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報告書7.8 MB - 製造科学技術センター
Contents
1.
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30. 90 SURVEY ON ENVIRONMENTALLY CONSCIOUS DESIGN IN JAPANESE ELECTRONICS INDUSTRY Keijiro Masui Tomoyuki Hata and Yasushi Umeda National Institute of Advanced Industrial Science and Technology Environmental Management for Sustainability Inc Osaka University Abstract In electrical and electronic industries some technical guides regarding environmentally conscious design ECD have been published and the standard is being prepared It is important to make them appropriate and available to manufacturers From this view points we surveyed the current status and the problems in integrating the environmental consciousness into the existing product development processes in the industries In the survey we visited fourteen manufacturers and discussed the following issues 1 Definition of eco product 2 ECD process and tools utilized and 3 ECD management scheme The survey revealed that three t
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62. ASR ASR ASR ASR
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290. Definition Criteria of assessment Labeling for ECPs e The names to environmentally conscious products are various like Eco products or green products e The standard is set so that the ratio of eco products to all products may become several percent 60 80 of products come to fill the standard in five years e Recognition of environmentally conscious design is lower than environmentally conscious products appliances Environmental aspects of products are evaluated from the three main viewpoints of material energy toxicity because these items are measurable by design engineers Environmental profile of products is actively provided to consumers The green products are recognized by the evaluation items that relate the items of product assessment used on design stages In addition the product with the feature of the industry leading might be called a Super Green Product Type II environmental labeling by ISO 14021 Self Declared environmental claim is used maker The efforts to advance the circulation type production such as parts reuse is remarkable compared with other industries Type I environmental labeling like Ecomark in Japan is essential for printers and copiers Many companies are involved in type III labeling that based quantitative evaluation Type II labeling is also used at the same time manufacturer Lower exhaust e
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300. 4 0 0 29 496 17 696 5 9 0 0 23 5 5 9 0 0 0 0 5 9 0 0 Nn X X S X 2 X N Nn X 25 0 20 0 15 0 14 3 0 0 20 0 0 0 0 0 35 0 50 0 25 0 13 3 0 0 16 7 10 0 35 0 20 0 10 0 14 3 28 6 N S X LI EN X Nn gt X X e o ER o X S eR o X o X N eo D X 29 2 33 3 8 3 45 8 133 3 4 2 12 5 58 3 8 3 4 2 0 0 70 8 37 5 Pa 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 40 0 0 096 0 0 0 0 40 0 0 0 me 10 0 00 0 50 0 30 0 i 10 0 0 0 0 096 30 0 0 0 0 096 0 0 30 0 0 0 D LI Jae H ox mue D D X X D D X X N a c CEP gt S A S N X X Tel R N w oO lt R XA ARE 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 0 50 0 0 0 50 0 0 0 0 0 0 0 50 0 0 0 0 0 0 0 50 0 50 0 23 1 23 1 0 0 15 4 30 8 26 9 34 6 19 2 57
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305. smooth and efficient discussion a questionnaire was sent to a company beforehand and the interview was carried out along the questionnaire basically The contents of the questionnaire include the three main topics as follows 2 2 1 Environmentally conscious product ECP First of all we asked progress in development of ECPs The questions include Internal name e g green product eco product definition criteria of assessment Labeling for ECPs Proportion of ECPs in all products 2 2 2 Environmentally conscious design ECD process and tools utilized Next we asked the company standard regarding to new product development process as well as ECD process We also asked which tools were utilized for ECD The concrete survey items are as follows Process for new product development described in company standard Process integrating environmental requirements to products and support tools Referred guidelines or documents e g IEC Guide 114 ISO TR 14062 product assessment guidelines published by industries association 2 2 3 Environmentally conscious design ECD management scheme The final question is concerning management scheme for ECD There are two major interests concerning ECD management One is consistency of the environmental targets for the whole company and its Table 1 Survey results on ECPs in each sector Manufacturer of electric Business machine Automobile Question Internal name
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309. 2005 4th Inter Sym on Environmentally Conscious Design and Inverse Manufacturing Tokyo CD ROM 1D 1 1F December 12 14 2005 4 M Ernzer M Lindahl K Masui and T Sakao An International Study on Utilization of Design for Environment Methods DfE A pre study Proc of EcoDesign 2003 Third Inter Sym on Environmentally Conscious Design and Inverse Manufacturing Tokyo pp 124 131 December 8 11 2003 5 M Ernzer C Gr ner and H Birkhofer Implementation of DfE in the Daily Design Work An An Approach Derived from Surveys Proc of DETC 02 ASME 2002 Design Engineering Technical Conferences and Computer and Information in Engineering Conference Montreal CD ROM DTM 34032 September 29 October 2 2002 6 Y Umeda J Fujimoto T Tamura M Tsutsumida T Tomiyama and F Kimura Proposal of Service Oriented Products based on the Inverse Manufacturing Concept 2 Report Reconfigurable Design and Life Cycle Evaluation Proc of Electronics goes green 2000 Berlin pp 211 216 September 11 13 2000 7 K Masui T Sakao M Kobayashi and A Inaba Applying Quality Function Deployment to Environmentally Conscious Design International Journal of Quality and Reliability management 20 1 pp 90 106 2003 8 Y Umeda A Nonomura and T Tomiyama Study on life cycle design for the post mass production paradigm Artificial Intelligence for Engineering Design Analysis and
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318. HHHUHHHHHUHHHHHUHHH BIHPEAHSHEEDTHEEAESHERNHSHAHEHRERHSHRHUHEERHNHEHEE HHHHHUHHHHHHHHHHL HHHHHH 1 K Masui T Sakao M Kobayashi and A Inaba Applying Quality Function Deployment to Environmentally Conscious Design International Journal of Quality and Reliability management 20 1 pp 90 106 2003 2 Y Umeda A Nonomura and T Tomiyama Study on life cycle design for the post mass production paradigm Artificial Intelligence for Engineering Design Analysis and Manufacturing Cambridge University Press 14 2 pp 149 161 2000 3 H Kobayashi Strategic evolution of eco products a product life cycle planning methodology Research in Engineering Design Vol 16 No 1 2 pp 1 16 2005 ee EE O 3058564 HHHHHHHHHH D OPERATE Eels EP EEC EDIE Teh TEL TS TEMS TEL 029 861 7226 FAX 029 861 7201 Email k masui aist go jo 18 2 WG 6 C
319. Manufacturing Cambridge University Press 14 2 pp 149 161 2000 9 H Kobayashi Strategic evolution of eco products a product life cycle planning methodology Research in Engineering Design Vol 16 No 1 2 pp 1 16 2005 OO Dk U DIL HHHHHHHL OHHHHH HHHHHHHHHk masui aist goJjp Survey on Environmental Conscious electronics Suo J0p Ead LUULU LLLLL LL 2006 HHHHHLUHEIHHHHHHHHHHHLHHHHLH Design in Japanese electrical and industry O Keijiro Masui AIST k masui aist go jp Tomoyuki Hata EMSI and Yasushi Umeda Osaka Univ Abstract In electrica and electronic industries some technical guides regarding environmentally conscious design ECD have been published and the standard is being prepared It is important to make them appropriate and available to manufacturers From this view points we surveyed the current status and the problems in integrating the environmental consciousness into the existing product development processes in the industries In the survey we visited fourteen manufacturers and discussed the following issues 1 Definition of eco product 2 ECD process and tools utilized and 3 ECD management scheme The survey revealed that three tools product assessment LCA and database of chemical substances were often utilized as design support tools while systematic design tools available in early stage of product development were not introduced Further we found that manufac
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321. Prototype Fig 1 Current ECD process and future works DR3 Bees Added value efficiency Th Business Unit Business Unit Ur 4 DISCUSSION 4 1 ECD process in Japanese electronics industry Through this survey we found the current ECD process in Japanese electric and electronics industry as shown figure 1 In this figure the items surrounded with the dotted line should be added to ECD process in the future Namely systematic design tools like QFD should be introduced in order to analyze which environmental parameters are important for satisfying the environmental requirements in early stage of product development 7 Further life cycle planning by using life cycle simulation is necessary for consideration of the optimal life cycle scenario of a product 8 9 4 2 Consistency concerning the environmental target All companies we interviewed are big companies which have several business units They have to allocate the numeric target for reduction of the environmental burden to business units Each business unit has to set the environmental target for individual product so that the amount of reduction on the environmental burden could satisfy its own target Most companies use eco efficiency as an indicator for environmental management If the definition of the added value in product s eco efficiency is different from the whole company s one it becomes more difficult to manage progress in ECD 5 CONCLU
322. RHHHHHHHHHH ES N E ee eee E eee ae ae E e E ee HHHHHHHHHH DRHHHHHHHHHHHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH ELELET E RD a E EE EE LEER E BE E E HHHUHHHHHUHHHHHHHHUHHHHHUHHH UU RR REN dh MOO 3 2 a ene HHHHHHHHHHHHHUHUHHHHHHHHHHHL HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHUHHHHHUHHHHHHHHHHHHUHHH HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHHHHHH HHHHHHHUHHHHHHHHHUHUHHHHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH C EE E RO ON EO E OO RN E NOE NAO EEEE BE EEE EE EI ETL EVERBI BU BEER ETE nooo oo f 000000 00000000 eRASQOUUUUUU HHHHHHUHHH UUDUUUUUD UUDUUUUUD UUDUUUUUD HHHHHUHHL 33 HHHHHHHHHHHHHHHUHHL HHHUHHHHHHHHUHHHHHHHHHHHHL HHHUHHHHHUHHUHHHHHUHHHHHUHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH EL EPOEEPEPBU BET E BEBE PETERE BT PEE BD B HHHUHHHHUHHHHHHHHUHHHHUHHH HHHUHHHHHUHHUHHHHHUHHHHHUHHH HHHHHHUHHHHUHH HHHUHHHHHHHHUHHHHHHHHHHHHL HHHUHHHHHUHHHUHHHHHUHHHHHUHHH BEHPEAHSHSELUPEAHSHRENESHAHSHREAHSHEHUHRERHNHEHNE HHHUHHHHHUHHHUHHHHHUHHHHHUHHH HHHUHHHHHUHHUHHHHHUHHHHHUHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH HHHUHHHHHUHHHHHHHHUHHHHHUHHH HHHUHHHHHUHHHUHHHHHUHHHHHUHHH HHHHUHUHHHHHHHHHUHHHL 4 HHHHHHHHHHHII Ax GRE EWE GEC ET E ETE SE HHHHHHHUHHHHHHHHHUHUHHHHHH BREE REECE EA REAR e NEN RE Ree Roe Ae Re eee eye HHHUHHHHUHHHHHHHHUHHHHUHHH a A a sdds NE HER e oo ye a aa H ro o O ET A A ES
323. SION The survey revealed that three tools product assessment LCA and database of chemical substances were often utilized as design support Added value Sales volume Pr Business Unit Business Unit i Se Added value Function of product Fig 2 Consistency concerning the environmental target tools while systematic design tools available in early stage of product development were not introduced Further we found that manufacturers require strategic approach which assures consistency between the companywide environmental goal in the medium term and the environmental target to individual product 6 ACKNOWLEDGEMENTS This survey was executed as an activity of Inverse Manufacturing Forum funded by Ministry of Economy Trade and Industry Authors would like to thank all the interviewed company representatives and the committee members who cooperated with this survey 7 REFERENCES 1 H Kaebernick and S Kara Environmentally Sustainable Manufacturing A Survey on Industry Practices Proc of 13 CIRP Inter Conf on Life Cycle Engineering Leuven pp 19 28 May 31 June 2 2006 2 B Kuhrke S Feickert and E Abele LCA and EcoDesign in the German Electronics Industries Proc of 13 CIRP Inter Conf on Life Cycle Engineering Leuven pp 317 321 May 31 June 2 2006 3 M Lindahl Designers Utilization of and Requirements on Design for Environment DfE Methods and Tools Proc of EcoDesign
324. So Sn oae s DS S Honest i NER on ANE jn i ee Pinna E a e ee I MO PUT aliene a Ne MS ms ee NU RAS ND i OT m SONNEN Mtm NES ERSTES MIS CRIME j A i IR RR A ANNE a OD NN UN NN MUS UE IA NN TURAE a ee MAE 0 ian Ih E li i his 0 ANUN TR IIE i SR OR EUN Pip MM eT iun Se enim NS on Ue m mno jeep uet 9 ON NM i IO A 3 RUIN SUR OM j i ERES BRA nes D il 1 A UE NIS nmm i Sut PATI j p ies pa Hci RR i im SU B 6 i 2 Jette Sa NU lL A EATON AUST GO ASMA OATES IS SOD BE ESE MUTA APR ROBES AIS PSS ICTS ON oen n e sp GHD ea GT ER NS A ND SOUS SCHRIEB reer Troe eh rite Trt ROGER SO MER DE PE GERAIS YON eng ST Teta I sei E NRE ns tM utt Mes PAINE REI 3 Homme mnm EE ROOMY TIE Step 3 Step 2 Siete rec ee mie ee en ITTR permets MMO ee if IOM FUTT ESTO RN SIT THEATER Hae II DS tdeo n Bump SRI n EEN RUPES ERTEILEN SUMMUS A Dona le i ii i AAV SAREE NM seo TRE tea Mp RN ONAN SEX SI MORS Meson QS M PAGOS ORR QU RAE K wits SUM COMM CNET T A vert tp Mein eio Mittit abesse RUD OP 2 ee Se Te D RR ee ch ls andes IN i i erre D e ro T iS SUEDE d Hino eS en met nn it x f Jn SINT ENN So cH SUR SEA e enl aa Bint i Sateen s NNN EMMA MOMMA Meee Me d pura SRI S qun lll RR ADVAN e un
325. UE 28 8 4 Yo 4 956 _ _ 20 ho m 4 4 8 14 O J375 cs 21 4 21 6 14 38 16 2 1 A 72 6 36 6 IJ3 I 32 5 mu 3 13 8 4 J Moss EuP RoHS WEEE S 2 3 122 2 3 e e RoHS ROHS 2006 7 J Moss
326. development Table 3 management scheme Many companies use the idea of environmental efficiency eco efficiency and its factor as an indicator for measuring progress of ECD shows the survey results on ECD Eco efficiency is a good indicator when we consider trade off between functionality of product and the Table 3 Survey results on ECD management scheme common eEnvironmental goal of the whole company is set in its midterm plan eln many cases the environmental target of individual product is not consistent with the environmental target of the whole company see section 4 in this paper eMany companies use the idea of environmental efficiency eco efficiency and its factor as an indicator for environmental improvement eThere are various ways to evaluate functionality of a product that is the numerator of environmental efficiency elt is important to integrate environmentally conscious design into usual product development processes Namely it is necessary for manufacturer to construct the system by which designer can work on ECD in extension of usual task Manufacturer of electric appliances e In some cases the environmental targets of the whole company and each business unit are decided at the conference where the representatives from the environment division and each business unit participate The environmental target for individual product is often set inside business
327. function Therefore the development of environmentally conscious product accompanies a hardware technological innovation e Preparation for RoHS was very difficult because the information of chemical substances had to be collected along the supply chain Especially it was severe for the small and medium sized enterprises to response to the requirement environmental burden There exist various ways to evaluate functionality of a product however standardization for the measurement of functionality seems to be necessary Further some companies take sales volume as the added value which is the numerator of the environmental efficiency when they set the environmental target for the whole company see section 4 in this paper The distance between new product development and ECD is becoming closer For instance some companies have constructed the system that automatically calculates the environmental burden from the result of the product assessment or CAD data As aresult designer s task is reduced and ECD comes to be merged with usual product development Life cycle a simulation 3 1 QFD v I Current ECD process in electronics industry Product profile Environmental target DRO Elemental tech Process tech Product planning available Conceptual design Product assessment Evaluation criteria Chemical substances database Testing
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330. ltaneously practiced in the new product development process The following researches are enumerated as the ones of treating the concrete relation between product development and ECD Lindahl et al focused on ECD method and tools and compiled the feature of the ECD tools accepted easily by the designers 3 4 Ernzer et al executed survey to the manufacturers in Germany and considered the strategy for implementation of ECD in the daily design work from the viewpoint of the new product development process and the organization in the company 5 The Life Cycle Design LCD Committee organized in the Inverse Manufacturing Forum established in 1996 has examined upgradability of the product and possibility of parts reuse from the standpoint of design method 6 For the purpose described above this committee surveyed the current status and the problems in integrating the environmental consciousness into the existing product development processes in the Japanese industries last year 2 METHODOLOGY 2 1 Object of interview In the survey we visited eight manufacturers of electronic appliances such as washing machines and air conditioners three business machine manufacturers producing copiers and printers and three manufacturers in automobile industry for comparison We made interviews and discussion with product design engineers and technical staffs from the environmental management department 2 2 Questionnaire For the
331. mission car is recognized as a green product Fuel consumption exhaust gas and noise are main targets to improve However the above three items have been considered as the essential qualities and performances of products Chemical substances management at manufacturing stage is promoted through supply chain Recyclability has been recognized as important concern on design issues Table 2 Survey results on environmentally conscious design process and tools common Manufacturer of electric appliances e Environmental must be carried out on review DR according to the standard 1n the Business machine maker e Green purchase is big motivation of environmentally conscious design e Green procurement and chemical Automobile manufacturer e Use of IMDS is in progress in automobile industry When LCA is executed the data on parts and materials should be provided from Question ECD e Design Review DR is process executed on each design product stage such as product assessment planning conceptual design detail design and Design testing prototype e Main ECD support tools are Design product assessment tool company support LCA and chemical tools substances database e Disassemblability evaluation Their tool was used but it is not product often used One of the assessment reasons is that design and engineers have already Referred recognized the points of g
332. n management have progressed items e Some companies are equipped with digital tools such as 3D CAD so that LCA are carried out easily product or Eco product Generally recognition level of ECP is higher than that of environmentally conscious design ECD It seems that the result of low environmental impact is more important for manufacturers than the process of ECD In terms of environmental labeling for ECPs manufacturers of electric appliances and business machines are active in disclosing the environmental information compared with automakers 3 2 ECD process and tool utilized Table 2 shows the survey results on ECD process and design support tools utilized Product development process usually consists of four stages such as product planning conceptual design detail design and test prototype Design review DR follows the each product development stage There are three major ECD tools which are product assessment tool LCA and chemical substances database DR is important in ECD process as well as in the process of anew product development So product assessment tool is necessarily used to check the progress of ECD on every DR On the other hand systematic design tools like QFD available in early stage of product development were not introduced 3 3 ECD management scheme Question ECD management scheme goal setting linkage between new product development and ECP
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334. ools product assessment LCA and database of chemical substances were often utilized as design support tools while systematic design tools available in early stage of product development were not introduced Further we found that manufacturers require strategic approach which assures consistency between the companywide environmental goal in the medium term and the environmental target to individual product 1 INTRODUCTION The approach on the environmental protection of the enterprise shifts from environmental consideration in the factory to the development of environmentally conscious product ECP because of the strong concern for environmental aspects of the product in recent years Therefore the importance of the environmental conscious design ECD increases more and more Especially in electrical and electronic industries some technical guides regarding ECD have been published and the standard is being prepared in IEC TC111 It is important to make them appropriate and available to manufacturers First of all it is necessary to understand the current state of the approach of ECD in the industrial world Some survey researches about current status and the spread strategy of ECD in the industries have already been done e g 1 2D Some of them are the questionnaire surveys concerning the motivation ECD tools used and the environmental aspects considered in the enterprises however they are not investigations how ECD is simu
335. turers require strategic approach which assures consistency between the companywide environmental goal in the medium term and the environmental target to individual product 1 OUUU HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHL Technical Gude IEC TC 111 O Sandad i rii i B b a UO B 7E B 7E 7 7T 7 HE E L HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL HHHHHHHHHHHHHHHHHHHHHHHHL 2 UUUU ei HHHHHHHHL HHHUHUHHHHHHHUUHHHHHHHHHHHL HHHUHHHHHUHHHHHHHHHHHHUHHH HHHUHHHHUHHHHHHHHHHHHUHHH HHHU3HHHUHHHHHHHUHHHHHHHHH HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHHHUUHHHUHHHHHHHHHHHHH 22 JUUL HHHUHUHHHHHHHUHHHHHHHHUHHHL HHHUHHHHHUHHHHHHHHHHHHUHHH HHHHHUHHHHUHHHHHHHHHHHHL 221 HHHHHHHHUHHL HHHHUHHHHHHHHHHHL 0000000 L 0000000 L rHHHUHHHHHHHHUHHHHH 222 HHHHHHHHUHHHUHHHHHHH HHHHHHHHHHH HHHHL HHHHHHHHHHHHRSOHHHHHHHHHHL HHHHHHHHHL 223 HHHHHHHHHHHHL 00000000L rHHHHHHUHHHHHHHHUHH rHHHHHHUHHHHHHHHHUHH 3 IU LL 31 HHHHHHHHHHHHHH HHHUHUHHHHHHHUUHHHHHHHHHHHL HHHHHHHHHHHTHHHHHHHHH d U HHHHHH HHHHHHHHHHHHHHHT HH HHHH HHH HHHHHH HHHHHHHHHH HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHUHHHHHUHHHHHHHHHHHHHUHHH HHHHHUHHHUHHHHHHHHHHHHHHHL UU HHHHHHHHHHHHHL DU i UD ODD HHHHHHHH elHHHHH e HHHHUHHHHHHHH e HHHHHHHHL HHHHHHL slHHHHHHHHHHHH Ug Dip
336. uideline disassemblability without their using such tools e Product design considering product s lifecycle has been executed but the design of product lifecycle itself is not examined enough e Product designers do not know well the international guidelines related to ECD such as ISO TR 14062 products The other one is implementation structure of ECD For instance in some companies the environmental expert might be involved in product development from the early stage of design On the other hand the environmental expert might only check the environmental aspects of the product which design engineers have developed in some companies Related to these issues we investigated the following items Indicator for the environmental target management In terms of environmental targets of products goal setting process on design specification Role of each division involved in ECD Internal interaction between each division 3 RESULTS 3 1 Survey results on ECP Table 1 shows the survey results obtained through the interviews There are various ways to call environmentally conscious products like Green criteria are made referring to the guidelines of the industrial association suppliers along the supply chain Product assessment guideline of industrial association focuses on recyclability Introduction of 3D CAD has progressed but it is not used for the purpose of ECD substances ow
337. unit The approaches that promote the designers ECD are executed in some companies For instance the education concerning ECD is executed to the designers In addition the designers ECD synchronizes with their performance evaluating Environmental consciousness might be achieved by the element technologies like newly developed materials and energy saving technologies proposed from research division For this case feasibility study is examined at the former stage of product planning Business machine maker e As for the environmental consideration items such as energy saving and parts reuse they might be treated as well as the conventional design requirements and ECD is advanced without especially considering Environment Some companies attach importance to the education of training related to ECD and the demand extraction from the recycling site etc The acquisition of high quality recycled material becomes a problem for advancing utilization of recycled material Automobile manufacturer e he restriction is big driving force for advancing environmental responsiveness Technological development 1S usually progressed with a target that is higher than restriction level e LCA is basically implemented by the specialist of environmental management department e The improvement of an environmental performance is often the same as the improvement of the product
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