Construction of an optimum system design method considering product lifecycle

This paper proposes an optimum system design method that especially considers product lifecycles and aims to help designers make effective decisions during the product design phase. By considering and estimating all lifecycle factors of cost and environmental impact in addition to the product performance, this method facilitates development of optimum design solutions that incorporate requirements pertaining to the product's entire lifecycle. Furthermore, quantitative estimation of lifecycle factors enables the numerical expression of optimum solutions, rather than depending primarily on experiment and designer intuition. To demonstrate the effectiveness of the proposed method, this paper develops an optimum system design method for a milling machine as an example of a machine product designed for long term use. The lifecycle cost and the lifecycle environmental impact are generally expressed as the summation of each value during manufacturing phase, usage phase, disposal phase and recycling phase. In this example model, Eco-indicator 99 is used to evaluate environmental impact. In the proposed lifecycle design optimisation method, the relationships among the product performance, the lifecycle cost and the lifecycle environmental impact are evaluated as a multi-objective optimisation problem. Analysis of the obtained Pareto optimum solution sets subsequently enables designers to pursue breakthrough product design solutions.     

Assessing sustainability in nature-inspired design

In the field of sustainable product development, a new perspective for approaching sustainability has been advocated, challenging designers and engineers to aim beyond ‘reducing unsustainability’. Several design strategies – including Biomimicry and Cradle to Cradle – have been suggested for developing truly sustainable, or ‘beneficial’, products. But do these strategies help in developing such products, and how to assess their ‘sustainability’? Based on a review of the objectives in nature-inspired design, we argue that assessing environmental sustainability is not straightforward. Whereas both Biomimicry and Cradle to Cradle build on the perspective of ‘achieving sustainability’, current life-cycle assessment-based tools are geared towards reducing current impacts. As a consequence, existing tools are insufficiently equipped for the purpose of the assessment: they do not cover some of the main results that nature-inspired design is set out to accomplish. To be able to include these results, we propose two new constituents to current life-cycle-based product assessment: assessing against conditions of sustainability and assessing ‘achievement’, the extent to which these conditions of sustainability have been achieved. Furthermore, the product context needs to be included for assessing beneficial impacts. This article discusses how these constituents can contribute to an assessment tool that enables designers and engineers to assess the development of environmentally sustainable solutions.     

Selection of green product design scheme based on multi-attribute decision-making method

The function, cost and environmental performance are the primary decision-making factors for scheme selection in green design. For the comprehensive and accurate decision-making in selecting green product design scheme, a quantitative analysis method of multi-attribute decision-making (MADM) is presented. With analysing the multi-attribute of scheme selection, the MADM model is established, which takes environmental impact of materials, disassembly performance, recycling performance, energy efficiency, noise, pollutants to environmental and functional values. Fuzzy technique for order performance by similarity to ideal solution method is applied to solve this model for the feasible solutions. Finally, a case study is given to validate the application of this methodology as a useful design guideline for scheme selection in green design.     

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.     

CAD and DFM: enablers of sustainable product design

Sustainability has been regarded as an important concept for survival in the contemporary scenario. Modern design engineers are in need of approaches for creating sustainable products. In this context, this paper reports a case study carried out in an Indian modular switches manufacturing organisation. The existing handle of the switch has been modelled using computer-aided design (CAD). Then, the sustainability analysis has been carried out for determining the environmental impact. This is followed by the redesign of the handle using design for manufacturability (DFM) principles. The sustainability has been measured in terms of carbon footprint, energy consumption and air–water impacts. It has been found that the redesigned handle possesses minimal environmental impact. It could be inferred from the results of the case study that CAD and DFM could lead to the development of sustainable product design with minimal impact on the environment.     

Sustainable design of sprocket using CAD and Design Optimisation

The contemporary manufacturing organisations recognise sustainability as a vital concept for survival in the competitive scenario. The modern design engineers are in need of approaches for creating environmentally friendlier products. In this context, this project reports a case study carried out in an Indian sprocket manufacturing organisation. The existing sprocket has been created using Computer Aided Design (CAD). Then, the sustainability analysis has been performed for determining the environmental impact. This is followed by the optimisation of sprocket design using Design Optimisation. The environmental impact has been measured in terms of carbon footprint, energy consumption and air/water impacts. It has been found that the optimised sprocket design possess minimal environmental impact. The results of the case study indicated that CAD and Design Optimisation could lead to the development of sustainable design with minimal impact to the environment.     

Sustainable supply chain network design: a multicriteria perspective

In this paper, we develop a rigorous modelling and analytical framework for the design of sustainable supply chain networks. We consider a firm that is engaged in determining the capacities of its various supply chain activities, i.e. the manufacturing, storage and distribution of the product to the demand locations. The firm is faced with both capital costs associated with constructing the link capacities and the links' operational costs. Moreover, the firm is aware of the emissions generated associated with the alternative manufacturing plants, storage facilities and modes of transportation/shipment, which may have different levels of emissions due, for example, to distinct technologies of, respectively, production, storage and transportation. The firm is assumed to be a multicriteria decision-maker who seeks to not only minimise the total costs associated with design/construction and operation, but also to minimise the emissions generated, with an appropriate weight, which reflects the price of the emissions, associated with the various supply chain network activities. We provide both the network optimisation modelling framework and an algorithm, which is then applied to compute solutions to a spectrum of numerical sustainable supply chain design examples in order to illustrate our approach.     

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 meta‐heuristic approach for supporting adaptive disassembly sequencing using a multi‐objective concept

One of the key features of environmentally conscious manufacturing has been the efforts to promote product recycling and remanufacturing. Efficient material re‐utilisation through product disassembly to retrieve the desired parts and/or subassemblies is one rational approach. This is because it can promote the conservation of both material and energy resources whilst concurrently reducing environmental impact. However, because manufactured products may be made from many components, disassembly load becomes a critical factor that may obstruct the recovery of materials. Accordingly, it is essential to develop a practical method for deriving a disassembly plan to decrease such load, and to endow a certain value to the product at the end of its life cycle. With this understanding, the authors have developed a practical procedure to produce an adaptive disassembly strategy. The authors have applied a meta‐heuristic method known as genetic programming (GP) as a search engine to derive the adaptive disassembly sequence together with a multi‐objective optimisation method termed MOON^2R. The authors have also proposed a hierarchical sequencing method to cope with large/complex products and added several ideas to increase the applicability associated with the interests in disassembly of hazardous and/or valuable parts, and alternative disassembly actions. Through numerical experiments, the authors examined the effectiveness of the proposed approach by showing its support for relevant planning and design decisions for product recycling and remanufacturing from various viewpoints.     

Industrial energy efficiency potentials: an assessment of three different robot concepts

The rise in energy consumption and the associated costs instigate financial concerns among industrial energy consumers. For industrial processes addressing heating and cooling as well as material transformation, a wide range of energy efficiency measures have been developed and successfully implemented. In contrast to that, most robot-based operations such as pick-and-place motions or assembly tasks still use inefficient standard concepts causing high-energy consumption and high-energy costs. Thanks to a rather low payload-to-weight ratio of new robot designs, such as parallel kinematic or hybrid robot manipulators, a high potential for energy savings is expected. This article identifies potentials for energy saving concerning industrial consumers by assessing three different robot concepts. Based on a literature review, two existing designs for robots – the conventional serial robot and the parallel kinematic robot are analysed and compared with respect to the energy utilised during a typical item placement task. Afterwards, the concept of PARAGRIP, a hybrid of the two presented robot designs is introduced and examined based on simulation regarding its energy consumption. The final results demonstrate significantly different energy consumptions between the robot concepts, identifying potential savings of about 40% in a selected industrial application scenario.     

Metamodelling-based Product Family Design of Plug-in Hybrid Electric Vehicles

Development of plug-in hybrid electric vehicles (PHEVs) is stimulated by the need to replace non-renewable energies with sustainable and more environment-friendly new energy types. PHEVs benefit from a combination of an internal combustion engine and an electric motor with a rechargeable and larger battery pack than conventional hybrid vehicles. In order to maximise customer satisfaction and motivate replacement of the conventional vehicles with this new technology, the design of PHEVs requires sufficient differentiation in the product specifications for diverse market segments. The added set-up time, processes, costs and longer lead time for designing and manufacturing a diverse range of such vehicles is a hurdle towards increasing their diversity. This study proposes an efficient product family design (PFD) method for mass customisation of the PHEV powertrains. The methodology is less dependent on expensive simulations due to use of metamodelling and non-conventional sensitivity analysis. The PFD concept and its implications to a family of five PHEVs are investigated, and benefits as well as limitations of a sustainable development for this complex product are discussed.     

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.     

Multi-objective design optimization of sustainable commercial a-ircraft: performance and costs

The present work deals with a multi-objective optimisation approach to incorporate up-to-date financial models in the multidisciplinary conceptual design of a commercial aircraft. Design optimisations based on financial objective functions are compared to standard performance-based optimal solutions. The main novelty is in the extension of the financial models to the long-term investments of a wider group of stakeholders. The rationale underlying this research stems from two considerations: (i) the environmentally sustainable development of the air transportation system in the next 20 years is subordinate to breakthrough technologies, since the consolidated ones have reached their saturation point; (ii) the economic impacts of highly innovative concepts on the stakeholders chain is still uncertain. The problem is addressed at the conceptual design level and the analysis is performed within a comprehensive multidisciplinary framework, adopting all the technical constraints required in aeronautical design. The Pareto fronts obtained using performance and financial merit factors, reveal that the proposed financial model yields highly efficient, technically sound concepts. The design space point corresponding to the negative cash flows minimum turned out to be very close to the one corresponding to minimum acoustic emissions, confirming that the financial model drives the optimiser towards environment-friendly designs.     

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.     

Rural change and multidimensional analysis of farm’s vulnerability: a case study in a protected area of semi-arid northern Nicaragua

This paper presents an empirical research in a protected area of northern Nicaragua, aimed at: (a) classifying predominant narratives surrounding present and future pathways of the local rural system, drivers of change, features of livelihoods’ vulnerability; (b) understanding current functioning of local metabolic patterns of rural systems by developing a typology of farms and (c) comparing types’ vulnerability to current drivers of change. To achieve these objectives, we integrated qualitative and quantitative analytical approaches. The different visions of rural spaces, which emerge from the analysis of the narratives, and the five types of farms, characterized by specific land-time budget and energy and monetary flows, suggest two emerging dynamics of local restructuration in protected areas: (1) a dominant land re-concentration process which is generating increasing inequality in access to resources and a progressive marginalization of the self-sufficient economy of landless and subsistence households; (2) an emergence of a paradigm of ‘environmentalization’ of rural spaces together with a valorization of small and medium-scale diversified economies. Moreover, the vulnerability assessment focuses on multidimensional features of types’ sensitivity to crisis, i.e. risk unacceptability, production instability, economic inefficiency, food and exosomatic energy dependency, as well as capacity to buffer and adapt to change, i.e. access to assets, including labour for men and women, social safety nets and degrees of economic diversification. The discussion highlights the occurrence of trade-off between the solutions adopted by farms within different development paths, suggesting the relevance of the proposed framework of analysis at the interface between science and policy.     

Comprehensive emergy evaluation and optimization of corn straw power generation system: a case study

Biomass energy has become an important measure to alleviate ecological environment security and energy supply security in China. Emergy accounting method is used to analyze and evaluate economy, environment, and sustainability of corn straw generation system, which includes corn planting subsystem, collection and transportation subsystem, and corn straw power generation subsystem. The key substances that need to be optimized in the system are identified by using sensitivity analysis. Based on the position of key substances in the system, emergy accounting optimization methodology is conducted. Corresponding optimization design scheme is proposed based on the “3R” (reduce, reuse, and recycle) principle of circular economy. Current study shows that emergy yield ratio, emergy investment ratio, environmental loading ratio, and emergy sustainability index of the corn straw power generation system are 3.69, 2.68, 1.61, and 2.29, respectively, which are better than wind power generation system and thermal power generation system. In addition, it is proposed that the fertilizer alternative plan and the transportation redesign plan can replace 50,000 tons potash and reduce equipment resources by 20% and energy resources input by 30%. Economy and sustainable development of the system is significantly improved. The optimization design method based on the “3R“ principle proposed in this paper can provide a useful reference for the research in the field of resource recycling.     

Assessing the role of consumers in sustainable product policies

A global analysis shows that considerable forces contribute nowadays to the perpetuation of the so-called “developed” model of consumption, and its extension to growing parts of the world, despite reiterated calls for “modification of production and consumption patterns”. Environmental product regulation can be situated in this general perspective. This paper returns to the framing of policies devoted to ecologically sustainable consumption, taking the example of the Integrated product policy at the European level. How are the objectives of such policies defined? What instruments are privileged? Comparing theoretical approaches with policy design, we focus on the role devoted to consumers in these contexts. Bringing in literature evidence, survey results and findings from an original study, we argue that appropriate knowledge of the diversity of consumers’ attitudes and about the limitations of their possible actions is not properly taken into account in product policies, notably when information and voluntary tools are dominant. From this point of view, environmental product regulations are well justified, but they should, as all policy instruments implicating consumers, take careful notice of their situation.     

Performance evaluation of solar photovoltaic electricity-generating systems: an Indian perspective

The present work seeks to assess the sustainability of different solar photovoltaic (SPV) electricity-generating systems based upon energy, environment and economics. The sustainability indicators evaluated for energy, environment and economics are electrical output, life-cycle greenhouse gas (GHG) emissions and life-cycle cost of electricity generated per kilowatt hour. The selected SPV-based electricity generation technologies for sustainability evaluation are amorphous, monocrystalline and polycrystalline at different locations and tilt angles across India. For SPV systems, most of the emissions are the result of electricity use during manufacturing. In these cases, an average grid mix for the region of manufacture is typically used to calculate energy use and emissions. Based upon these three indicators, a figure of merit (FM) has been proposed. The results proposed that polycrystalline gives the maximum electrical output, minimum GHG emission, minimum cost and maximum FM at a radiation level of 6 kWh/m²/day with latitude and tilt angle of 34° and 35°, respectively. This work will be helpful to users of solar energy, academicians, researchers and other concerned persons, in understanding the importance, severity and benefits obtained by the application and implementation of the SPV electricity-generating systems.     

A framework to minimise total energy consumption and total tardiness on a single machine

A great amount of energy is wasted in industry by machines that remain idle due to underutilisation. A way to avoid wasting energy and thus reducing the carbon print of an industrial plant is to consider minimisation of energy consumption objective while making scheduling decisions. To minimise energy consumption, the decision maker has to decide the timing and length of turn off/turn on operation (a setup) and also provide a sequence of jobs that minimises the scheduling objective, assuming that all jobs are not available at the same time. In this paper, a framework to solve a multiobjective optimisation problem that minimises total energy consumption and total tardiness is proposed. Since total tardiness problem with release dates is an NP‐hard problem, a new greedy randomised multiobjective adaptive search metaheuristic is utilised to obtain an approximate pareto front (i.e. an approximate set of non‐dominated solutions). Analytical Hierarchy Process is utilised to determine the ‘best’ alternative among the solutions on the pareto front. The proposed framework is illustrated in a case study. It is shown that a wide variety of dispersed solutions can be obtained via the proposed framework, and as total tardiness decreases, total energy consumption increases.