends L. Deshayes, L. Welsch, A. Donmez, R. Ivester, D. Gilsinn, R. Rhorer, E. Whitenton and F. Potra...363 Development of methods to support the implementation of a PDMS J. Feldhusen, B. Gebhardt, N. Macke, E. Nurcahya and F. Bungert...381 The role of knowledge management in product lifecycle G. Colombo and D. Pugliese...397 A product-process-organisation integrative model for collaborative design F. Noël...407 Dynamic life cycle performance simulation of production systems J. Niemann and E. Westkämper...419 LC universal model for the enterprise information system structure A. Bernard, M. Labrousse and N. Perry...429 Authors index...447

Introduction to Innovation in Life Cycle Engineering and Sustainable Development This book presents a selection of papers related to the 12th CIRP International conference on Life Cycle Engineering, held at the university of Grenoble, France, in April 2005. The CIRP Life Cycle Engineering conference is an annual event and contributes to a continuous updating of research in the field of environmental issues in mechanical engineering, design and manufacturing. The scientific committee members of the conference have selected all the lectures from complete papers, which is the guarantee for the conference of quite an outstanding scientific level. After that, a new selection has been carried out to retain the best publications, which establish in a book, a state-of-the-art analysis as regards Innovation in Life Cycle Engineering and Sustainable Development. The 30 papers in the book, were selected from the 71 papers presented during the conference. Sustainable development is more and more at the core of governments and industries policy. Industrial production and consumption culture are facing dramatic changes due to pollution and waste problems, exhaustion of available non-renewable resources and rapid growth in world population. So, the environmental focus has shifted from production processes to the product's entire life cycle. The potential of technology to create synergies between environmental protection and economic growth has been recognized. Life cycle engineering aims at providing engineering tools targeted towards cleaner product-oriented activities for improving the environment while contributing to competitiveness and growth. It is within this context that the following themes were highlighted during the conference: ix

x Introduction Business models, which aims at determining how efficient can be a life cycle strategy from different point of view (customer, policy, environment, economics, ). End of life strategies, presenting recent approaches and technological solutions for end-of life treatments. Product development for sustainability, which aims at showing how designers integrate environmental considerations to improve their solutions. Product life cycle management, dealing with methods and tools to support life cycle considerations. This book is divided into four sections reflecting the above themes and will be of interest to academics, students and practitioners, specializing in environmental issues in mechanical engineering. We hope that you will find it of the greatest interest to compare your various points of view within the field broached throughout the conference. We hope you all enjoy reading this book, which aims to be a reference textbook for all researchers in this particular field and for the teaching staff confronted with training methodologies in integrated design and environment. It will allow you to assess the scope of the development prospects in an extremely wide ranging field. Finally, we would like to highlight the very significant input of the members of the organizing committee for the success of the conference and to express our sincere appreciation to all the authors and to the members of the international program committee. Daniel Brissaud Serge Tichkiewitch Peggy Zwolinski

Integrated Design Centre 3S Laboratory University of Grenoble, France The Integrated Design Centre is part of the 3S Research Laboratory sponsored by the technological university of Grenoble (INPG), the scientific university of Grenoble (UJF) and the National Centre for the Scientific Research (CNRS). Objectives For more than ten years, the activity of the Integrated Design Centre has focused on the improvement of engineering design and on the development of mechanical products/systems. New models, methods and computer tools dedicated to Integrated Design into a context of Concurrent Engineering have been developed. This aims at contributing to a better understanding of engineering design and to an improvement of the performance of design considered as a collective activity and a complex process. As seen by the research team, Design is a collaborative and distributed activity, that covers the whole product life cycle. It incorporates analysis as well as synthesis activities. Such a context involves skilled actors having points of view, knowledge and tools, interactions with an organization, shared knowledge, decision-making processes, as well as technologies for cooperation activities, for the multi-representation and for shape generation of a product. The main topics are the product-process integration and the integration of downstream activities within the design process (manufacturing, assembly, recycling, etc.), CAD and geometric modelling, design methodologies and collaborative engineering involving new IT technologies. Research is carried out strongly connected to other disciplines (i.e. industrial sociology, cognitive ergonomics, computer sciences, applied mathematics, etc.). 3 main research directions Methodologies for Integrated Design, Collaborative Engineering, Innovation. This research axis is based on observations conducted on real design processes. On-site studies in companies, experiments about the design activity to set up methodologies for analysing the design process are realised. They lead to methods for incorporating innovative solutions in a design process and they help for the management of the concept of value throughout the design process. Software tools and models for defining the product model and an integrated design environment for multi-actors: network-based, plug and play approaches, are proposed. Some experiments xi

xii Integrated Design Center are conducted to characterized synchronous and asynchronous tasks among distant or co-located designers. Concepts for providing common work environments between designers having different skills are proposed. Experiments for the evaluation of software tools used in a collaborative context help to validate these concepts. Product-process integration in design. This second research direction focuses on the formalization of knowledge and on methods related to process and production skills in mechanical design. The different explored fields are manufacturing processes (forging, assembly, machining, process planning, aluminium extrusion, composite materials), end of life processes (disassembly, recycling, re-use), tolerancing. Models for the dynamic behaviour of a machining system to improve the design process, to set up new technologies for the drilling process are examples of detailed contributions whereas concepts of product-process co-development, of product life cycle address a global level of the design process. Development of software demonstrators for product-process integration are realized to help the validation of the proposed approaches. Digital Mock-ups for Integrated Design. This direction is necessary to provide methods for performing shape changes with a digital product models. Geometry simplification, adaptation for design and downstream processes, design data adaptation and idealization for mechanical simulations, free-form shape parameterisation and deformation, shape optimisation, surface mesh generation and adaptation are examples of researches to produce such mock-ups. Methods for knowledge, know-how and services management around digital mock-ups are also addressed through the capitalization, re-use of models concerning mechanical analyses of the products. Thus, new concepts for the use of digital mock-ups in design can be evaluated through the development of software demonstrators and libraries for digital mock-ups of products. The whole team in April 2005. Prof. Daniel Brissaud, Prof. Jean-Claude Léon, Dr. Jean-Luc Marcellin, Dr. Philippe M Marin, Dr. Philippe R Marin, Mrs Fadila Messaoud, Dr. Peter Mitrouchev, Dr. Gabriel Moreau, Dr. Frédéric Noel, Dr. Henri Paris, Dr. Frank Pourroy, Dr. Guy Prudhomme, Dr. Guillaume Thomann, Prof. Serge Tichkiewitch, Prof. François Villeneuve, Dr. Peggy Zwolinski. Sabeur Bettaieb, Cyrille Beylier, Vincent Capponi, Vincent Cheutet, Alexandre Ciclet, Lidia Dejeu, Guillaume Drieux, Rosalinda Ferrandes, Gilles Foucault, Alexis Gehin, Okba Hamri, Nizar Haoues, Denis Lovinfosse, El-Hadi Mechekour, Chaiwat Noomtong, Kusol Pimapunsri, Bruno Radulescu, Vincent Riboulet, German Ruiz, Aurélie Vacher, Frédéric Vignat, Omar Zirmi, Said Zirmi.

Eco-development of products and sustainable manufacturing strategies The key interests of the Integrated Design Centre The Integrated Design Centre objective is to: promote the change toward sustainable manufacturing paradigms - lifecycle orientation of the manufacturing industries - development of product oriented services increase engineering competence - methods and tools for design and engineering contribute to environmental goals - protection and conservation of natural resources: increase of material life time - clean processes: sustainable protection and consumption practices - eco-product development: optimization of products life cycle This paper aims at presenting the recent and on-going research studies in the field at the Integrated Design Centre. Legislative constraints Design parameters : material, joining techniques, structure, pollution,... Design Wastes - pollution Energy consumption Manufacturing Life cycle Transport Packaging Distribution End of life Remanufacturing - Reuse Energy and material saving Use Maintenance Energy consumption xiii

xiv Eco-development of products and sustainable manufacturing strategies Environment and lifecycle product design The optimization of the product life cycle stages needs an integrated definition of the product throughout designing. New environmental objectives lead to support new design situations calling upon new competences, knowledge and tools. It opens the way to research on new design methodologies based on the entire lifecycle of the product, with benefit to the environmental impacts, a clean consumption and a sustainable production, and resulting in an increase of the innovative power of companies. Product Profiles to design remanufacturable products The remanufacturing is an end of life strategy that reduces the use of raw materials and saves energy while preserving the value added during the design and manufacturing processes. But, in most of the cases, remanufacturing processes must be adapted to existing products because products have not been designed to be remanufacturable. However, the process adaptations increase costs and this can lead the overall benefits obtained with the remanufacturing process to be reconsidered. The aim of our research was to propose an approach for the designers to integrate remanufacturing constraints throughout the design process and mainly in the earliest phases. For the product profiles definition, 8 categories of design criteria were identified based on a survey of about thirty products successfully remanufactured. The methodology is supported by REPRO² (REmanufacturig with PROduct PROfiles), a tool developed for a real integrated design of remanufacturable products.

Eco-development of products and sustainable manufacturing strategies xv emanufactured products products emanufactured Environmental & Market aspects Durability of parts To reduce the use of natural resources? Profiles of of products products Profiles Structure of the product & quality tests Upgradeable architecture Refurbishment & Valorisation Economic & Technical aspects Energy and materials saving From Integration of remanufacturing constraints during the design process of products, PhD thesis, 2004, Miguel Angel LOPEZ-ONTIVEROS Change in manufacturing industry to support sustainable products A sustainable product is a product which life is extended by partly or entirely re-using for a new life cycle. It contributes to a world where material is used up to its final properties and where energy consumption and wastes are minimized by keeping product added-value in use. It also impacts new ways of consumption. The project aims at examining the necessary condition to transform the industrial organisation to develop and manufacture sustainable products. It focuses on products remanufacturing and reuse strategies and covers the new economic and social paradigm to implement, the environmental impact to minimize and the engineering methodology and tools to develop. From Integrated design of sustainable products, PhD thesis, in progress, Alexis GEHIN

xvi Eco-development of products and sustainable manufacturing strategies Environment-based design methodology for innovative products A 2 years observation of the industrial practice has been realised at RENAULT. It was a mean to identify the tools and approaches used in a firm. The aim of the study was to define the industrial concept of recyclability to translate this constraint to the design. Integration resulted in adding Recyclability as constraints equivalent to the usual three industrial constraints - Quality, Delay and Costs to control the development process of a new product. From Integration of the recycling constraint during the design process, PhD thesis, 2000, Thierry GAUCHERON Disassembly for product recycling Recent actions engaged by manufacturers are focused on the recycling rate required by the European Directives on EEE. Along with traditional recycling process as shredding, improving product end-of-life treatment needs the disassembly of the product or part of it. A "Noble" recycling must be managed easily from this. Product disassembly offers new solutions for valorisation: reuse of components, high quality material recycling with better economical indicators and decrease of landfilled wastes. The design work should be assisted by methodologies early in the conceptual design phase of the product and supported by CAD/CAM software identifying and evaluating assembly/disassembly sequences and issues.

Eco-development of products and sustainable manufacturing strategies xvii From Development of disassembly methodologies for product end of life: Application to electric and electronic products, PhD thesis in progress, Nizar HAOUES Other studies A new manufacturing paradigm: the extended products and their design, PhD thesis in progress, Nicolas Maussang Trajectories to implement eco-design support in a company practices, PhD thesis in progress, Tatiana Reyes The validation and improvement of a product remanufacturability assessment and design aid, Engineering final project, Jamie O Hare

xviii Eco-development of products and sustainable manufacturing strategies Main recent publications Lopez-Ontiveros M.A., Zwolinski P., Brissaud D. Integrated design of remanufacturable products based on product profiles, Journal of Cleaner Production, to be published. Gehin A., Brissaud D., Zwolinski P. Imaging a Tool to Implement Sustainable End-of-Life Strategies in the Product Development Phase, in: Actes du 10ème congrès ERSCP, Anvers ERSCP 2005. Maussang N., Brissaud D., Zwolinski P. Design of Product-Service Systems, in: Actes du 10ème congrès ERSCP, Anvers ERSCP 2005. Zwolinski P., Prudhomme G., Brissaud D. Environment and design : Toward methods and tools for integration and co-operation, in Methods and tools for cooperative and integrated design, Kluwer Academic Publishers ISBN 1-4020-1889-4, 223-232, 2004. Zwolinski P., Lopez-Ontiveros M.A., Brissaud D. Product end of life characterisation for integrated design, International Journal of Production Engineering and Computers, vol.6, No 7, 85-89, 2004. Brissaud D., Zwolinski P. End-of-Life-Based Negotiation Throughout the Design Process, Annals of CIRP, vol 53/1/2004, 155-158, 2004. Haoues N., Zwolinski P., Cornier A., Brissaud D. How to integrate end of life disassembly constraints in the early design phases? International Journal of Production Engineering and Computers, vol.6, No 7, 59-64, 2004. Haoues, N., Froelich, D., Zwolinski, P. Disassembly for Valorization in Conceptual Design. In proceedings of the SPIE : International Conference on Environmentally Conscious Manufacturing IV, Philadelphia, October 2004., Volume 5583, 31-42, 2004. Lopez M., Zwolinski P., Brissaud D. Profile of products for the creation of remanufacturable products during the conceptual design phase. Proceedings of CIRP seminar on life cycle engineering 2003, Copenhagen (Denmark), 11p, 2003. Prudhomme G., Zwolinski P., Brissaud D. Integrating into the design process the needs of those involved in the product life cycle, Journal of Engineering Design, vol. 14, No 3, 333-353, 2003. Contact: Daniel.Brissaud@inpg.fr, Peggy.Zwolinski@hmg.inpg.fr