Integration of DFE and DFMA for the sustainable development of an automotive component

The recent developments in manufacturing organizations recognize sustainability as an important value addition for survival in the competitive scenario. The design engineers are in search of approaches for creating environmental conscious products. The purpose of this paper is to report a research carried out for ensuring sustainable product design by the integration of Design for Environment (DFE) and Design for Manufacture and Assembly (DFMA) methodologies. In this context, this paper reports a case study carried out in an automotive component. The candidate product is the charge alternator pulley. The existing pulley has been created using Computer Aided Design. Then sustainability analysis was conducted on the existing component for determining environmental impact. This is followed by the engineering analysis of the component using ANSYS. Then conceptual design changes were developed in the proposed product using DFMA concept. Then the environmental impact has been evaluated in terms of carbon footprint, energy consumption and air/water impacts on proposed product. It has been found that the optimized pulley design possesses minimal environmental impact. The result of the case study indicated that the integration of DFE and DFMA concept could initiate new developments in sustainable designs with minimal impact to the environment and it also reduces the product cost.     

Treating design uncertainty in the application of Eco-indicator 99 with Monte Carlo simulation and fuzzy intervals

In incremental eco-design improvements, design engineers attempt to modify an existing product via some eco-design measures to reduce the product’s environmental impacts (e.g. reduction of material usage and energy consumption). In this process, several design concepts can be proposed, and concept selection is required to allocate resources sensibly to promising design concepts only. In this context, the research purpose is to estimate the environmental impacts of each concept given the uncertainty of design information. In the proposed methodology, the fuzzy interval arithmetic is used to specify and propagate imprecise design information. Then, the centroid concept is applied to model different views of imprecision (i.e. pessimistic, balanced and optimistic) associated with fuzzy impact assessment. Accordingly, a decision scheme is developed to support concept selection and suggest the potential areas for further eco-design improvements. A coffee maker is used as an example to demonstrate the proposed methodology. Also, the Monte Carlo Simulation is applied for the same example to compare the numerical outcomes by the fuzzy interval approach.     

Environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method

This paper presents a methodology for environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method. An ‘environmental impact assessment index’ is proposed that evaluates and ranks the manufacturing processes for producing a given engineering product or component. The index is obtained from an ‘environmental impact assessment factors function’ considering environmental impact assessment factors and their relative importance for the considered application. An example is included to illustrate the approach.     

土地生态适宜性分析在城市规划环境影响评价中的应用

规划环境影响评价是规划工作的一项重要内容，也是规划环境影响评价体系不可或缺的组成部分。鉴于理论、方法上尚存在某些空白，基于土地生态适宜性分析在城市规划环境影响评价中应用的必要性和可行性，从生态学的角度，依据生态位理论，以上海市某新城作为实证，探讨在城市规划环境影响评价中土地生态适宜性分析与评价的方法、程序及内容，从而为城市环境影响评价提供内容上的补充和技术方法上的完善。     

Developing an integrated approach to enhance the delivering of environmental goods and services by agro-ecosystems

It is widely acknowledged that the implementation of the majority of agri-environmental measures (AEMs) does not allow for the quantification of expected environmental benefits, thereby undermining the possibilities to assess both their effectiveness and efficiency. The objective of this paper is to show how an approach to develop agri-environmental measures based on the multifunctional character of agro-ecosystem is useful to overcome the difficulties in assessing expected environmental benefits. In the following sections, the main theoretical concepts underlying the actual European model of multifunctional agriculture are introduced. Following a critique of some aspects of the current analysis of the joint production of environmental non-commodities, the rationale to operate a shift of focus from multifunctionality of agriculture to that of agro-ecosystems is proposed. Finally the methodology developed by the AEMBAC project, based on the assessment of impacts exerted by agriculture on the capacity of local agro-ecosystem to perform environmental functions, is presented to explain how this shift of focus facilitates the assessment of the delivering of multiple environmental goods and services.     

A design for EoL approach and metrics to favour closed-loop scenarios for products

Recently, environmentally conscious design and extended producer responsibility have become key aspects for companies that need to develop products that are sustainable along their whole life cycle. Design for End of Life (EoL) is a strategy that aims to reduce landfill waste through the implementation of closed-loop product life cycles. It is important to consider disassembly and EoL scenario management as early as the design phase. For these reasons, this paper presents an approach to help designers in the evaluation and subsequent improvement in product EoL performance. The method is based on four innovative EoL indices that compare different EoL scenarios for each product component. In this way, the designer can modify the product structure or the liaisons to maximise the reuse and remanufacture of components as well as material recycling. The presented case studies confirm the validity of the approach in helping designers during the redesign phase of goods and products to reduce the quantity of materials and industrial wastes sent to landfill.     

Design for environment as a tool for the development of a sustainable supply chain

In this work, design for environment (DfE) methodologies have been used as a tool for the development of a more sustainable supply chain. In particular by combining life‐cycle assessment (LCA) techniques and by using the quality function deployment (QFD) multi‐criteria matrices, an ‘environmental compromise’ can be reached. In this work, the QFD matrices have been developed in a new way using an iterative process that involves the whole supply chain starting from the product life‐cycle, taking into consideration the machines that make the product and their components. This methodology is compatible with the requirements of the various stakeholders, suppliers, manufacturers and clients, involved in the supply chain. To assess the validity of the proposed approach a specific supply chain was studied concerning packaging systems for liquid food substances (beverage cartons). Firstly all the stages which are most critical from the environmental point of view in the supply chain of packaging systems were identified and assessed. The starting point for the analysis of environmental aspects and impacts which characterise the supply chain was LCA, which proved to be useful for the identification and the environmental assessment of the various stages in a packaging system. Through the use of ‘iterative QFD’ it is possible to arrive at a definition of the engineering characteristics of all the machinery which is involved in the supply chain. In particular in this work the authors have tried to identify the critical points in the design of those machines which either make the beverage cartons or are involved in the filling process.     

A hybrid approach for environmental impact evaluation of design options

The strengthened environmental regulatory requirements and general awareness of the need for environmental conservation worldwide, design for environment has become a key design criterion in new product development processes. Due to their resources-consuming attribute and the prerequisite expert knowledge in environmental sciences for the impacts interpretations, the existing forms of product-oriented environmental impact assessment methods are impractical to be adopted by product designers in small-and-medium enterprises. Life Cycle Assessment (LCA) is a generally accepted quantitative approach to assess a product’s environmental impact. However, a full LCA study often requires a considerable amount of data and therefore, it is regarded as not a handy tool for product design evaluations particularly at the initial design stage. This leads to our intention to develop an immediately applicable approach for decision-makers to evaluate the design options. The proposed approach integrates Analytic Hierarchy Process and Fuzzy Theory, with Evidential Reasoning (ER) to support the environmental impact evaluations of design options. A case study is carried out to demonstrate its applicability to prioritize the environmental impact of various design options. A symmetrical triangular distribution is introduced for calculating the expected utility and for testing the sensitivity of results.     

The elaboration process – an approach for sustainable product development: a case study

Environmentally conscious product development, eco-design or design for environment is the methodology trying to introduce environmental requirements into product design. The first step of this process is the gathering of customer requirements for a structured product development procedure, such as quality function deployment (QFD). The problem is that environmental requirements are usually unspoken by the customers. This paper describes a methodology for uncovering such requirements by using environmental default questions in an elaboration process. This leads to an increased customer environmental awareness, and it generates a comprehensive list of requirements suitable for use in a subsequent QFD process. The effects of the elaboration process are demonstrated in one case study.     

Application of QFD for enabling environmentally conscious design in an Indian rotary switch manufacturing organisation

Many businesses are recognising that environmental consciousness is an important concept for survival in today's highly competitive market. This paper presents a project in which quality function deployment (QFD) for environment (QFDE) has been applied to an Indian rotary switch manufacturing organisation to enable environmentally conscious design at the early stage of product development. QFDE consists of four phases. QFDE phases I and II are concerned with the identification of the rotary switch parts that are important in enhancing environmental consciousness. QFDE phases III and IV are concerned with the evaluation of the effect of design improvement on environmental quality requirements. The results obtained from the case study revealed that QFDE could be applied in the early stage of rotary switch product development as it identified the vital components from an environmental perspective and enabled the options for design improvement to be effectively evaluated. The managerial implications of the case study have also been presented.     

A hybrid approach using AHP–TOPSIS–entropy methods for sustainable ranking of structural materials

Nowadays, many countries are looking towards sustainability as a goal because our world has limited resources and serious environmental impacts. In the construction industry, the process of sustainable selection of structural material is considered one of the keys to achieve more sustainable construction. In this paper, the theories of decision making are utilised to develop an approach for evaluation and ranking the structural materials over their total life based on sustainability criteria using multi-attribute decision-making methods. One of them is Analytical Hierarchy Process which is utilised to build the problem hierarchical structure and assign weights of the predetermined sustainable factors. The other is Technique for Order Preference by Similarity to the Ideal Solution which is utilised to rank the structural materials within both each material life cycle phase and the complete material life cycle phases. The third is the concept of entropy by Shannon to evaluate the weight factor for each phase of material life cycle. The proposed approach presents an objective, systematic and comprehensive method for the sustainable ranking of materials that links between the structural element design and the sustainable selection of materials.     

Implementation of a software platform to support an eco-design methodology within a manufacturing firm

The paper aims to explore the implementation of an eco-design methodology and the related software platform (G.EN.ESI – Green ENgineering dESIgn) within technical departments of a manufacturing firm. The G.EN.ESI eco-design methodology is based on the life cycle thinking concept and the software platform is conceived as a set of inter-operable software tools able to efficiently exchange data among them and with the traditional design systems (i.e. CAD, PDM and PLM). A multinational company, designing and producing household appliances, adopted the proposed methodology and related software platform for redesigning two cooker hood models with the aim to improve their environmental performances. Design and engineering departments evaluated the methodology and platform impact on the product development process, as well as the platform inter-operability with traditional design tools. The results indicate that methodology and software platform satisfy the requirements of the enterprise in terms of: (i) degree of expertise and training requirement on this subject, (ii) low impact in a consolidated design process and, (ii) good level of inter-operability among heterogeneous tools. However, the testing results highlight the necessity of a further platform optimisations in terms of software integration (single workbench made by integrated software tools with the same graphical user interface).     

How environmentally focused is the German sustainability strategy? A critical discussion of the indicators used to measure sustainable development in Germany

There are hardly any critical discussions of sustainable development indicator sets designed for use at the national level. This article aims at rectifying this omission in critical academic research by contributing to the discourse on environmental sustainability with an assessment of the indicator set used for the measurement of sustainable development in Germany. It will evaluate to what extent the sustainable development concept is reflected in the structure of the strategy and analyse in how far fundamental environmental issues are covered by the indicator set. The discussion will show that the environmental dimension of the sustainability concept is not sufficiently integrated in the German National Sustainable Development Strategy. Although the strategy??s indicator set contains a range of environmental indicators, gaps in the German indicator set become apparent when contrasted with important issues of sustainability. It will be concluded that the environmental dimension of the sustainable development concept is not the recurrent theme in either the strategy or the indicator set.     

Evaluation of sustainability using an integrated approach at process and product level: a case study

The present world is facing problems like rapid depletion of natural resources and undesired environmental changes on a global scale. Manufacturing organisations are realising the importance of mitigating the present crisis and are adopting sustainable manufacturing principles. Since it is important to achieve sustainable manufacturing, sustainability assessment models were developed. Sustainability assessment models have their own drawbacks and may not provide clear scope for complete sustainable development. A system approach has been developed to overcome this shortcoming by integrating various sustainability assessment models that are already in practice. This article reports the advantages of collecting the advantages of individual sustainability assessment models and how the implementation of the integrated approach has helped to identify the current sustainability level and the scope for future developments in an automotive industry.     

Regional multi-compartment ecological risk assessment: Establishing cadmium pollution risk in the northern Bohai Rim,China

Ecological risk assessment (ERA) has been widely applied in characterizing the risk of chemicals to organisms and ecosystems. The paucity of toxicity data on local biota living in the different compartments of an ecosystem and the absence of a suitable methodology for multi-compartment spatial risk assessment at the regional scale has held back this field. The major objective of this study was to develop a methodology to quantify and distinguish the spatial distribution of risk to ecosystems at a regional scale. A framework for regional multi-compartment probabilistic ecological risk assessment (RMPERA) was constructed and corroborated using a bioassay of a local species. The risks from cadmium (Cd) pollution in river water, river sediment, coastal water, coastal surface sediment and soil in northern Bohai Rim were examined. The results indicated that the local organisms in soil, river, coastal water, and coastal sediment were affected by Cd. The greatest impacts from Cd were identified in the Tianjin and Huludao areas. The overall multi-compartment risk was 31.4% in the region. The methodology provides a new approach for regional multi-compartment ecological risk assessment.     

Economic and environmental value stream map (E2VSM) simulation for multi-product manufacturing systems

Value stream mapping (VSM) is a well-accepted tool within lean manufacturing concept which is often used for analysing and designing the flow of materials and information required to manufacture a product. However, the analysis is static and single product oriented, which fails to cope with either the variation of production plan or a multi-product environment. In addition, the environmental impact of a manufacturing system is highly associated with the dynamic consumption of energy and resources. Despite the recent integration of VSM with simulation or environmental studies (in the domain of energy efficiency), still neglected is the dynamic assessment of all the resources involved in a multi-product production environment. This paper presents a methodology for modelling multi-product manufacturing systems with dynamic material, energy and information flows with the aim to generate economic and environmental value stream maps (E²VSM). The proposed methodology is validated with an industrial case.     

The use of construction equipment productivity rate model for estimating fuel use and carbon dioxide (CO2) emissionsCase study: bulldozer,excavator and dump truck

Carbon dioxide (CO₂) emission has drawn a great attention in recent years all over the world, and it plays a very important role in the process of global warming. The off-road equipment, which includes construction equipment, accounted for 7.5% emission of CO₂. The objective of this article is to propose a groundwork for a methodology that can be used to estimate the total fuel use and CO₂ emissions from construction equipment activities based on its productivity rate. Currently, there is not a methodology or technique for estimating productivity, fuel use and emissions at once. The multiple linear regression analysis has successfully modelled the productivity rate and good to be used as a benchmark for estimating fuel use and CO₂ emissions from various types of construction equipment performing earthwork activities. The proposed methodology will help the contractor to estimate the total expected pollutant emissions for the project, which would be valuable information for a preliminary environmental assessment of the project. By using construction plans and specifications, the methodology and tool presented in this research can be used to estimate cost, fuel use and emissions from commercial, residential, industrial or heavy highway. By the proposed approach, it is possible to develop new fuel use and emissions inventories for construction industry in general.     

A sustainable method for optimizing product design with trade-off between life cycle cost and environmental impact

In today’s competitive market, corporations have learned that taking sustainability issues into account can significantly improve their public image. Modern producers therefore must simultaneously reduce the environmental impact of their products and make economic gains. Therefore, making trade-offs between economic and environmental issues is required to ensure a company’s continuity. In doing so, companies have attached a great deal of importance to the new product design phase. However, optimization at the design stage becomes very complex for a product with a large number of parts, which can have several design alternatives with similar forms and functionality, but different costs and environmental impacts. In the automobile, shipbuilding and aircraft industries, if the conventional complete enumeration method is applied, the time required for selecting the optimal combination of design alternatives with respect to life cycle cost and environmental impact may exceed a human’s natural life span. To overcome this limitation, this paper introduces an optimization method for use as a design aid tool that enables a designer to assess the life cycle cost and environmental impact of his/her design very early in the product development process. To support the developed method, an illustration is provided using a case study on a locally manufactured automobile.     

Analysis of building environment assessment frameworks and their implications for sustainability indicators

Green construction is gaining increasing attention in the global context. However, the construction of sustainable green buildings and environments involves different tools and systems and diverse perspectives. Therefore, the development of environmental assessment tools is an important task for managing green housing and green building projects. In this paper, we discuss the benefits, limitations, and future directions of the assessment framework. There are four characteristics of building environmental assessment, i.e., comprehensiveness, design guideline, signaling, and communication tools, which afford both benefits and limitations. We illustrate the role of the assessment framework as a hub promoting integration of diverse knowledge, as a design guideline encouraging better design and action, as signaling environmentally friendly design and action, and as a communication tool. On the other hand, there are limitations, such as the use of a mixture of quantitative and qualitative measures, ambiguity of weighing, lack of financial evaluation, and lack of involvement of diverse disciplines and stakeholders. To develop an effective assessment framework, the following three factors must be considered: knowledge, power, and implementation. We propose that knowledge innovation, a credible approach for a salient solution, and collective action represent the future challenges of the assessment framework.     

Application of environmentally conscious manufacturing strategies for an automotive component

Application of appropriate environmentally conscious manufacturing strategies enables the sustainable development of products and processes. Automotive component manufacturers recognise the potential of applying appropriate strategies for attaining Triple Bottom Line benefits. In this context, three strategies such as eco-efficiency, waste minimisation and material efficiency are being applied to minimise environmental impacts associated with the manufacture of automotive products and its associated processes. A case study of an automotive component manufacturing firm has been exemplified. After conducting the study, the potential environmental impact was reduced by 20% and eco-efficiency was improved by 13%. Further, improvements have been observed in terms of overall resource consumption and material efficiency. The overall power consumption was reduced by 18% and weight of the component was reduced by 11%. The study aimed at improving the sustainable performance of product by incorporating green and environmentally friendlier manufacturing practices.

Abbreviations: USEPA: United Nations Environmental Protection Agency; OECD: Organisation for Economic Co-operation and Development; WBCSD: World Business Council for Sustainable Development; Eco-QFD: Environmental Quality Function Deployment; WCED: World Commission on Environment and Development; LCA: Life Cycle Assessment