Design for Disassembly (DFD)

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Design for Disassembly (DFD)

• By Tyler Britten
• OISM 470 W

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What will be covered

• What is DFD?
• Why DFD?
• How does DFD work?
• Who currently uses DFD?
• How can you use DFD?
• Resistance to DFD
• Summary

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What is DFD? (1/3)

• Design for Disassembly(DFD) is
• A type of green manufacturing
• 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.

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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..

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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

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Why DFD?

• Unlike other green business programs, DFD has
  financial benefits as well as environmental ones.

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Why DFD?

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

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Why DFD?

• 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.
• Similar legislation is expected in the US in the
  not-to-distant future.

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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

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Green Product Designfrom a Environmental
Perspective

• Design for Disassembly
• Slows the depletion of Natural Mineral Resources
• Lower 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.

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Green Product Designfrom 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.

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Green Product Designfrom 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

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How Does DFD work?

• Design for Disassembly/Green Design
• Emphasis on reducing parts
• Rationalizing materials
• Reusing components
• Green Products more efficient
• to build and distribute than conventional ones

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How Does DFD work?

• Design for Disassembly/Green Design
• DFD experts fit into Concurrent Engineering
  teams easily
• DFD reduces waste, which is an enemy of total
  quality management

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Examples of DFD

• Eastman-Kodak
• Hewlett Packard
• Vehicle Recycling Development Center

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Eastman-Kodak

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

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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.

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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.

• Recycled over 39 million hp LaserJet cartridges
  worldwide
• HPs workstation designers new chassis reduces
  transport packaging by 30, while disassembly
  time has been cut 90.

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Vehicle Recycling Development Center

• Established in 1994
• Joint venture of GM, Chrysler, Ford
• Goals of VRDC
• Finding ways to recycle automobile "fluff"--the
  25 or so of material remaining after recycling
  of the ferrous, nonferrous, and other readily
  recycled components.
• Finding ways to more cost-effectively disassemble
  cars, including removal of fluids.

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How to implement DFD

• DFD is easily implemented in most Quality
  Strategies
• DFD involves considering the products entire
  life cycle.

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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.

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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

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Resistance to DFD

• 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

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Summary

• DFD involves examining a products entire life
  cycle
• DFDs benefit, both financial and ecological,
  outweigh the costs
• DFD is important part of a firms quality
  strategy.

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Summary (cont.)

• Many European Countries will soon require DFD by
  law
• Germany is the worldwide leader in DFD
• There is a resistance to DFD by United States
  consumers who want 100 new products

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Bibliography

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