Sustainable Product Design and Development

Cover
Half Title
Series Information
Title Page
Copyright Page
Dedication
Table of contents
Preface
Author Biographies
1 Introduction
	1.1 Definition of Sustainability
		1.1.1 Performance Evaluation of the Economic Pillar
		1.1.2 Performance Evaluation of the Environmental Pillar
		1.1.3 Performance Evaluation of the Societal Pillar
		1.1.4 Sustainable Product Indicators for the Economic Pillar
		1.1.5 Sustainable Product Indicators for the Environmental Pillar
		1.1.6 Sustainable Product Indicators for the Societal Pillar
	1.2 Definition of Design and the Engineering Design Process
		1.2.1 The Engineering Design Process
	1.3 Selection of Materials
	1.4 Selection of Machining Processes
	1.5 What is Design Review?
		1.5.1 Soft-Hard (S-H) Review
	1.6 Designing a Product for Functionality
		1.6.1 Case Study: Can Opener
			1.6.1.1 Guideline Development for Can Opener
		1.6.2 What Are the Manufacturing Attributes That Affect Functionality?
		1.6.3 Development of Linkages to Connect Functionality with Manufacturing
			1.6.3.1 QFD House 1: Transforming Functional Requirements into Technical and Design Requirements
			1.6.3.2 QFD House 2: Product Deployment—Converting Technical Requirements into Product Features
		1.6.4 Functionality Evaluation Test: Development of a Survey
	1.7 Designing a Product for Usability
	1.8 Golden Rules of Sustainable Product Design
	1.9 Conclusion
	References
2 Environmental Legislations
	2.1 Introduction
	2.2 Examples of Some Environmental Legislations around the World
		2.2.1 Environmental Legislation for the State of New York
		2.2.2 Environmental Legislation for the State of Illinois
		2.2.3 Environmental Legislation for the State of Virginia
		2.2.4 Environmental Legislations in Germany
		2.2.5 Environmental Legislations in France
		2.2.6 Environmental Legislations in England
		2.2.7 Environmental Legislations in the EU
		2.2.8 Environmental Legislations in the Netherlands
		2.2.9 Waste Electrical and Electronic Equipment (WEEE) Directive in the EU
		2.2.10 ROHS Directive
		2.2.11 R2 Standard
		2.2.12 E Stewards Standard
		2.2.13 Environmental Laws in China
		2.2.14 Product Takeback Law in India
		2.2.15 Product Takeback Program: Caterpillar Reman
		2.2.16 Product Takeback Program: Dell
		2.2.17 Product Takeback Program: Ford
		2.2.18 Product Takeback Program: Daimler
	2.3 Key Takeaways from State Laws Dealing with Disposal of Electronic Waste
		2.3.1 Takeaway 1
			2.3.1.1 E-waste Collection Volume Depends on Collection Infrastructure and/or Clearly Documented Collection Goals
		2.3.2 Takeaway 2
			2.3.2.1 Manufacturers Often Adhere Strictly to State Laws and Will not do any More than Required
		2.3.3 Takeaway 3
			2.3.3.1 Some States Whose Laws Cover Cost of Collecting e-Waste Have Higher Collection Numbers
		2.3.4 Takeaway 4
			2.3.4.1 Goals for e-Waste Collection Should be Set High and They Should be in the Form of Minimums
		2.3.5 Takeaway 5
			2.3.5.1 Manufacturers Seem to Prefer Collection in Urban Areas Over Rural Areas
		2.3.6 Takeaway 6
			2.3.6.1 The Level of Recycling is Enhanced by Bans on Landfills
		2.3.7 Takeaway 7
			2.3.7.1 Environmentally Responsible Handling of e-Waste is Ensured by Proactive Decision Making on the Part of the Individual
		2.3.8 Takeaway 8
			2.3.8.1 Remember: Despite the Obvious Advantages of Recycling, Reusing a Product is Always Preferable to Recycling it
		2.3.9 Takeaway 9
			2.3.9.1 Consumers Would Like to Bring Back “all” Electronic Products not Just a Few Selected Ones
		2.3.10 Takeaway 10
			2.3.10.1 Product Takeback Programs Should be Transparent
	2.4 Conclusion
	References
3 Design for Disassembly
	3.1 Importance and Definition of Design for Disassembly
	3.2 Disassembly Process Planning
	3.3 Design for Disassembly Guidelines
		3.3.1 The Need for Extensive Assembly Should be Minimized
		3.3.2 Configuration of the Product Should Always be as Predictable as Possible
		3.3.3 The Process of Disassembly Should be Facilitated as Much as Possible
		3.3.4 Product Should be Easy to Handle
		3.3.5 Components Should be Designed so They Are Easy to Separate
		3.3.6 Part Variability Should be Reduced
	3.4 Product Modularization for Disassembly: Design Approach to Disassembly
	3.5 Disassembly Algorithms and Sequence Plans: Reactive Approach to Disassembly
	3.6 Using Predetermined Motion Time Systems (PMTS) to Evaluate Ease of Disassembly: Proactive Approach
	3.7 Framework of an Interactive System for Design for Disassembly
		3.7.1 Computing Disassembly Time
		3.7.2 How Does the Interactive Design for Disassembly System Work?
		3.7.3 Case Study
		3.7.4 How is a Product Being Designed Based on Current Practice and Literature?
		3.7.5 Solution in the Form of Design Modifications
		3.7.6 Design Option I
		3.7.7 Design Option II
		3.7.8 Design Option III
		3.7.9 Advantages of the Proposed System
	3.8 Conclusion
	References
4 Designing for Assembly
	4.1 Definition and Importance of the Assembly Process
	4.2 Definition of Design for Assembly
	4.3 Types of Assembly Methods
	4.4 Different Modes of Assembly and Design Guidelines to Facilitate Them
		4.4.1 Design Guidelines for Manual Assembly
		4.4.2 Design Guidelines for Automatic Assembly
		4.4.3 Design Guidelines for Robotic Assembly
	4.5 Methodologies for Evaluating DfA
		4.5.1 The Hitachi Assemblability Evaluation Method
		4.5.2 The Procedure for Design Analysis Using Hitachi Evaluation Method
		4.5.3 The Lucas DfA Evaluation Method
			4.5.3.1 Functional Analysis
			4.5.3.2 Feeding Analysis
			4.5.3.3 Fitting Analysis
			4.5.3.4 Manufacturing Analysis
		4.5.4 The Boothroyd Dewhurst DfA Method
		4.5.5 A DfA Methodology Based on MTM Standards
	4.6 Conclusion
	References
5 Designing for Maintenance
	5.1 What is Maintenance?
	5.2 What Are the Factors That Affect Maintainability?
	5.3 Elements of the Maintenance Operation
	5.4 Types of Maintenance Procedures
		5.4.1 Corrective Maintenance
		5.4.2 Predictive Maintenance
		5.4.3 Maintaining a Degrading System
		5.4.4 Aggressive Maintenance
	5.5 Planning for Maintenance and Its Management through Design Review
		5.5.1 Reviewing Design Specifications at the Initial Stage
		5.5.2 System Review before Delving into Detailed Design
		5.5.3 System Review Post Equipment Design
		5.5.4 Evaluation of Equipment
			5.5.4.1 Evaluating the Concept
			5.5.4.2 Device Performance Index (DPI)
			5.5.4.3 Analyzing the Profile of the Parameter
		5.5.5 Analysis of Components
	5.6 Models Used to Facilitate Equipment Design for Ease of Predictive Maintenance
		5.6.1 The RCA Method
		5.6.2 The Federal Electric Method
		5.6.3 Design Attributes for Enhancing Maintainability of a Product
		5.6.4 The SAE Maintainability Standard
		5.6.5 Location (SAE J817)
		5.6.6 Access (SAE J817)
		5.6.7 Operation (SAE J817)
		5.6.8 Miscellaneous Considerations (SAE J817)
		5.6.9 Frequency Multiplier (SAE J817)
		5.6.10 The Bretby Maintainability Index
		5.6.11 Description of the Index
		5.6.12 Part 1 of the Index: Accessibility
		5.6.13 Part 2 of the Index: Operations
		5.6.14 Bretby Index: Other Features
		5.6.15 Using the Index
	5.7 Design Recommendations for Ease of Maintenance of Air Force Weapon Systems
		5.7.1 Design Requirements for Accessibility
		5.7.2 Types of Access in Order of Preference
		5.7.3 General Design Requirements for Accessing a Component
		5.7.4 Shape of Access
		5.7.5 Location of Access
		5.7.6 Size of Access
		5.7.7 Design Requirements for Handles
		5.7.8 General Requirements When Designing Handles
		5.7.9 Location of Handles
		5.7.10 Additional Use of Handles
		5.7.11 Design Requirements for Fasteners
		5.7.12 General Fastener Requirements
		5.7.13 Types of Fasteners in Order of Preference
			5.7.13.1 Quick Disconnect Devices
			5.7.13.2 Latches and Catches
			5.7.13.3 Captive Fasteners
			5.7.13.4 Combination—Head Bolts and Screws
			5.7.13.5 Regular Screws
			5.7.13.6 Bolts and Nuts
			5.7.13.7 Internal Wrenching Screws and Bolts
			5.7.13.8 Rivets
	5.8 Conclusion
	References
6 Consideration of Reuse, Recycling and Remanufacturing
	6.1 Introduction
	6.2 What is Product Reuse?
	6.3 Product Modularization for Ease of Reuse
	6.4 What is Recycling?
	6.5 Types of Recycling
	6.6 Components of a Recycling System
	6.7 Design for Recycling
		6.7.1 Criteria Applicable to Individual Components
		6.7.2 Criteria Applicable to Subassemblies
		6.7.3 Criteria Applicable to Disassembly Operations
		6.7.4 Criteria Applicable to the Entire Product
		6.7.5 Criteria Applicable to Recycling Logistics
	6.8 Assessing Recyclability
	6.9 Manual Material Separation versus Mechanical Separation
	6.10 Design Guidelines for Material Separation
	6.11 Applying Material Selection Guidelines to Different Scenarios
	6.12 What is Remanufacturing?
	6.13 Comparing products that Have Been Remanufactured, Recycled, Reconditioned and Repaired
	6.14 What Type of Products Can be Remanufactured?
	6.15 Conditions Necessary for Remanufacturing to be Profitable
	6.16 Types of Remanufacturers
	6.17 Guidelines for DfRem
	6.18 Benefits of Remanufacturing
	6.19 Metric Development for Assessing Remanufacturability
	6.20 Case Study to Evaluate Product Remanufacturability
	6.21 Conclusion
	References
7 Costing for Sustainable Product Design
	7.1 Introduction
	7.2 Basic Definitions and Types of Cost
		7.2.1 Types of Indirect Costs
	7.3 Mathematical Models to Predict Development Costs for Various End-of-Life Options
		7.3.1 Recycling Cost
		7.3.2 Remanufacturing Cost
		7.3.3 Refurbishing Cost
	7.4 Conclusion
	References
Index