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Dr. L. Ramakrishnan, FIEMA, C.Env.

Regional Environmental Coordinator – Philips Lighting, Asia Pacific

2006.03.07

Green Manufacturing and Management

in Electronics Industry

CONFIDENTIAL 2Workshop on Green Manufacturing and Management, Pune Ref: Greenpeace

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Environmental Issues of Products

The number of computers in India:

+/- 14,000,000 (growth: 25 % per year)

- Each one of these PCs is a TOXIC Trap

- Workers working in chip making facilities are likely to be

exposed to toxic chemicals that may lead to cancer, miscarriage,

birth defects etc.

- Many manufacturing sites of chips generate hazardous wastes

and contaminate ground water; for every 2 gm of chip about

1260 gm of chemicals and materials are used

CONFIDENTIAL 4Workshop on Green Manufacturing and Management, Pune

Environmental Issues of Products

- EOL PCs contribute to the mounting

“electronics” waste EOL PCs find their way to

many Asian countries including India for

Recycling where workers are exposed to

toxins leading to damage to the central nervous

system, endocrine disruption, interference with

brain development and organ damage

- A typical computer monitor with a cathode ray

tube contains 2-4 Kg of Lead, as well as

phosphor, barium and Chromium (VI)

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CONFIDENTIAL 5Workshop on Green Manufacturing and Management, Pune

Environmental Issues of Products

- the chip resistors and semiconductors contain

Cadmium;

- Mother Boards and connectors contain Beryllium

- Printed Circuit Boards and Plastics casing

contain Brominated flame retardants (e.g.

PBBE)

(Source: Worldwatch Institute)

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Design

Transport

Use

EOL Product

Reuse, Repair, Remanufacture, Recycle

Manufacture

Landfill, Incinerate

Green Manufacturing & Management Supplier

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Design for Environment:

Focal Areas:

Mass reduction – Reduced consumption of resources

Reduction/elimination of hazardous substances (Cd, Pb, PBBE etc)

Reduction in consumption of energy (standby and in operation)

Recyclability (disassembly, monomaterials, pressfit, glue, welding)

Packaging Mass (elimination of PVC, PU, EPS)

Repairability and long life

Design

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SupplierGreen Purchasing:

Focal Areas:

Compliance – Reduced Risk

Substances – in process and in product

Eco-Efficiency – Resource Consumption

Recirculation of Packages

Environmental Management System

(Supplier Sustainability Audits)

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Green Manufacturing:

Focal Areas:

Energy Consumption

Water Consumption

Hazardous Substances

Waste Reduction (Hazardous and non-hazardous Waste)

Emission Reduction (Lead, solvents, decomposition products)

Mass Balance

Manufacture

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2006-2009

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CONFIDENTIAL 21Workshop on Green Manufacturing and Management, Pune

760000

780000

800000

820000

840000

860000

880000

900000

920000

940000

2001 2002 2003 2004

Energy Consumption (GJ) – Philips India

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

2001 2002 2003 2004

Water Consumption (KL) – Philips India

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

2001 2002 2003 2004

Waste Generation (KG) in Philips India

0

500

1000

1500

2000

2500

2001 2002 2003 2004

Mercury Emissions (KG) – Philips India

0

1000

2000

3000

4000

5000

6000

7000

2001 2002 2003 2004

Cat II (EGE, Toluene, Xylene, Sb, Pb) Emissions (KG) –

Philips India

0

100000

200000

300000

400000

500000

600000

2001 2002 2003 2004

Cat III (VOCs, SOx, NOx etc) Emissions (KG) – Philips India

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TransportGreen Supply Chain (Logistics):

Focal Areas:

Compliance

Optimization

Handling of goods at transfer points

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CONFIDENTIAL 23Workshop on Green Manufacturing and Management, Pune

Use

Use:

Major Issue:

Energy Consumption

Maintenance

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End of Life Product:

E-Waste

Recycling, Repair & Reuse, Remanufacture

Incineration / Land-fill

EOL Product

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In Essence

“Green Manufacturing and Management” is about

Designing products using Design For Environment Principles,

manufacturing them with eco-efficient processes,

delivering them to the customer with the least environmental

impact and

applying “Cradle to Cradle” or similar approaches for handling

EOL products.