Sustainable product design using CAD: a case study in an Indian rotary switches manufacturing organisation

Sustainability is gaining importance in contemporary manufacturing organisations. Modern design engineers need approaches for creating environmentally friendly products. In this context, this paper reports a case study carried out in an Indian rotary switches manufacturing organisation. A component of the rotary switch has been modelled using computer-aided design. Then, the sustainability analysis has been carried out for determining the environmental impact. The environmental impact has been measured in terms of carbon footprint, energy consumption and air/water impacts. The handle design has been modified to minimise the environmental impact. The results of this case study indicate that appropriate modifications in design could lead to the development of sustainable design with minimal environmental impact.     

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     

Application of fuzzy QFD for enabling sustainability

Contemporary manufacturing organisations recognise sustainability as an important concept for survival. Environmental awareness and recycling regulations have been compelling manufacturers and consumers to evolve sustainable strategies. The modern customers' voices need to be translated with care into technical requirements. Quality function deployment (QFD) is a technique extensively used for this purpose. In order to cope with the vagueness associated with relationships and correlations in QFD, fuzzy numbers have been integrated within a QFD framework and fuzzy QFD has been used in this study. The study is concerned with the application of fuzzy QFD for enabling sustainability in an Indian modular switches manufacturing organisation. The approach is effective in the identification of sustainable competitive bases, sustainable decision domains, sustainable attributes and sustainable enablers for the organisation. The improvement in sustainability has been measured from three perspectives. The results gained as a result of the study indicated that fuzzy QFD could be used as an enabler of sustainability.     

Design of automobile engines for remanufacture with quality function deployment

Parallel with the increase in environmental problems, the importance of design of environmentally friendly products has become more important together with the design for remanufacture. This paper presents the application of quality function deployment (QFD) methodology in the design of products for remanufacture. The main goal of this paper is to determine the engineering characteristics of automobile engines that firms have to focus on, in order to design automobile engines for remanufacture. In this paper, how a product can be designed for remanufacture using QFD and house of quality (HOQ) has been highlighted. A questionnaire survey was conducted on automobile engine refurbishing & remanufacturing facilities in order to find out what is required of the products which are remanufactured. With the establishment of the HOQ, the engineering characteristics that firms should focus on for designing automobile engines for remanufacture have been found as ‘position of the parts’ and ‘ types of parts used’.     

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.     

An enhanced sustainable approach for design and manufacturing with an application to fuselages for mono-seat civil sailplanes

Abstract

A number of tools and software systems have been developed in order to reduce the time for the design and manufacturing of industrial products. Nowadays, virtual modelling by Computer Aided Design (CAD) systems and process simulation by the application of Finite Element Method (FEM) software is a standard routine in order to compress product design activities and to achieve the optimal solution before producing any real components. These developments provided not only a reduction in the time to market but a higher complexity of the project and an improved quality of the industrial products. With the aim to further improve the sustainability of this activity, the implementation of a tool that adds automatic operations into the design activity is demonstrated. This software can interact with any CAD and helps designers when the object dimension and shape can be affected by limits and constraints deriving from different features and targets, such as the spatial collocation of the component and the interaction with other limiting items, for examples the material and the manufacturing issues. The concept was developed into the software SFIDA (Sailplane Fuselage Integrated Design Application) that is a first attempt to automatically manage multiple relations and optimise their combination.     

A method for supporting the design of efficient heating systems using EU product policy data

The design of heating, ventilation and air conditioning systems is still a challenging engineering task which requires experienced and informed decision-making. These systems have a great energy-saving potential at the system level rather than at the level of the individual products of which they are composed. European environmental product policies have been very useful in facilitating a homogeneous rating scheme which can be used to compare the energy performance of different products that provide the same service. This paper proposes a simplified design method which uses the performance of components that are regulated by European product policies to obtain the overall performance of heating systems in residential buildings. It is a flexible method and allows different product configurations to be assessed so as to optimise the system performance during the design phase. The method is tested on a real case study with domestic hot water and space heating systems. The case study shows the potential for improving the heating systems according to the performance levels of its products currently available in the market. Results of the domestic hot water system show that upgrading its storage tank to the maximum energy class (A⁺) could bring the highest energy savings ( 4162 kWh/y).     

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.     

Putting consumers first in design for sustainable behaviour: a case study of reducing environmental impacts of cold appliance use

To slow down the increasing environmental degradation, design for sustainable behaviour (DfSB) has emerged in sustainable design aiming to promote behavioural change through design innovations to reduce environmental and social impacts from the demand side or consumer side. This paper presents a practice-based journey to investigate the process and results of the application of social-psychological theories into sustainable design. Focusing on the behaviour-related impacts of products and services during the use stage, a Design Behaviour Intervention Model (DBIM) is developed through the analysis and synthesis of the social-psychological theories and behaviour-changing strategies. The DBIM indicates that an in-depth study of consumer behaviour is the preliminary step in DfSB, which determines the application of design strategies and potentially the effectiveness of design interventions. A case study is presented to demonstrate the application of the model. The results show that consumer behaviour insights offer rich resources to assist designers in sustainable design innovation. Product-based design suggestions and a proposed solution highlight that the application of DBIM coupled with consumer involvement throughout the design process could produce desirable and sustainable patterns of household fridge use. Finally, the structured consideration of behavioural change and their possible application in DfSB are discussed.