The use of Life Cycle Engineering/ Life Cycle Assessment within the design process of production facilities; A business case: Different options of handling overspray
Authors: Binder Marc , Florin Harald , Kreissig Johannes 
Published: April 2011

AbstractThis presentation will illustrate how to expand the view by considering the total life cycle in an efficient way into the decision making process and why it is important to do so. The business case will show, how the ecological and economic aspects considering the total life cycle of different design options have been considered when determining the preferable design options out of an holistic point of view. Life Cycle Engineering (LCE)/ Life Cycle Assessment (LCA) integrated in the design Process LCE methodology is evaluating ecological, technical and economic aspects considering the total life cycle of processes/products. LCA studies are the basis for the ecological evaluation within LCE. LCE studies are based on material and energy flow information needed while running the facilities or for producing products. LCE is a simulation tool show optimization potentials as well as supporting the decision making process within the design phase. As various databases hold information on ecological impacts of material- and energy production and information on the economic values is available within the involved companies, time consuming research on basic materials and energies is not necessary. Therefore first estimations on scenarios can be made within days to support the decision process not causing any time delay. LCE studies can be conducted within the design process and on existing facilities/products. If LCE is used within the design process optimization potentials can be shown in early stages of the design phase of facilities/products. Integration of LCE within early stages of the design ensures an efficient way of improving the ecological profile of processes and products and reducing the overall costs considering the total life cycle. Realization within a software tool The software tool GaBi4 is developed and designed to support LCE efficiently and in a transparent way. The design of the facilities can be modeled according to the material and energy flow. This enables the user to run scenario analysis for different design options based on the process flow model. Business case The methodology of LCE has been integrated into the design process of the new rear axle paint shop focusing on the handling of the overspray. Different design options have been analyzed and arguments were made explicit to support the decision making process. As LCE was part of the whole design process from the beginning, the effort for all participants could have been minimized. Conclusions The case study has shown that the integration of LCE into the design process provides additional information and is not causing any delay of the decision making process. LCE enables a transparent presentation of the economics and ecological impacts on a process bases. Optimization potentials, ecological and economic, can be shown at all stages of the design phase and result in reducing the overall costs and environmental burdens caused by the paint process.