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The automobile painting is a very energy and emission (solvents) intensive process step in the production of automobiles with regard to the small amount of paint applied to the car body. The awareness has risen that cleaner production technologies must substitute end-of-pipe control technologies. If these technologies strive for being a competitive option in corporate decision-making process, not only their environmental but also their technical and economical performance has to be on the same or better level compared to conventional technologies. The approach of Life-Cycle Engineering (LCE) by PE and IKP investigates technical, environmental and economical aspects of products and technologies. It is developed to a simulation tool to analyse weak points and optimisation potentials as well as to support product and technology development in the painting industry.

The total life cycle approach makes use of data for various sub-systems and modules to describe the relevance of a defined system under consideration. The different processes and steps take place in several locations. The life cycle approach is an assessment tool beyond this spatial dimension. Often these basic information is not available any more or never has been considered as valuable. By this, different emission sources and different receiving environments are simply neglected by summing up for the total life cycle contributions. The spatial dimension is of outstanding importance for the determination of relevance and meaning of environmental burdens. A more advanced life cycle concept should cover this. Besides the spatial differentiation within on product system, life cycle consideration are also often used to compare different production sites.

Total Life Cycle studies of systems like automotive parts, systems or entire vehicles are characterized by an enormous complexity and amounts of individual data points. A full assessment of this variety of information and data requires suitable and reliable data processing systems. The recently developed software system GaBi 3 allows the flexible modeling of life cycles with parameterized process modules. In this way GaBi 3 provides the basis for parameter variation and scenario analysis. Besides these essential elements for identifying improvement potentials, the system enlarges the environmental calculations by an economic and a technical dimension.

This paper presents some results of the cooperation between Opel and Norsk Hydro for optimizing the life cycle of an automotive structural part using a holistic life cycle assessment approach. The aim of the study presented in this paper was to compare, already in the vehicle development stage, the environmentally relevant parameters of two alternative material applications for a vehicle component with functional equivalence, using the Life Cycle Engineering approach developed by PE Product Engineering GmbH. The comparison of the two alternative part designs made out of steel and magnesium alloy considered the production of materials, the processing of the materials to manufacture the cross beam component, and the use phase as a part applied to the complete vehicle. End-of-life options were also taken into consideration.

The international standardisation of Environmental Management (EM) is documented by the ISO 14000 series. Within this series a number of Environmental Management tools are treated. Therefore, it can be seen as a ‘toolbox’ which offers several options for sound Environmental Management practices in organisations. However, a number of questions remain because they are not treated by the standards themselves. Some examples are, which of the tools should be applied to what kind of Environmental Management problem or what are the synergisms and antagonisms between these tools. To illustrate the importance of a comprehensive choice and a compatible approach towards EM-tools, Life-Cycle-Assessment (ISO 14040 series) is discussed in the context of Environmental Management Systems (ISO 14001). The focus of ISO 14001 are organisations, while LCA deals with products or processes.

An important cornerstone of our society is the individual mobility which, today, chiefly can only be offered by the automobile. However, in the industrial countries the car at the same time is exposed to harsh criticism as far as environmental pollution is discussed. Goal of this presentation is to show a scientific method by means of which environmental loads during manufacture, use and utilization/disposal of whole systems - in this special case vehicles - can be quantified and optimized. In order to do this, the instrument of life cycle analysis of parts and processes is used and in the same way the scientific method is developed beyond the level of literature. Due to these modifications the results are only useful if the boundary conditions are mentioned in detail. Considerations on the system such as the examination of an automobile require a method extended by essential criteria due to its complexity.

Products and services cause different environmental problems during the different stages of their life cycle. The Life Cycle Assessment tool aims to identify possibilities to improve the environmental behavior of the systems under consideration. Herefor it is necessary to systematically collect and interpret material and energy flows for all relevant processes. The whole life cycle of a system has to be considered to prevent the neglecting of shift of possible important environmental aspects. In order to support designers, engineers and decision makers to make better informed decisions, it is necessary to perform LCA studies and economical assessments at a very early stage in product design. It is very well known, that the cost and environmental performance responsibility for a product lies mainly in the hand of the designers. Therefore management tools and procedures have to be found or developed to include LCA in this early stage.

Products and services cause different environmental problems during the different stages of their life cycle. The Life Cycle Assessment tool aims to identify possibilities to improve the environmental behavior of the systems under consideration. Herefor it is necessary to systematically collect and interpret material and energy flows for all relevant processes. The whole life cycle of a system has to be considered to prevent the neglecting or shift of possible important environmental aspects. These results have to be included in the overall decision making process. In the last years PE developed the Life Cycle Engineering approach, which consist of the dimensions LCA, Life Cycle Cost and TQM. In order to support designers, engineers and decision makers to make better informed decisions, it is necessary to perform LCA studies and economical assessments at a very early stage in product design.

Latest developments in oil filtration are moving from the conventional spin-on filter to a filter housing with an exchangeable filter element. This new filter element is designed almost entirely of the actual filter media. The so-called metal-free element can be disposed of easily and completely through incineration and, therefore, provides a great environmental and economical solution. In this paper two principles of metal-free elements are compared using a life cycle assessment. Analysis shows that in all categories the thermoset-cured design has advantages versus the nylon 6 injection molded version, even if 100% post consumer nylon is used.