Repair, Refurbishment and Testingby Japanese Manufacturers achieving
Product Quality/Safety Assurance andEnvironmental Conservation
The Japanese Four Electrical and Electronic Industry Associations
Workshop 2014 of the Asian Network, Okayama, Japan
27 November 2014

Outline
0. About us
1. Our Mission and Current Operations for Used Products
2. Cases
3. Survey Results
4. Conclusions

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About Us
 Basel Task Force established in Dec 2012 under the Japanese Four Electrical and Electronic IndustryAssociations•

The Japan Electrical Manufacturers' Association (JEMA) / 275 companies•Japan Electronics and Information Technology Industries Association (JEITA) / 397 companies•Communications and Information network Association of Japan (CIAJ) /227 companies•Japan Business Machine and Information System Industries Association (JBMIA) / 53 companies

 Member companies•Fuji Xerox (chair)•Canon (co vice-chair)•Sony (co vice-chair)•Fujitsu•

Mitsubishi Electric•

NEC•

Panasonic

•

Ricoh

•

IBM Japan (observer)•HP Japan (observer)3

Our Mission
 To enrich people’s lives through providing safe and high-quality
products with due consideration to the environment
 To provide promptly appropriate product guarantees andmaintenance services in case of occurrence of defective products
or product failures
 To give consideration to attain both environmental conservationand economic efficiency on a global basis in accordance with the“Mottainai Spirit (a Japanese traditional value to avoid waste)”throughout the whole life cycle of electrical and electronicequipment

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Current Operations for Used Products Repair/Refurbishment•

Defective/used products are shipped (export/import) to the repair/refurbishment center withspecialized techniques/technologies•

Repaired/refurbished products are back to customers and used continuously•

Contributes to reduction of waste and effective utilization of resources by extending theuseful life of valuable products as well as by limiting demand for new natural resources Testing (e.g. failure analysis, field test)•Defective products are shipped (export/import) to the development center or the quality
assurance center of the manufacturer•

Results of testing are reflected on the product development on a timely manner•

Contributes to development and supply of future products to be used safely for a long timeby preventing product failure and improving product quality

Effective, efficient and uniform services are made possible by regionally centralized
facilities covering several countries
5Cases1.

Refurbishment in Thailand - Ricoh & Fuji Xerox

2.

Testing in Thailand - Mitsubishi Electric

3.

Repair in Malaysia

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Refurbishment in Thailand Approx. 50 workers, 1,200 m2
 400 - 500 units/month Multi Functional Printers (MFP), Printers
1. Receive

5. Exterior cleaning

2. Storage

3. Removal of covers

6. Parts exchange

7. Assurance

4. Interior cleaning

8. Packaging

9. ShippingRefurbishment in Thailand
Processes established with strong support by the government of Thailand
Processes at site

Shipping & Sale

Exchanged parts(non reusable)
become waste in
the disassembly
process

Metal parts(Steel, copper,aluminum)

Assurance

Assembly

Cleaning & Repair

Disassembly &Parts exchange

ReceiveImport

ExportExchanged parts

Little hazardous waste isgenerated from equipment
compliant with applicablechemical regulations worldwide
Authorized Recyclers

Processes at recyclers Resource recovery Heat recovery Disposal
> 89%
10%
(ProperSteelmaking
treatment)
Steel/copper//non-ferrous< 0.5%
aluminummetals smelting
Recycledpellets

Plastic parts

Pelletization

Rubber parts

Incineration

Glass parts

Crushing into cullets

Recycled
glassesCrushing &non-ferrous smelting

Steel/copper/
aluminum/precious metals

ElectronicParts (e.g. motor,Printed circuit board)

Alternative
fuelNote: Pre-treatment is done in the Philippines, and smelting in Germany.

BurnedashLandfillTesting in Thailand
Asia, Oceania,
Middle East, EU, etc.

Feedback for design quality
improvement

Manufacturing Factoryin Thailand
Product design

Defective / field tested
air conditioners

Failure analysis
Data analysis of field test

Recycled materials

Recyclers
Sorted materials

Manual disassemblyby materialTesting in Thailand
Failure analysis

Data analysis of field test

Defective air conditioners(countries of sale)

Field test to collect data under
different conditions(in some countries)

Identify defective part

ClimateExportdefective Urgent
products

Product quality management(Importing country)
Verificationof defectivepart

Investigation offailure
causeCountermeasure

ResidentialstructureLife style

ExportField tested units

Product development(Importing country)
Data analysis
on parts andperformance

Productdesign

Improvementof productperformanceTesting in Thailand
Processes at site
Disassembly

Failure Analysis

ImportExport

Products after failure analysis aretransported to waste management centerand sorted to each materials for recycling.
Authorized Recyclers
Sortedparts/material

Processes at recyclers(waste disposer)

Metal parts(Steel, Copper,Aluminum)

Steelmaking/non-ferrous
metals smelting

Steel/Copper/
Aluminum

Pelletization

Recycledpellets

Plastic parts

Resource recovery Heat recovery
> 98%
< 1%

Incineration

Alternative
fuel

Wood packaging

Shredding/incineration

Paper packaging

Paper manufacturing

Recycled
paper

Printed Circuit
Boards (PCB)

Pre-treatment

Steel/Copper/
Aluminum

Note: Smelting is done outside of Thailand.

Disposal(Propertreatment)< 0.5%

BurnedashLandfillRepair in Malaysia• Malaysian Government allows repair operations for many companies on
the basis that:• Product shipped in for repair, if non repairable must be shipped out for ESM– usually in Singapore
Product for repair is received
from 14 Countries

Repaired product shipped out to5 Countries• Scheduled Waste (hazardous waste) generated locally from repair operations
stays within Malaysia for treatment by a DOE approved facility:-Repair process includes:
Receive

Repairable
products

Testing

Non Repairable
ProductsRepair

salvaged parts
Salvage parts

Repairing IT Products andParts

Ship repaired items toClient Service Centers

Volumes – 1 facility= 13,000+ pcs per month

Ship non hazardous
scrap out of Malaysia
for ESM

Scheduled Waste

600+Employees

Manufacturing factory
operating refurbishment

Receiving of Used Products• Palletised• Properly
packaged• Labelled

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Packaging• Individual/collective packaging• Cushioned

Storage

Interior View
• Parts exchange• Assurance

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Ready for shipping18

Waste management center(in manufacturing factory)

エアコンの場合

Stored parts(heat-exchanger before disassembling)Disassembled materials
Steel

Aluminum finCopper pipe

Printed circuit board

Survey Results

Estimated Yearly Amount of Transboundary Movement of Used Products
tons/year
Estimated yearlyamounts
imported/exported

Type of used products

Purpose

Product body

Repair, Refurbishment, and Testing

17,500

Spare parts

Repair, Refurbishment, and Testing

1,100

Total

18,600*1 The figures above represent not only imports and exports from/to Japan, but also those between

overseas offices of Japanese manufacturers.
*2 The figures come from part of the Japanese manufacturers.

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Survey Results

Trade Patterns of Transboundary Movement of Used Products

FROMTOOECD countries

 OECD countries

OECD countries

 Non-OECD countries

tons/year
Quantities per year
17,100750

Non-OECD countries  OECD countries

300

Non-OECD countries  Non-OECD countries

450* The figures come from part of the Japanese manufacturers.

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Survey Results

Trade Patterns of Transboundary Movement of Used Products
tons/year
TO →FROM ↓NorthAmerica

JapanEurope

Asia/ Africa/Mid
Oceania dle East

Central/SouthAmerica

Japan
000
400
00North13800017,151
America
Europe1045
54240
0Asia/0087
402
00Oceania
Africa/Middl00141000e EastCentral/South0360004*America
The figures of the transboundary movement amount come from part of the Japanesemanufacturers.
Total

274273856

240

17,155Total
400
17,190340489141
4018,600* The figures come from part of the Japanese manufacturers.

24Survey Results

Estimated Yearly Amount of Waste
tons/year
Hazardous waste
out of the total waste

Waste
OECD countries

1,175

196

Non-OECD countries

177

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Total

1,352

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*1 The figures above are for the total transboundary movement of 18,600 tons/year*2 Hazardous waste is those listed in Basel Convention Annex Ⅷ Table A(e.g. printed circuit boards, CRT, fluorescent tube)

Survey Results

Waste Management (some specific cases in Thailand and Malaysia)

Traceability

Authorized
services

Check oftreatment
process

Material recovery(smelting)

Yes

Yes

Yes

Plastic

Material recovery,
Partially heat recovery
and landfill

Yes

Yes

Yes

Glass

Material recovery,
Partially landfill

Yes

Yes

Yes

Composite parts

Material recovery

Yes

Yes

Yes

Hazardous
component

Material recovery(smelting)

Yes

Yes

Yes

Type of sorted
material/component

Treatment

Iron/non-ferrous
metalConclusions
 Our transboundary movement of used products forrepair/refurbishment/testing are distinct from improper
export/import conducted by some traders Repair/Refurbishment of used products allows realizing reductionof waste and effective utilization of resources Testing contributes to development of future products withenhanced safety and longer life All processes of current operations are well controlled We are managing waste including those hazardous generated
from repair/refurbishment/testing in an appropriate manner27Regarding the E-waste Guidelines
We need your support to continue
our legitimate repair/refurbishment/testingcurrently being operated globally.
Conditions need to be:Feasible; andAcceptable for all stakeholders
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Thank you very much!

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