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Over 250 million tires are scrapped in the United States each year. Tires have been a problematic scrap because they have been designed to resist destruction, and have a tendency to float upwards in landfills. Improper storage has resulted in tire fires1--an even more problematic environmental concern than unsightly piles which can serve as breeding grounds for insect vectors. A better solution is to recover materials for use in new components. Not only does this resolve the landfill issue, but it also serves to conserve resources, while returning an economic benefit to society. This paper traces the introduction of tire material recovery at NRI Industries and DaimlerChrysler Corporation (DCC), the development of the infrastructure and materials, and the launch of the Jeep Grand Cherokee thermoplastic elastomer (TPE) radiator seals, comprised of post consumer tire crumb.

Managing regulatory content is a complex process for any industry, but particularly for the automotive industry, which is heavily regulated. Several approaches for managing content are discussed along with implications for the industry. The response of an Original Equipment Manufacturer (OEM) to the recent European Parliament End-of-Life Vehicle Directive (EU 2000/53/EC-ELVs)1 is discussed from a North American perspective as well as trickle down expectations for the automotive supply base. Design, sourcing and labeling issues associated with the ELV directive as well as domestic regulations are discussed.

Life cycle benefits of using polyols, recovered from polyurethanes, for the manufacture of new automotive components are detailed. Design, manufacture, use and end-of-vehicle-life phases are reviewed and presented using a life cycle management approach. This methodology has been found useful to examine complex systems to guide decision makers in optimizing total life cycle costs. This paper discusses the factors, decision process, and path that led to the establishment of an alliance to develop the waste collection infrastructure, chemical recovery process (glycolysis), recyclate polyol product and the resultant vehicle components.

Life cycle benefits of a chrome-free sealing wash were evaluated. Material consumption, disposal costs, water pretreatment, waste water treatment and product performance were used to compare a chrome-free product to traditional washes. Acquisition costs and vehicle weight impacts were also considered. The direction of domestic and international regulatory initiatives will play a significant part in the application of this study=s findings. The paper discusses the factors and decision process that led to the trial of chrome free rinse in a vehicle assembly plant and the results of this test. Durability testing was performed with current and evolving primer systems. Equivalent durability was shown with multiple supplier/multiple primer process combinations. The study indicated that chrome-free sealing wash would yield a small cost savings and a minor reduction in weight with equal performance to the current chrome containing process.

Life cycle benefits of a fully integrated thermoplastic instrument panel (IP) are compared to a traditional steel lattice construction. Design, manufacture, use and end-of-life phases are reviewed and presented in a life cycle management methodology. All components and processes are reviewed in a design for “X” format (i.e., recyclability, assembly, separability, disassembly, etc.) The IP objectives that were balanced include: design implications; feature content; consumer appeal; occupant energy management; quality, warranty, and NVH performance; design flexibility, materials of construction; weight savings and time to market. This methodology has been found useful to examine complex systems to guide decision makers in optimizing total life cycle costs.

Environmental costs are a delayed financial burden that result from product decisions made early in the product life cycle--early material choices may create regulatory and waste management costs that were not factored into the acquisition cost. This paper outlines a step-wise approach to determine decision points; environmental, health, safety and recycling (EHS&R) cost drivers that affect decisions; and sources of information required to conduct a Life Cycle Management (LCM) review. Additionally, how LCM fits into the larger concurrent engineering framework is illustrated with an electrocoat primer example. Upstream and downstream supply chain processes are reviewed, as well as organizational challenges that affect the decision process.