Implementation of Design for Sustainability in Product Engineering ^†

Abstract

Product engineering involves the design and development of new products or the improvement of existing products to efficiently meet market needs and ensure high quality. Design for Excellence (DfX) concepts, such as Design for Manufacturing, Design for Assembly, Design for Reliability, Design for User Experience, Design for Testability, and Design for Security, are essential in product engineering. These concepts enhance manufacturability, ease of assembly, and serviceability, thereby improving overall product performance and user experience. Integrating sustainability principles into product engineering practices is crucial due to growing concerns about environmental sustainability. Sustainability involves responsible resource use, waste and emission reduction, and consideration of social and economic impacts. Adopting sustainable practices is essential for addressing global challenges like climate change, resource depletion, and pollution. Consequently, sustainability has become a significant factor for businesses and government policies worldwide. Product engineering possesses significant potential for contributing to sustainability goals. In this view, this paper discusses a new approach called “Design for Sustainability (DfS)” that focuses on developing sustainable products. The paper discusses the various steps involved in implementing DfS in the product engineering process, highlighting its importance and benefits. By implementing DfS practices, businesses can create innovative and marketable products that minimize environmental impact while meeting consumer demands.

1. Introduction

Design for Excellence (DfX) is a set of principles and methodologies employed in the field of engineering and product design to optimize various aspects of a product’s performance, manufacturability, reliability, and other key factors. The “X” in “Design for X” represents different elements or objectives that can be targeted for improvement [1,2,3]. Design for Sustainability (DfS) plays a crucial role in the development of sustainable products. Three key dimensions need to be considered, as shown in Figure 1. Environmental factors include considerations such as resource depletion, pollution, waste generation, greenhouse gas emissions, and the overall ecological footprint of the product. Economic factors involve assessing the economic feasibility of a product’s lifecycle, including its production, distribution, use, and end-of-life management. Sociocultural factors include understanding the needs, values, and behaviors of the target market or user group.

Sustainability involves the careful use of natural resources to ensure their availability for future generations, focusing on two fundamental principles: using fewer resources and choosing eco-friendly alternatives [4]. When considering resources in the context of sustainability, it includes not only raw materials but also design and manufacturing processes, systems, transportation, distribution, and other elements involved in product development [5,6]. The design phase significantly influences product engineering, impacting the environment through material choices, factory processes, installation, maintenance, and disposal. Numerous studies have shown that effective design processes can mitigate the majority of a product’s negative environmental impact [7]. Therefore, incorporating design for sustainability is vital for the future of product engineering [8].

In recent years, there has been increasing awareness of the harmful effects of products and processes on the environment due to excessive resource utilization. While this issue has been recognized since the early days of the industrial revolution, empirical data were unable to substantiate concerns [9,10]. However, modern technologies and methodologies have provided clear evidence that these negative environmental impacts are real and pose significant risks. The consequences of inaction are severe, including the depletion of natural resources, ultimately risking human life. To ensure a high quality of life for future generations, it is essential to adopt sustainable practices and develop products that minimize or eliminate environmental harm. The responsibility lies with engineering and manufacturing teams to create products that meet their objectives while having minimal or no environmental impact. In this view, this paper explores DfS in product engineering, delving into its principles, methodologies, and potential implications. By understanding and implementing sustainable design practices, we can create a path towards a more environmentally aware and responsible future in product development, safeguarding the well-being of present and future generations.

2. Production Engineering

Production engineering is a dynamic field that plays a vital role in shaping the modern industrial landscape. It includes a wide range of disciplines and techniques aimed at optimizing production processes, improving efficiency, and enhancing product quality. With the increasing demand for innovative and cost-effective manufacturing solutions, production engineering has become a crucial component of the global economy. The key stages involved in the process of product engineering are shown in Figure 2 and explained as follows.

• ▪ Conceptualization: This includes finding customer needs and market demands, as well as generating ideas/concepts for new products. Market research, surveys, and brainstorming sessions are conducted to gather information and make innovative ideas.
• ▪ Design: Once a concept is selected, product engineers work on creating detailed designs. This includes developing 2D or 3D CAD (computer-aided design) models, conducting engineering analyses, and selecting appropriate materials and components.
• ▪ Prototyping: Prototypes are created to validate and test the design. This could involve building physical models or using virtual simulations to assess the product’s functionality, performance, and durability. Feedback from prototype testing helps in refining the design and addressing any issues.
• ▪ Manufacturing: After the design is finalized, product engineers collaborate with manufacturing engineers to establish efficient production processes. This involves determining the best manufacturing methods, selecting equipment and tools, and developing quality control procedures.
• ▪ Testing and Validation: Product engineers conduct rigorous testing and validation to ensure that the product meets performance standards, safety regulations, and customer expectations. This may involve various types of testing such as functionality testing, stress testing, and environmental testing.
• ▪ Continuous Improvement: Product engineering involves a continuous improvement cycle. Feedback from customers, market trends, and manufacturing data are analyzed to identify areas for improvement. Engineers then refine the design, manufacturing processes, and performance to enhance the product’s quality and competitiveness.

Through the product engineering process, interdisciplinary collaboration is essential. Product engineers often work closely with industrial designers, mechanical engineers, electrical engineers, software developers, and other professionals to integrate different aspects and ensure the final product meets the desired specifications. Product engineering combines creativity, technical knowledge, and problem-solving skills to transform ideas into tangible products that meet customer needs and offer value in the marketplace.

3. Steps for Implementing DfS

In the near future, achieving a fully sustainable product with genuine mass and energy balance may present significant challenges. However, by adhering to specific principles and guidelines, advancements can be made towards that goal. Enhancing the situation requires further research and development in this domain. The key steps involved in the implementation process are shown in Figure 3 and described as follows.

(A)

Material Selection: The selection process for materials used in the product should consider the total material and energy consumption involved in their extraction and transportation. Preference should be given to reducing the amount of material used or using alternative materials that are easier to extract and consume less energy. Additionally, it is important to have a proper waste and disposal plan for the materials. When considering design alternatives, all use cases should be taken into account. Using less material, reducing the number of components, and exploring alternative technologies can help achieve the same functionality. This approach reduces costs associated with packaging, storage, and overall carbon footprint.

(B)

Modular Design Principles: A modular, reusable design involves utilizing interchangeable modules and components that can be employed in multiple products, allowing for various combinations and resulting in different product variations. Despite the numerous advantages this approach offers and the flexibility it provides to designers, products have traditionally been designed as monoliths due to factors like ease of design and manufacturing. However, such monolithic designs contribute to resource waste and energy consumption in maintaining inventory and spare parts, as well as present challenges when disposing of obsolete components over time. Instead, investing additional costs and time during the design phase to create innovative building blocks that can be assembled to meet evolving demands proves to be a more efficient approach.

(C)

Alternative Energy Resources: Industrial sensors, control systems, and various products often require a power source for their operation, which can vary in terms of magnitude. But the traditional approach of laying power cables over long distances and trenches and requiring numerous accessories results in a significant consumption of materials. The rise of renewable energy sources with a smaller footprint and higher power density provides an opportunity for designers to consider alternative power solutions [11]. Mini/micro forms of solar, thermal, vibration, and hydraulics can be utilized to generate the necessary power to sustain the sensor’s functionality and transmit signals to upper layers [12].

(D)

Serviceable Products: Promoting serviceable products instead of use and throw opens up new opportunities in the industry. By creating equipment that can be used in multiple locations, business models such as rentals and leasing can emerge as alternatives to traditional sales. This enables companies to develop products that are designed for reuse.

(E)

Circular Economy: Generally, the economy has been perceived as a linear progression where resources are extracted from natural sources, transformed to add value, and transported for consumption by end users. Once utilized, products mostly end up as waste, except for those containing precious metals, resulting in irreparable harm to the soil, water, and air. This linear economic model inevitably generates waste, and its magnitude continues to grow. An alternative approach is known as the circular economy, which emphasizes resource reuse, waste reduction, and the extensive reutilization of disposed products [13]. Such a system and its associated products are highly resource-efficient, lessening strain on natural resources and minimizing environmental impact. While they may appear costlier initially, consumer preferences can mitigate such concerns. Ideally, once a circular economy is established, it becomes increasingly efficient, particularly when our focus shifts towards developing sustainable products [14]. Within this context, individuals involved in product design and engineering can adopt the 4Rs as a guiding principle or a NorthStar. As shown in Figure 4, the 4Rs stand for reduce, reuse, repair, and recycle. A sustainable design should prioritize and incorporate the 4Rs.

(F)

Long Service Life: The majority of sensors used in industrial applications are intended to have a long lifespan, typically more than 10 years. However, the upper layers of these systems, such as third-party personal computers and other components designed for different purposes, may not possess the same longevity. To ensure improved and prolonged service life, the software must be independent of the specific hardware it runs on. Additionally, specialized hardware platforms should be developed to align with this software and provide extended durability. Similarly, the lifespan of cables and other consumables should be optimized for ruggedness and prolonged service. By designing these components to withstand challenging conditions and endure extended usage, overall system reliability can be significantly enhanced.

(G)

Transportation Impact: In the realm of industrial systems, components are sourced from different parts of the world, assembled in a separate location, undergo testing, and then shipped to the final destination. This process involves multiple movements of the same equipment without considering the environmental impact it generates. Cost and speed are the primary considerations, overshadowing environmental concerns. However, future designs and business models aim to minimize these impacts by promoting a model where equipment is assembled and used in the same location, reducing the need for extensive transportation. This approach avoids long-distance commuting/transportation and mitigates associated environmental consequences.

(H)

Simulation: Product engineering involves creating prototypes based on certain assumptions and testing them to meet specified requirements. However, this process often generates a significant amount of waste, particularly during the production of prototype PCBs and 3D-printed materials. Simulation can be used to test different design alternatives quickly and efficiently. Nonetheless, by implementing a robust simulation strategy and utilizing available tools and extensive databases on similar products, more optimal outcomes can be achieved. Simulation can help to identify and quantify the environmental impacts of a product design. By leveraging these tools, the need for expensive trial-and-error prototypes and excessive paperwork is minimized, leading to reduced costs, waste, and a more sustainable use of resources [15]. Simulation tools are also instrumental in conducting various analyses such as stress, vibration, thermal, and impact. Simulation can be used to predict the performance of a product. They enable designers to identify and address potential issues early in the design process, thus avoiding costly tests and associated material waste.

4. Sample Case Study

To understand the impact of DfS, a sample case study is provided as follows for the “Electric vehicle battery pack” application. It includes various steps and the expected results of implementing the DfS.

• ▪ Material selection: Select materials that are lightweight, durable, and recyclable.
• ▪ Modular design principles: Design the battery pack in a modular way so that individual modules can be easily replaced.
• ▪ Alternative energy resources: Use renewable energy resources, such as solar or wind power, to charge the battery pack.
• ▪ Serviceable products: Design the battery pack so that it can be easily serviced and repaired.
• ▪ Circular economy: Design the battery pack so that it can be recycled at the end of its life.
• ▪ Long service life: Design the battery pack to have a long service life.
• ▪ Transportation impact: Minimize the transportation impact of the battery pack by designing it for local production and distribution.
• ▪ Simulation: Use simulation to optimize the design of the battery pack for sustainability.

Expected result: The DfS redesign of the electric vehicle battery pack results in improved performance and lifespan and provides a significant reduction in environmental impacts and cost.

5. Research Directions

Future research directions in sustainable product engineering involve the integration of emerging technologies, designing for disassembly and upgradability, and the promotion of education and training in sustainable product design. These are given as follows:

(A)

Integration of Emerging Technologies: As the field of product engineering continues to evolve, the integration of emerging technologies plays a crucial role in driving sustainable design practices. Emerging technologies, such as artificial intelligence (AI), the Internet of Things (IoT), and advanced manufacturing techniques, offer significant opportunities to enhance the sustainability of products. For example, AI can be utilized to optimize energy efficiency and material usage in product design, while IoT enables real-time monitoring and data collection for performance analysis and resource optimization. Additionally, advanced manufacturing techniques, including additive manufacturing and nanotechnology, allow for more efficient production processes, reduced material waste, and customization of products to meet specific consumer needs.

(B)

Designing for Disassembly and Upgradability: Disassembly refers to the ease with which products can be taken apart at the end of their lifecycle, allowing for the recovery of valuable components and materials. By designing products with disassembly in mind, engineers enable efficient recycling and reuse processes. Further, design for upgradability involves creating products that can be easily upgraded/repaired instead of being replaced entirely. This extends the product’s lifespan and reduces the need for new production.

(C)

Education and Training: Educational institutions and training programs can include sustainability-focused courses. These programs emphasize concepts such as life cycle thinking, environmental impact assessment, eco-design principles, and the application of sustainable materials and manufacturing techniques. With these, we can foster a new generation of product engineers who are well-versed in sustainable design principles and equipped to create innovative and environmentally responsible products.

6. Conclusions

Design plays a crucial role in product engineering in industries such as automotive and medical, as it shapes the user experience and functionality, and ultimately impacts customer satisfaction and market success. This paper recommends incorporating DfS (Design for Sustainability) by implementing sustainable design practices throughout the product life cycle, including reducing resource consumption, enhancing productivity, utilizing modular and reusable components, incorporating business models like leasing, and promoting the use of recycled or reclaimed materials. These practices can have a substantial positive impact on the environment and society. Furthermore, to facilitate informed decision-making by customers, researchers can explore the establishment of a dedicated weightage factor and universally accepted numerical value. This standardized approach would enable customers to make conscious choices regarding the sustainability of products, thereby encouraging the adoption of eco-friendly solutions in various industries.