Case Studies (part 1)

Alarm signaling devices

Fulleon Ltd

"We have found that using cleaner design techniques within a concurrent approach has resulted in effective product development." (Mr TS Strong, Managing Director)
Significant cost savings and environmental benefits could be achieved by considering a comprehensive approach to the redesign of break-glass call point products. The benefits to Fulleon Ltd of applying this approach to the call point redesign include:
• 35% reduction in the number of components making up the product
• 27% reduction in weight of plastic used
• 35% reduction in assembly time

A product development team was set up for finding improvement potentials concerning the whole life-cycle. Meetings with other experts at the end of each phase of the redesign process, helped to meet all essential requirements and to shorten product development time. Checklists were used to keep the general overview.

Environmental benefits:

• Reduced material consumption

Economic benefits:

• Cost savings of £92 650/year

Audio technology

Konftel AB (Umeå, Sweden)

The Swedish company Konftel AB actively implemented green design strategies already in the 1990s due to requirements from customers' procurement departments at e.g. telecom companies. First activities have been supported by a funded project, leading to a continuous commitment to eco-design. Konftel uses LCA tools and realised increased cost efficiency for their products.

Environmental benefits:

• Reduced energy consumption (stand-by function added)
• Reduced material variety

Economic benefits:

• Reduced transport costs due to reduced product and packaging weight and size

Audio and medical equipment, electronics manufacturing service

IMM Group (Mittweida, Germany)

IMM is supplier for audio and medical equipment. To name some products: PCI/PCMCIA Interface PCBs, high end devices for sound studios, USB decoupler. IMM also acts as electronics manufacturing service. In 2005 approx. 200 employees work for IMM.
The company philosophy includes the target: "Producing efficiently by saving natural resources. To link profitability and ecology is seen as a chance for sustainable business success in the present and future."

Environmental benefits:

• Leadfree transition and increase in energy efficiency of the production facilities

Economic benefits:

• Reduced energy costs

Automotive electronics

Connaught Electronics Ltd. (Ireland)

Connaught Electronics Ltd (CEL), dedicated to the design and manufacture of electronic systems, is one of Ireland's leading suppliers to the luxury automotive electronics sector. CEL highlighted a need to create efficiencies and cost reductions in their business and operational processes.
The ESP project was to improve the environmental performance (including manufacture, use and ultimate disposal) of these RKE (remote vehicle security keyless entry) units. The project resulted in the substitution of the unit's principal sub component (previously an import) with CEL's own component while also achieving significant environmental benefits, namely a 40% reduction in materials content (particularly hazardous materials) and a three fold reduction in the unit's energy demand. The new unit is also easier and cheaper to produce.

Environmental benefits:

• 40% reduction in materials content (particularly hazardous materials)
• three fold reduction in the unit's energy demand

Economic benefits:

• new unit is easier and cheaper to produce

Computer equipment

The Austrian Centre of Excellence for Electronic Scrap Recycling & Sustainable Product Design

Eco-mouse - an EcoDesign role model|
The Austrian Centre of Excellence for Electronic Scrap Recycling & Sustainable Product Design has developed an EcoDesign computer mouse - Eco-mouse.
Eco-mouse represents the implementation of a comprehensive, ecologically based approach, which consists of: improved power management, employment of components with low levels of hazardous substances, a casing made of renewable materials, lead-free soldering, and recycling-oriented product design.
The objective was to create a role model for EcoDesign of elec-trical and electronic products and to show the innovative bene-fits of EcoDesign.

Environmental benefits:

• Reduced energy consumption
• Leadfree transition and reduction of hazardous substances in general
• Use of renewable materials
• Enhanced recyclability

Economic benefits:

• Not applicable (technology demonstrator)

Electronics Manufacturing Service

Dinema spa (Italy)

The SME Dinema spa. is a leading Italian enterprise for production of electronic circuits as OEM and EMS. Dinema is the electronic part of the Lonati group. Dinema initiated a ?Project RoHS?, aimed at achieving compliance with RoHS and WEEE directives on an organisational, technical, and logistics level. The actions undertaken in the project can also be seen as a first important step in the analysis of the product, having the framework of an IPP strategy in mind.

Environmental benefits:

• RoHS and WEEE compliance

Economic benefits:

• Managemental synergies in legal compliance

Entrance control systems

Gunnebo Entrance Control (Sweden)

GEC manufactures entrance control systems and conducted an ecodesign project for a specific product. Realised improvements comprise better energy efficiency, enhanced recyclability and reduced number of parts and materials. Especially the latter imposes economic benefits.

Environmental benefits:

• Reduced energy consumption (up to 90%)
• Less material consumption

Economic benefits:

• Fewer product parts led to fewer suppliers and lower distribution costs

Gas transportation and devices

Transco Plc

The aim was to improve an existing hazard lamp by taking ecodesign requirements, like minimization of diversity of materials, using energy in an efficient way and implementing a modular design concept, into account.
The implementation of ecodesign principles also brings a few financial benefits generated through a reduction in battery purchase, collection and disposal costs, extended life cycle of the product and an improved public image. The design was recently awarded the Welsh Development Agency Technology Prize for Energy and also won an Institute of Engineering Design Award.

Environmental benefits:

• Increased product life time and repairability
• Reduced battery (hazardous) waste

Economic benefits:

• Adding up the savings from having to buy new batteries, time spent replacing stolen and damaged lamps and paying for appropriate disposal the potential savings calculated by Transco could be as much as £500,000 a year

Hearing devices

Bo Edin AB (Sweden)

The main business of the Swedish company Bo Edin is loop amplifiers. Main eco-design activities focussed on energy efficiency as well as phasing out now banned materials. Bo Edin conducted a Life Cycle Analysis to achieve an Environmental Product Declaration, expecting a better position in the market.

Environmental benefits:

• Reduced energy consumption in stand-by mode

Economic benefits:

• Environmental Product Declaration (EPD) is expected to result in a better market position

Heat exchangers and radiators

Jaga

The Belgian company Jaga manufactures heat exchangers and radiators (400 employees).
Philosophy: 100% satisfaction for specific target customers, internationalisation is a very important aspect and there is significant pressure from the market. The focus on high quality products covers at Jaga explicitly also environmental aspects. Image building is very important to Jaga. In 2001 Jaga initiated an ecodesign project, targeting first at obtaining knowledge on the environmental profile of their products. Benchmarking with competition is a key issue: "How good are we in our sector"?.
The project was undertaken in cooperation with the Belgian VITO, using the software Ecoscan based on eco-indicator 99. Jaga performed for one of their heat exchangers a calculation of the environmental performance according to the LCA methodology.

Environmental benefits:

• Increased energy efficiency (optimized heat exchange)

Economic benefits:

• Image building and increased customer satisfaction