SustainableSustainable Product DevelopmentProduct DevelopmentSustainable Sustainable Product Development Product Development with with

Green DesignGreen Design WorkbenchWorkbenchTMTM**Green Design Green Design WorkbenchWorkbench

Agenda

Section 1

Section 2

Green Business Drivers & Sustainability Challenges

Green Design WorkBench™ Introduction

Environmental Regulatory Compliance Management SolutionSection 3

Section 4

GDW Benefits Summary

Global Compliance Solution Case study – Hi-Tech Giant

Section 5

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Business Drivers & Challenges in Green / Sustainability

Business Drivers in Sustainability

Cost of non-compliance to Green

Business Challenges

Lack of collaboration among globally spreadCost of non compliance to Green

Cost of in-action on Green initiatives –impact on Carbon Credit

Increased consumer preference for

Lack of collaboration among globally spread R&D teams

High cost of green product development

Lack of visibility on ROI for green initiatives

energy efficient products/ solutions

Increased organizational drive for efficient products and processes

E i i t f

Lack of comprehensive/ in-built framework facilitating easy compliance to RoHS/ REACH/ WEEE/ JEDEC during the product development

Linking Carbon credit to product & it’s easy tracking Ever increasing cost of energy

Alternate technologies such as renewable energy sources, composite materials

g p y gat the global level

IT Challenges

Sustainability of the available natural resources

Corporate social responsibility

Defining, Implementing and Monitoring GPIs

Determining Cost of Conformance, Cost ofnon-conformance and Efficiency Benefits

3

End-of-Life Reverse manufacturing challenges

Organizational Challenges in Implementing GREEN

GREEN Definition for a Global Manufacturing Enterprise

Green Portfolio

Green Product Design

Green Drivers

Standards ComplianceMaterial characteristics – reuse, recycle, decompose, performanceProduct Efficiency – energy, water, gas, other consumablesEnvironment, Health and Safety – Emission, heat, radiation,

pCost of non-conformanceCost of ConformanceEfficiency Benefits

GREEN PERFORMANCE

, y , , ,waste, etc

Green ManufacturingConsumables characteristics – reuse, recycle, decompose, performance

TARGETS (GPT)

GREEN PERFORMANCE INDICATORS(GPI)

performanceOperating Efficiency – energy, water, gas, other consumablesEnvironment, Health and Safety – Effluents, emission, heat, radiation, waste, etcManufacturing performance Rework/ scrap/ wasteINDICATORS(GPI) Manufacturing performance – Rework/ scrap/ wasteManufacturing Process Automation

Green End-Of-Life – Reverse ManufacturingReverse Supply chain and logistics performance

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CONTINUOUS IMPROVEMENT

Reclaim profile & performanceReuse/ Reduce/ Recycle performance – Bin/ Scrap/ Waste

Green Design Workbench (GDW™*)

HCL’s Green Design Workbench (GDW™) is an enterprise class framework & solutions to enable sustainability, environmental compliance and other green processes during the product design,

development operation and EOL managementdevelopment, operation and EOL management.

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GDW Solutions Map

Part Regulatory

Data

Audit Trail/ Traceability

Global Regulations Database

Compliance enabled

Workflows

Compliance Documenta

tion

BOM/ Product

Compliance

Compliance Reporting

Environment Compliance Regulations Data Database Workflows tionComplianceRegulations

Supplier Qualification

Workflows/ Data

Logistics Performance/

Reverse SupplyDeclaration Standards

Automatic Error Checking Green

Procurement Qualification Requisition Reverse Supply Chain

Standards Tracking/ ReportingProcurement

Design products composed of recycled or

Benchmarking with Global Database/

Recycle/Reuse performance - EOL BOM Recycle/

DisposalRRR composed of recycled or reclaimed materials

Global Database/ Reporting

performance Bin/Scrap/Waste Design Disposal

EfficiencyRRR

Design energy ManufacturingMonitor/ ReportingResources/ Energy Green Performance

Resources or E

Green Product GREEN

Design energy efficient products

Manufacturing Simulation

Resources/ Energy consumptionand emissions

Green Performance ReportingEnergy

Consumption

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Green Design Green Operation EOLDevelopment/ Manufacturing

GREENFoundation

GDW - HCL’s Environmental Regulatory Compliance Management Solution

Business ChallengesLack of comprehensive /in-built framework facilitating easy compliance to RoHS, REACH, WEEE, JEDEC during the product developmentComplexities in involved in development of products to meet multiple Complexities in involved in development of products to meet multiple regulationsLack of streamlined processes to support changes in compliance definition, history and tracking across product life cycleNeed for systematic automated processes to identify alternate complaint Need for systematic automated processes to identify alternate complaint components in the product development

The Solution helpsTo proactively address sustainability / compliance during product design to

Features Compliance Data Management To proactively address sustainability / compliance during product design to

o Avoid after-the-fact redesigns, o Avoid physical prototyping & enabling virtual analysiso Measure green index of the product during designo Product design with environment friendly materials

Data Collection – MDR, Supplier qualification & integrationEnvironmental Regulatory Standards – EU RoHS, REACH, ELV, WEEE, JIG, China RoHS, GASDL

To manage compliance with REACH, RoHS, WEEE etc. during product development To create the product development IT framework for future compliance standardsTo measure supplier characteristics/performance for sourced components to GREEN conformance

Information Exchange Standards – IPC, IMDSCompliance Analysis & Reporting – Internal, ExternalIntegrate & Analyze External BOMs

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To support product compliance tracking at the substance, material, part and product levelsTo improve data collection, analysis and reporting from the beginning of product design to final disposal and recycling

Compliance Definition Change ManagementRoHS Component ReplacementSystem Integration – PLM, ERP, Legacy Systems

GDW Framework – Logical Architecture

Green Solutions SuitePLM

Global Databases / Repository

Compliance Regulations IMDS

Global / StandardonGreen

Reporting

Template MgtIndustry / Standard /

Resources and Energy

tiRRR

MPMERP

Global / Standard Templates / Declarations

Green Standards & Industry Standards

XML / SOA

A In

tegr

atio

BIReporting

Benchmarks

Green Templates

Green Solution Componentsconsumption

Environmental Compliance

Green Procurement

MES / Shop floor apps

SCM XM

L/S

OA

Green Foundation / SchemaExternal Databases

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Compliance Management – Process Details

Compliance Definition

Compliance Definition

Identify Regulatory

Requirements

Identify Regulatory

Requirements

Define Compliance standards

Define Compliance standards

Compliance Definition Changes

Compliance Definition Changes

Identify Products /

P t

Identify Products /

P t

Identify products and demanding

standards

Identify products and demanding

standards

Initial compliance

analysis

Initial compliance

analysis

Roll-ups / compare

with targets

Roll-ups / compare

with targets

Capture unreported

parts, update exemptions

Capture unreported

parts, update exemptionsPartsParts

Integrate S l Ch i

Integrate S l Ch i

standardsstandards analysisanalysis with targetswith targets

Notify Suppliers for unreported

Notify Suppliers for unreported

exemptionsexemptions

Follow-up and collect

i f ti f

Follow-up and collect

i f ti f

Validate the informationValidate the information

Update the compliance

i f ti i

Update the compliance

i f ti iSupply ChainSupply Chain

Impact Impact

for unreported parts

for unreported parts information from

suppliersinformation from

suppliersinformation

receivedinformation

received information in system

information in system

Impact analysis Impact analysis Customer or Customer or Remediation ( t

Remediation ( tpac

Analysispac

Analysis on the identified assemblies

on the identified assemblies

Region specific Analysis

Region specific Analysis

(component replacement / design

changes)

(component replacement / design

changes)

A l i /A l i / S b i iS b i i

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ReportingReportingAnalysis / Internal Reports

Analysis / Internal Reports

Customer Reports

Customer Reports

Submission to

Customers

Submission to

Customers

Supplier Collaboration for Compliance Management

Material Structure/ Substances MasterCompliances – RoHS, REACH, IPC, ELV, JAMA

Host Org

Standard Formats-IPC 1752

Product StructureBill Of Materials

Part Composition Requests

IPC 1752, Compliance Connect

S b it t S li

Multiple Composition Requests

Submit to Suppliers

IPC 1752, Compliance Connect

Completed Composition DataDistributed to applicable parts/products

Declaration with Multiple Compositions Returned

Suppliers

System Validates InputsApprove/Reject

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Compliance Definition Change Management (CDCM)

Business Challenge –Compliance definition standards changes are coming into force due tonew regulation or changes in existing regulation from governmentnew regulation or changes in existing regulation from governmentstatuary bodies.

Compliance Definition Change Management (CDCM) –CDCM process facilitates maintaining the complete history of theCDCM process facilitates maintaining the complete history of theCompliance Definitions in the system like:Details of the changes, Reason for change, Impact analysis, Compliance status of the affected parts and products & Traceability of the compliance data

Key AdvantagesApply changes in compliance definitionRecording the reason for the change, Change g g , gdescription, Approval & Effectivity datesImpact analysis and reporting after applying the changes Implementation of the changes (if needed)

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p g ( )Compliance HistoryCompliance Traceability

RoHS Component Replacement Processes

Business Challenge –Shorter lifecycle of Hi-Tech products need to address changes in products, new product development identification of alternate parts and changes innew product development, identification of alternate parts and changes incompliance definitions require ability to identify suitable alternate parts to meetthe environmental compliance for the final product.

RoHS Component Replacement processes –p p pEnables component replacement in an integratedPLM environment to meet compliance regulations.Process/ workflow automation for capturing compliance data, validation and approval

Key Advantages

Faster identification of suitable alternate component/component replacement for compliance

Enhanced collaboration with the suppliers to shorten the cycle time to improve productivity

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Green Procurement – Supplier Qualification for Green

Business Challenge –Developing green products requires collaborating working with vendors & suppliers todevelop greener products/components Identifying these green suppliers and ensuringdevelop greener products/components. Identifying these green suppliers and ensuringprocess compliance for green is a major challenges in developing green products

Supplier Qualification for Green –Process based on weighted scorecard of greenProcess based on weighted scorecard of greenprocess complianceWorks as additional qualification to identify green suppliersEncourage/ award vendors to adhere to green processesfor providing quality & reliable components/ parts meeting compliancesfor providing quality & reliable components/ parts meeting compliances

Key Advantages

Quick identification of competent suppliers, who can develop and supply components meeting regulatory compliances

Reduced cost of the green components

Green process compliance & traceability

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Green process compliance & traceability

Helps in third party Green certification of vendors

Green Procurement – Green RFQ Process

Business Challenge –Procuring a green part within a given timeframe and at a competitive costis a challengeis a challenge.Vendor selection based on the complex criteria involving cost, response time,green process compliance & reliability etc.

Green RFQ Process –Green RFQ Process –A RFQ process designed to capture applicable greenparameters for the suppliers Calculates weighted scorecard on relativegreen compliance parametersgreen compliance parametersAwards contract based on green capabilities, green index ofthe product, green supply-chain cost, quality reliability and

cost of the developed part..

Key AdvantagesKey Advantages

Faster procurement of green parts/components

Reducing cost of green procurement

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Encouraging suppliers- embracing green processes

REACH Analysis

• Analyze Part ,Product Structures

For all Enterprise Parts • For all the Products in all the

Product Lines,• MEPs, Supplier data• Collate Reference /absolute

Weight • Substance Concentration

Analysis

• Aggregate substance weight, concentration levels at the Product Level

• Arrive at the Total Mass of SVHC shipped with Product

,• Aggregate mass of

concentration to arrive at Annual Shipped Quantity

• If Annual Shipped Quantity > 1 Tonne, Report ExcessAnalysis

For Every SVHC at Part Level

SVHC shipped with Product Level Concentration and EU Shipment Volume

, p

EU REACH limit analysis

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REACH Content Report

Choose REACH Compliance DefinitionCompliance Definition

REACH Substance Usage Details

REACH Detailed Report16

Compliance Dashboard

Rollup Options:• All MEPs Compliant• At Least One MEP Compliant• Preferred MEP Compliant

Compliance Report for the Computer Assembly Option to Override

Compliance Scope At Assembly Level

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Compliance Roll-Up Reports

Roll Up Report of typePreferred MEP Compliance

Roll Up Report of typeAt Least One Part is

Compliant

Roll Up Report of type All MEPs are Compliant

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Global Compliance Solution Case study – Hi-Tech Giant

• Analysis of global compliance requirements for RoHS and REACH

• Supplier Central / portal integration with green procurement on MCC

• AML/ASL synchronization between  PLM and ERP

• Global Compliance Implementation

• Business Analysis and solution definition of compliance practices

• Integration with ERP and other CAD systems for the green indices

• Mapping of business requirements into identified PLM solutions

• Modularized implementation for Scaling

• Business Process Analysis, Solution Architecting, Detailed Design and custom implementation on PLM

• Centralized Compliance reports

• Global roll –out

• Adhere to RoHS (EU, China, California), EU REACH, JIG A & B regulatory compliances f ll P d t hi d

• Standardized processes across the globe for compliance definition and management

Si l t f li d th l tifor all Products shipped.

• Manage compliance definition changes, improve green indices on Products and manage green audit trail for Regulatory Agencies and customers across all Product li

• Single system for compliance reduces the cycle time 

• Product information including compliance enables quicker reporting

• Process standardization

• Upgraded system to minimize customization leveragelines

• Lack of robust change management process

• Product structure streamlining

• Upgraded system to minimize customization, leverage pre‐built processes and reduced maintenance cost

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GDW™ – Business Benefits

Green Portfolio

Enable Sustainability beyond just compliance

Ability to driving Sustainability as continuous improvement program

Sustainable reporting, data collection, analysis, Audit & traceability

Address sustainability during product design to:Address sustainability during product design to:Avoid after-the-fact redesigns, Avoid physical prototyping & enabling virtual analysisMeasure green index of the product during designProduct design with environmental friendly materials

Enable Design manufacturing process for greener product manufacturing

Enable measurement of supplier characteristics/performance to GREENEnable measurement of supplier characteristics/performance to GREEN conformance

EOL management facilitating Reuse, Reduce, Recycle (RRR)

Integrate the sustainable solution with other enterprise PLM and other apps

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Integrate the sustainable solution with other enterprise PLM and other apps

HCL Sustainability Solutions & Services

ng

Sustainable Product Development:Green Design Workbench (GDW™) is a framework & a setof solutions to enable sustainability, environmentalcompliance and other green processes during the productdesign, development, operation and EOL.

Green Products Development G

reen

M

anuf

actu

rin

Sustainable Operations

Solar Power system monitoring:Solar Power Data Analysis, Inference, Intervention andImprovement system is a web based monitoring and dataanalysis framework for power plants and cell/modulemanufacturers. SP DAIS provides customizabledashboards, issue management, automated alerts,statistical inference, parts obsolescence management,REC reporting and ROI analysisM REC reporting, and ROI analysis.

Emission Management:RtEMS is a solution providing real-time monitoring of Emissions and compliance reporting for manufacturing industry, focusing on ‘Direct Emissions’ or ‘Fugitive Emissions’.It interfaces with the Plant floor systems and Data Historians providing real-time environmental compliance

Green Product Design

Value Engineering

Ob l

End-of-Life reverse

manufacturing

RtEMSFrameEAD

SPC/APC implementation

Plant Automation

Emission Management

Renewable Energy

Energy Management

Historians providing real time environmental compliance data trends and rolling averages for the process manufacturing industry.

Manage Carbon is a real time Green House Gas emissionsmanagement framework complaint with GHGP protocol. Itenables to calculate the accurate emissions and variousanalytics using the emissions data and helps to measurethe effectiveness of the green initiatives taken by theObsolescence

ManagementAutomation

RtEMSGDW

GDW

the effectiveness of the green initiatives taken by theenterprise.

Energy Management :Integrated smart energy analytics dashboard (iSEAD), isan intelligent analytics solution focusing on the energyefficiency at the demand side of energy business spectrumaugmented with domain specific knowledgebase to form astrategic Decision Support System & an Intelligent Control

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strategic Decision Support System & an Intelligent ControlSystem. It supports most of the Open Standards (iLON &BACnet etc).

Thank you

For more information on our Engineering and R&D services for sustainability:

Visit us at www.hcltech.com

h h lWrite to me at  sujathaa@hcl.com

HOW CAN I HELP YOU?

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