6/30/2017. Life Cycle Assessment

Transcription

1 Life Cycle Assessment 1

2 GODREJ INTERIO Godrej Furniture Enjoying a prime position in households and hearts of Indians for more than SIX decades. Touching lives Everyday, Everywhere 2

3 OUR WAY TOWARDS SUSTAINABILITY OUR DEFINITION FOR GREEN PRODUCTS A Godrej Green product should address at least one of the six attributes Godrej Green Product Attributes 1 Reduce energy consumption by at least 20%* 2 Reduce water consumption by at least 20%* 3 Reduce GHG emissions by at least 20%* 4 5 Reduce material used (material eff.) in products incl. packaging by at least 20%* Use 100% recyclable, renewable and/or natural material in product incl. packaging 6 Eliminate toxic materials such as PVCs, BFRs, mercury, and others. 3

4 LCA JOURNEY AT G&B. FY ANSI/BIFMA e3 Furniture Sustainability Standard Life cycle framework into product design WISH workstation LCA using ISO and ISO LCA independently third-party reviewed LCA JOURNEY AT G&B. VERSA ACE SPLIT AIR CONDITIONER SAFE DEPOSIT LOCKER UNIT NOW, WE HAVE MORE THAN 20 PRODUCTS UNDER LCA COVERAGE LCA study of wish, ace and versa are third party reviewed. 4

5 DESIGN FOR ENVIRONMENT Commitment for environment conscious design and reducing Toxicity Components of DfE Policy: Increase use of recycled & renewable material Evaluation of raw material to improve recyclability and biodegradability Evaluation of water and energy pattern Reduce use of chemicals of concerns Design consideration to reduce environmental impact at end of life LCA STRATEGY AT GODREJ INTERIO Capacity building and Incorporation of LCA requirement in NPD Conduct LCA for high volume existing products Development of product specific impact reduction strategies Implementation and tracking for the impact reduction plan Horizontal deployment of successful strategies to other products / productlines 5

6 INCORPORATION OF LCA IN NEW PRODUCT DEVELOPMENT Phase 0 Setting Design for Environment (DfE) Targets at start of projects Phase 1 DfE checklist verification of product against targets and raw material classification and evaluation through Detailed material analysis of product Phase 2 LCA of products with annual projection pcs or 500 tonnes product weight Phase 2 Design output Review against DfE checklist and targets by design Head Phase 2 Preparing Green Assurance card of product LIFE CYCLE ASSESSMENT ACE CHAIR A study for Ace range of chairs was conducted in the year This product was selected a representativeof chairs as it was selected for BIFMA Level certification PU Foam 3% Polypropylene 8% Material Composition Cardboard and Paper 16% Others 2% Aluminium 23% Nylon Brass 14% 1% Steel 33% ACE Chair Components UPHOLSTERED CUSHION SEAT (WITHOUT SEAT DEPTH ADJUSTMENT) ALUMINIUM DIE CAST PEDESTAL UPHOLSTERED NET MID BACK ASSLY ALUMINIUM DIE CAST SPINE LUMBER ASSEMBLY SELF ADJUSTING & KNEE SYNCHRO MECHANISM ARMREST ASSEMBLY LH AUTO RETURN ASSEMBLY TYPE-R1 GLIDES (GD-408) FUH-SHYAN WITH PIN A-01 HARDWARE PACKET CARTON FOR ACE CHAIR Miscellaneous ARMREST ASSEMBLY RH ACE HEADREST 6

7 LIFE CYCLE ASSESSMENT ACE CHAIR LCA overall result for 1 unit of ACE CHAIR Acidification Potential (AP) [kg SO2- Equiv.] Eutrophication Potential (EP) [kg Phosphate-Equiv.] Global Warming Potential (GWP 100 years) [kg CO2-Equiv.] Photochem. Ozone Creation Potential (POCP) [kg Ethene-Equiv.] Primary energy demand (net cal. value) [MJ] Impacts at various stages of Product Life cycle HOT SPOT IDENTIFICATION- ACE CHAIR COMPONENT WISE IMPACT DISTRIBUTION FOR ACE 7

8 SCENARIO CREATION- ACE CHAIR Scenario- Aluminium Pedestal replaced with Nylon Pedestal Environmental Impacts Acidification Potential (AP) [kg SO2- Equiv.] Global Warming Potential (GWP 100 years) [kg CO2-Equiv.] Godrej Ace Chair with Aluminium Pedestal Godrej Ace Chair with Nylon Pedestal % Reduction Toxicity Potential in [kg DCB-Equiv] Primary Energy Use [MJ] 2, Fresh-water use [kg] 415, LIFE CYCLE ASSESSMENT- HOME STORAGES LCA study was conducted for three storage category products for getting comprehensive environmental profile of these products- Slimline, Kreation, Wardrobe Goal To identify opportunities for impact reduction and provide approaches for future products KREATION X2 Scope Evaluation of environmental impact of all the activities associated with extraction of raw material necessary for production, transportation of raw material, packaging, sale of product, use of product and disposal of product. Ie adoption of Cradle to Grave approach of assessment WARDROBE H FunctionalUnit 1 cubic meter of volume space for storage SLIMLIN E 8

9 LIFE CYCLE ASSESSMENT- HOME STORAGES SLIMLIN E WARDROBE H KREATION X2 Impact categories WARDROBE H KD SLIMLINE For Comparison between these three products, LCA impact results are calculated for one cubic meter volume of storage space KRETATION X2 WITH METAL DOOR KRETATION X2 WITH WOODEN DOOR Acidification Potential (AP) [kg SO2-Equiv.] Eutrophication Potential (EP) [kg Phosphate- Equiv.] Global Warming Potential (GWP 100 years) [kg CO2-Equiv.] Human Toxicity Potential (HTP inf.) [kg DCB- Equiv.] Primary energy [MJ] LIFE CYCLE ASSESSMENT- HOME STORAGES Environment impact réduction Kreation Wardrobe Slimline Reduction as compared to Wardrobe Reduction in kg of material per unit volume of storage Reduction in Global warming potential for unit volume of storage Slimline 16 % 17 % Kreation With Wooden Door Kreation with Metal Door 30 % 43 % 30 % 31% Actions taken to reduce weight of product- Change of thickness of steel coil from 0.9 to mm Use of stiffeners for thinner gauge to provide structural stability and prevent buckling of panels Rationalisation of coil to reduce process scrap 9

10 LIFE CYCLE ASSESSMENT- ORTHOMATIC DELUXE MATTRESS Acidification Potential (AP) [kg SO2-Equiv.] 0.43 Eutrophication Potential (EP) [kg Phosphate- Equiv.] Global Warming Potential (GWP 100 years) [kg CO2-Equiv.] Human Toxicity Potential (P inf.) [kg DCB- Equiv.] HT Primary energy demand [MJ] 4255 ORTHOMATIC DELUXE 78 X 72 X 5 FOAM 84X72X120 D90 BONDED kg PEELED FOAM QUILTING (D18)5MM 0.15 kg PEELED FOAM QUILTING(D18)10MM 3.51 kg Fabric 0.28 kg Total kg Impact Classification: 78% Foaming chemicals, 20 % End of Life, 2% other (electricity, transport, fabric) 20% 2% 78% Foaming Chmemicals Other End of Life SCENARIO CREATION Scenario 1: ORTHO DELUXE MATTRESS if we use 100% internal scrap for making bonded foam Scenario 2: ORTHO DELUXE MATTRESS if we use 50% external scrap for making bonded foam IMPACT CATEGORY SCENARIO 1 SCENARIO 2 REDUCTION Acidification Potential (AP) [kg SO2-Equiv.] % Eutrophication Potential (EP) [kg Phosphate-Equiv.] % Global Warming Potential (GWP 100 years) [kg Equiv.] CO % Human Toxicity Potential (P inf.) [kg DCB-Equiv.] HT % Primary energy demand [MJ] % OBERVATION Use of external foam scrap will reduce life cycle impacts of bonded foam. Take back policy for mattresses will reduce its impact at end of life disposal phase and may increase recycled content of bonded foam. 10

11 LIFE CYCLE ASSESSMENT- SAFE DEPOSIT LOCK Electricity is the major contributor, followed by Material HOT - SPOT COMPONENTS The analysis shows that the hot spots for electricity & material consumption are 1. Base plate 2. cover plate. 3. Bolt Cover Plate Base Plate Sub assembly Bolt S/A 11

12 S.D. BOLT CONVERTING FROM BRASS TO STEEL Considerations for converting Brass Bolt to Steel. Standards mention that bolt should be in metal. It should not attract corrosion in humid atmosphere at the basement of a bank. Component is Zinc plated with Brass effect self lubricating lacquer. Reduction in environmental impacts (100% RoHS Compliant) Steel gives improved resistance to fire as compared to Brass. It should work smoothly even when operated once in 6 months / 1 year BENEFITS DERIVED Durability Test: The lock has successfully pass the cycle test of cycles and operating as per requirement (Reqd.: 20000). Corrosion Resistance Test: The lock meet the requirements of grade 2 of EN1670:1998 and found functionally proper with 1.5NM Torque even after completion of 200 hrs. of corrosion resistance. (Reqd.: 96 Hrs.) Side Load Test: The lock with Steel bolt has withstood 1.6KN load as compare to that of existing brass bolt (1.4KN) (Reqd.: 1KN) Cost reduction: 10% GWP reduction: 5% 12

13 LIFE CYCLE FOR GREEN BALANCE AIR CONDITIONER INVERTER ACs Godrej Vs Competition Best models available 500 Competitor Hitachi 3 (470%) 400 Competitor Voltas 1 (343%) Competitor LG 2 (332%) GHG(%) Godrej (125%) Godrej (118%) Godrej (100%) ISEER Assumptions: - As per Schedule 19 of BEE, air conditioner runs for Hrs for 10 years. - The contribution of use-phase is 99.9%.The electricity is the major contributor then the emission due to refrigerant*. * As per LCA study on Green Balance AC. Source thinkstep. #Internal comparison based on ts results for GAD model LIFE CYCLE ASSESSMENT FOR PACKAGING INITIATIVE Change of Thermocol to AirPlus bags Before After Impact reduction Thermocol Air Bags Environmental Impacts Global Warming Potential kgco2- eq Acidification Potential Kgso2-eq Eutrophication Potential kg phosphate-eq Primary Energy MJ Thermocol 1 kg Air Plus Bags 0.44 kg* % reduction in Impacts 69% 65% 97% 60% Reduction in Absolute terms *1 kg Thermocol is equivalent to 0.44 kg of Airbags 13

14 LIFE CYCLE ASSESSMENT FOR PROCESS CHANGE Process Change for Pre treatment- Use of Phosphate Free Chemicals Objective: To implement the green technology focused pre-treatment process by implementing low temperature & long life cleaner & phosphate free conversion coating, replacing conventional cleaner & iron phosphate. Benefits- Lesser number of dumps, Higher bath time, ETP sludge reduction, Energy and water consumption reduction in process. Impact reduction in life cycle- Global Warming Potential kgco2-eq Acidification Potential Kgso2-eq Eutrophication Potential kg phosphate-eq Primary Energy MJ Raw Material Phase Results for Impact Reduction Chemicals datasets are not available in Gabi. Exploring the option of collecting datasets from chemicals suppliers Use Phase- Power saving End Of Life- Sludge reduction BENEFITS OF LCA MEASURE ENVIRONMENTAL IMPACT OF PRODUCT THROUGHOUT LIFE CYCLE DECISION MAKING FOR MATERIAL SELCTION WHILE NEW DESIGN OR MODIFICATION IMPROVE ENVIRONMENTAL PERFORMANCE THROUGH HOT SPOT ANALYSIS IDENTIFY HOT SPOTS IN PRODUCT VALUE CHAIN FOCUS ON OPERATIONAL EFFICIENCY AND SUPPLY CHAIN AT PRODUCT LEVEL BENCHMARKING AGAINST COMPETITOR S PRODUCT IMPACT AND GAIN MARKETING BENEFITS 14

15 CHALLENGES IN LCA Time required to complete a LCA study is high. Due to lack of vendors process data, more time taken for conducting LCA in new product introduction stage Data gaps in software and company data Greener material options not readily available WAY AHEAD Developing Godrej LCA database for all manufacturing processes involved and material compositions for more consistent evaluation of environmental impacts. Using LCA as decision making tool for process efficiency improvement Collaborations with suppliers or third party tie ups for research and development of green material Cascading life cycle thinking to vendors Shifting LCA requirement in early phase of design and capacity building of all product mangers for LCA 15

16 6/30/2017 RECOGNITION Recognition of G&B for conducting maximum number of LCA studies applying GaBi software in India, at Sustain Thinkstep Annual Meet THANK YOU 16