Design for sustainability

Development of blue economy involves the construction of marine infrastructures (harbors, marine wind farms, underwater data centers etc.) for which a precise knowledge of geological bottom properties is needed. Near shore and very near shore sites represent an important opportunity especially for closed basin with extended coast lines such as the Mediterranean basin or the Caspian one. For these activities conventional offshore drilling equipment is not well suited. For this reason, authors have developed a compact amphibious system to perform geognostic activities on near shore and very near shore sites, in this work authors focus their attention on the creation of a digital twin able to properly support system design.

Keywords: Geognostic , Hydraulic and Electro-Hydraulic System , Mechatronics , Near Shore Prospecting , Wireline Drilling

The goal of pursuing the circular economy (CE) is spreading more and more in industry, also driven by the introduction of new regulations, considerably affecting product design. However, a quantitative and rigorous evaluation of the environmental impacts of the results obtained by different design strategies used to implementing CE is missing in the literature. Those available only evaluate certain aspects of the life cycle of few products, belonging to specific application fields, in a qualitative way or they refer only to the global warming potential. This study provides a quantitative assessment of the environmental impacts reductions arising from the application of some common design strategies for implementing different CE options (e.g. reuse, waste to energy, remanufacturing), by using some standard indicators. The results were obtained by manually analysing 156 selected case studies of comparative life cycle assessment (LCA), extracted from 136 scientific articles. In them, the environmental impacts of design solutions for CE are compared with those of other solutions were wastes are not exploited. The obtained results have been used to evaluate the different design strategies for CE and to hierarchize them based on environmental sustainability of the solutions associated with them. In addition, an economic evaluation of the strategies, based on the life cycle costing methodology and exploiting the data available in the same articles, was also provided. Among the main achievements, it was found that the hierarchy of the CE options, pursued by the design strategies, to improve environmental sustainability is different from that provided by other studies. In addition, the environmental benefits associated with the different CE options strictly depend by the applied design strategies and the considered products.

Keywords: Circular economy , Design strategies , Eco-design , Life cycle assessment (LCA) , Literature review

Despite the increasing degree of automation in industry, manual or semi-automated are commonly and inevitable for complex assembly tasks. The transformation to smart processes in manufacturing leads to a higher deployment of data-driven approaches to support the worker. Upcoming technologies in this context are oftentimes based on the gesture-recognition, − monitoring or–control. This contribution systematically reviews gesture or motion capturing technologies and the utilization of gesture data in the ergonomic assessment, gesture-based robot control strategies as well as the identification of COVID-19 symptoms. Subsequently, two applications are presented in detail. First, a holistic human-centric optimization method for line-balancing using a novel indicator–ErgoTakt–derived by motion capturing. ErgoTakt improves the legacy takt-time and helps to find an optimum between the ergonomic evaluation of an assembly station and the takt-time balancing. An optimization algorithm is developed to find the best-fitting solution by minimizing a function of the ergonomic RULA-score and the cycle time of each assembly workstation with respect to the workers' ability. The second application is gesture-based robot-control. A cloud-based approach utilizing a generally accessible hand-tracking model embedded in a low-code IoT programming environment is shown.

Keywords: assembly , gesture-based control , Gesture-Based monitoring , manufacturing

The production of electric energy has been increasingly deriving from renewable sources, and it is projected that this trend will continue over the next years. Among these sources, the use of solar energy is supposed to be considered the main future solution to global climate change and fossil fuel emissions. Since current photovoltaic (PV) panels are estimated to have an average life of 25–30 years, their disposal is very important for the recovery of materials already used and for introducing them again into other processing cycles. Innovative solutions are therefore needed to minimize the emissions of pollutants derived from the recycling of photovoltaic panels that no longer work. In this research, an analysis of data related to durability, recyclability rates, different possible design layouts and materials used in the design and manufacture of PV panels was conducted. Through a Design for Recycling (DfR) and a Design for Durability (DfD), the authors identified the optimal materials, the best geometries and geometric proportions as well as the most convenient geometric and dimensional tolerances in the couplings between the layers and the components that comprise the panel to attain the most current, efficient and effective solutions for recycling end-of-life (EoL) PV panels and for longer durability

Keywords: coupling tolerances , EcoDesign method , end-of-life management , recyclability rates , sustainability

Sustainability and durability are not always interchangeable concepts, especially for products that require many resources during their long use phases, like energy related products. In addition, the literature either focuses on how the product performances change over time or evaluates the convenience of durable goods. In this context, the present work presents a durability assessment from an environmental perspective. Unlikely the existing literature, it simultaneously compares the different methods that describe how the product performances may vary with time, specifically how the foam aging influences the yearly energy consumption of refrigerators and assess the durability from the environmental point of view under different circumstances. The primary outcomes highlight the need to introduce a more accurate description of product performances during their lifetime (i.e. aging of components) to obtain realistic results. Furthermore, this work enlightens the need to align the analytical report on the deterioration of refrigerators' components and provides alternative exemplifications to assess the environmental sustainability of durability. As far as the latter case is concerned, multiple products can take advantage of it and have durability considered from the environmental point of view.

Keywords: Durability , Energy related products , Environmental assessment , Foam aging , Part substitution

The ease of disassembly and the application of repairability metrics are important in determining the ability to repair industrial products and goods (e.g., ease of Disassembly Method, Repair Scoring System, French repairability index, etc.). Increasing product repairability is a key aspect to tackle during the product development process aiming at the product lifetime extension and the reduction of industrial waste. The purpose of this work is to find eco-design actions by examining the ability to disassemble key components in different types of gas hobs. After the definition of target components, several disassembly tests were performed following the method proposed by the Joint Research Centre's report (Analysis and development of a scoring system for repair and upgrade of products) and the European standard EN 45554 (General methods for the assessment of the ability to repair, reuse and upgrade energy-related products). The Disassemblability Index of each priority part has been calculated, being able to verify that one of the factors that affect the most is the number of steps needed to remove the component. The outcomes offer interesting insights into the characterization of disassembly issues as well as for the identification of possible eco-design actions making the product repairability efficient and less costly.

Keywords: Cooking appliances , Design for Repairability , Disassembly , Eco-design , Sustainable design

In the last decade, the field of Human-Robot Collaboration (HRC) has received much attention from both research institutions and industries. Robot technologies are in fact deployed in many different areas (e.g., industrial processes, people assistance) to support an effective collaboration between humans and robots. In this transdisciplinary context, User eXperience (UX) has inevitably to be considered to achieve an effective HRC, namely to allow the robots to better respond to the users' needs and thus improve the interaction quality. The present paper reviews the evaluation scales used in HRC scenarios, focusing on the application context and evaluated aspects. In particular, a systematic review was conducted based on the following questions: (RQ1) which evaluation scales are adopted within the HRI scenario with collaborative tasks?, and (RQ2) how the UX and user satisfaction are assessed?. The records analysis highlighted that the UX aspects are not sufficiently examined in the current HRC design practice, particularly in the industrial field. This is most likely due to a lack of standardized scales. To respond to this recognized need, a set of dimensions to be considered in a new UX evaluation scale were proposed.

Keywords: Human-Robot Collaboration , Review , Transdisciplinary engineering , User experience evaluation , User experience scale

Joining is critical in shipbuilding impacting significantly on several aspects, i.e., properties, lightness, aesthetics, assembly/disassembly, maintenance employed workforce, emissions of fumes or gases. Consequently, it requires a significant study on impacts and risks. The aim of this work is to apply the Life Cycle Assessment to a friction stir welding process between aluminium and steel. The results confirmed that this welding is among the most sustainable (i.e., low energy, absence of filler, inert gases, and consumables). Moreover, was introduced a functional unit (i.e., length of weld divided by the thickness squared) that allows to compare different geometries and process parameters.

Keywords: Energy , Joining , LCA , Risk assessment , Sustainability

A deep research and analysis of a “critical waste” object has been carried out, understood as a subject that does not fare high on the separate collection and recycling system yet: the cigarette butt. This acknowledged social waste is the first among all the garbage detected everywhere around neighborhoods worldwide, and is therefore the epicenter of a situation so worrying that it is necessary to find a solution concerning the environmental pollution. The present exercise was developed, by means of proper product design methods like TRIZ and QFD driven by DFSS rulings, to conceive of new products and services in order to create incentive for the smokers to lessen the environmental pollution problem. The social implications are about the possibility of modifying the bad habits of the smokers and making the user act consciously towards the environment. Throwing the cigarette-stub in the new collection device, rather than on the ground, enables users to enjoy both moral and economic returns. The “Buttalo” service is aimed to incentivize the population to fight against environmental pollution whilst helping smokers to be conscious about it.

Keywords: benchmarking analysis , Design for Six Sigma (DFSS) , quality function deployment (QFD) , Top-Flop analysis , TRIZ

Complex manufacturing systems are recently undergoing a green revolution due to manufacturing customization towards sustainable products. A key enabler for the implementation of green and energy efficient production is simulation-based design, which supports system engineers and designers in making decision choices aimed at enhancing the performance of smart and sustainable production. In this context, this work proposes a simulation approach to support the design of the layout and operation of automated guided vehicles (AGVs) in complex production lines. In particular, a case study related to the assembly of electric axles for heavy-duty vehicles is presented: a scenario analysis implemented in the Plant Simulation platform is used to determine the optimal configuration of AGVs in terms of number of vehicles and operation (e.g., definition of charging strategies, scheduling of charging stops, routing). The simulation results first show that the reduction of the AGVs' energy consumption and the increase of production throughput are competing criteria; second, the choice of AGV charging strategies has a significant influence on the energy consumption as well as on the productivity performance.

Keywords: automated guided vehicle (AGV) , Complex manufacturing systems , discrete event simulation , sustainable and efficient manufacturing , what-if analysis

Customers are aware of the complexity of supply chains and link this to a high environmental burden. However, if not coupled with quantitative results, this may be overestimated. The present paper proposes a general method used in the specific case of deep environmental evaluation of a swimming goggles distribution. The results are compared to the consumers' perceptions, collected and analyzed from questionnaires, and the remaining product lifecycle stages, assessed through the life cycle assessment (LCA). The design and prototyping phases take place in Italy, the goods are manufactured in Asia, and further commercialized worldwide. The environmental analysis enabled the identification of the most impacting lifecycle phases. Results highlight that for small products, with a simple use phase like the goggles, the distribution phase retains a small percentage of the overall environmental impact; thus, it is reasonable to simplify the modeling of the supply chain by selecting a limited number of significant scenarios. This work proves how important is to quantify and rationalize the environmental impacts of a complex system. The end of life and transport phases are perceived as high impacting, but the life cycle assessment analysis reveals that the materials and manufacturing phases retain the highest impacts and are the first that should be improved. Consequently, proper dissemination, cooperation, and communication strategies should be carried out by the goggles brand toward suppliers and stakeholders; the company is now studying how to replace virgin materials with recycled content to lower the environmental impact without hampering the product's performance.

Keywords: computational foundations for engineering optimization , data-driven engineering , knowledge engineering

Recent advances in physiological monitoring devices have supported the diffusion of a human-centric approach also within industrial contexts, where often severe working conditions limit the analysis of the operators' User eXperience (UX). Several methodologies have been presented to the scientific community to assess the overall UX of workers performing industrial operations. These methodologies have also tried to encompass the diverse aspects of the physiological response (e.g., mental workload, stress conditions and postural overloads). The current study aims to refine a unique and comprehensive UX index to identify the specific causes of the user discomfort in advance and to optimize the overall system design. A full set of non-invasive wearable devices was applied to a virtual reality (VR) simulation while performing manual operations to collect relevant physiological parameters and to finally assess the overall UX. The results demonstrated the effectiveness of the proposed index in anticipating the operator's critical conditions by specifying the possible causes of the ergonomic discomfort. Future works will focus on investigating the theoretical foundation of proposed solution and on providing a statistical validation on a larger population.

Keywords: Ergonomic Index , Human Monitoring , Human-Centered Design , Industry 5.0 , User Experience , Virtual Reality

This paper is intended to offer a cue for optimizing a generic disassembly process for maintenance purposes. Through the use of a cutting-edge technology such as augmented reality, a key tool that makes it immediate to tell operators what they need to do, this can be made possible as never before within companies. A first aim of the work is to define the optimal disassembly sequence that can lead to the extraction of a target component of the assembly minimizing the number of parts to be removed, applying two methodologies within the framework of Design for Disassembly. Thus, the most important goal is to show and teach to maintenance technicians which steps they should follow in order to efficiently carry out the repair process built on that sequence so that they can work on a product while learning in parallel what they need to do exactly at the same time. This could be useful in case a component replacement becomes necessary especially because nowadays it is still performed inefficiently and lacks a rigorous logic and methodology aimed at its efficiency in companies.

Keywords: augmented reality , CAD modeling , Design for Disassembly , Industry 4.0 , maintenance optimization

Rapid development in vehicular technology has caused more automated vehicle control to increase on the roads. Studies showed that driving in mixed traffic with an autonomous vehicle (AV) had a negative impact on the time headway (THW) of conventional vehicles (CVs) (i.e., driven by humans). To address this issue, there is a need to equip CV with visual advanced driver assistance systems (ADASs) that helps the driver maintain safe headway when driving near AVs. This study examines the perception of drivers using visual ADAS and their associated risk while driving behind the AV at constant and varying speeds. The preliminary results showed that while visual ADAS could help drivers keep the safe THW, it could affect drivers' ability to react to emergencies. This implies that visual modality alone might not be sufficient and therefore requires some other feedback or intelligent transport systems to help drivers maintain safe driving in a mixed-Traffic condition.

Keywords: car-following , sustainable transport management platooning , virtual realtiy , visual advanced driver assistance system

Nowadays, mechatronic systems are used in every field and all around us, going through micro, small, medium and large power systems. Due to their widespread use, mechatronic system design plays an important role in energy sustainability.Mechatronic systems are generally complex systems from a modelling point of viewdue to the presence of several domains and a set of related interfaces for energy exchanges. Such a context needs a multi-domain and integrated design to correctlyevaluate mechatronic system performances. Modelling and simulation tasks are generally adopted to evaluate the behaviour of mechatronic systems in order to meet system requirements. Unfortunately, energy saving is not always considered among the set of primary requirements, while it is tackled only after reaching the expected system behaviour. The present chapter tackles themulti-domainmodelling and simulationof mechatronic systems according to V-model steps and using the RFLP approach driven by sustainability requirements. The key idea is to perform a concurrent evaluation of energy and domain performances. It summarises a case study, by using Matlab/Simscape environment, to illustrate the used approach. Moreover, it introduces the design of mechatronic systems pulled by environmental sustainability as a new paradigm in opposition to the design pushed by system performances.

The paradigm of Industry 4.0 allows to increase the efficiency and effectiveness of the production. Companies that will implement advanced solutions in production systems will increase their level of competitiveness and will be able reach high market shares. The present paper is focused on the development of advanced digital solutions to be implemented on a close power loop test bench designed to test high power transmissions for naval unit. In particular, the test configuration consists of a back-to-back connection between two identical mechanical reducers. Since the efficiency of these systems are very high, it is not necessary to use large electric motors, thus managing to contain the operating costs of the testing phase. The particular test bench allows to size the electric motor simply based on the dissipated power by the kinematic mechanisms. By means of suitable sensors installed on the test bench it is possible to extrapolate countless technical data. The implementation of Industry 4.0 enabling technologies allows to evaluate the increase in efficiency compared to traditional systems in terms of reduction of noise and vibrations, efficiency of lubrication, reduction of consumption, installation and maintenance cost of the entire system.

Keywords: Cad modeling , digital transformation , Experimental tests , Industry 4.0 , Internet of things , Shipyard 4.0 , Sustainability , Test bench

Background: In this study, we promote a global approach to occupational risk perception in order to improve occupational health and safety training programs. The study investigates the occupational risk perception of operating room healthcare workers using an Analytic Hierarchy Process approach. Methods: A pilot study was carried out through a cross-sectional survey in a university hospital in Southern Italy. An ad hoc questionnaire was administered to enrolled medical post-graduate students working in the operating room. Results: Fifty medical specialists from seven fields (anaesthetists, digestive system surgeons, general surgeons, maxillofacial surgeons, thoracic surgeons, urologists, and gynaecologists) were questioned about perceived occupational risk by themselves. Biological, ionizing radiation, and chemical risks were the most commonly perceived in order of priority (w = 0.300, 0.219, 0.210). Concerning the biological risk, gynaecologists unexpected perceived this risk as less critical (w = 0.2820) than anaesthesiologists (w = 0.3354), which have the lowest perception of the risk of ionizing radiation (w = 0.1657). Conclusions: Prioritization methods could improve risk perception in healthcare settings and help detect training needs and perform sustainable training programs.

Keywords: Analytic hierarchy process , Healthcare workers , Occupational risk perception , Prioritization risk methodology

The optimization of the energy consumption of Industrial Robots (IRs) has been widely investigated. Unfortunately, on the field, the prediction and optimization strategies of IRs energy consumption still lack robustness and accuracy, due to the elevated number of parameters involved and their sensitivity to environmental working conditions. The purpose of this paper is to present, and share with the research community, an extensive experimental campaign that can be useful to validate virtual prototypes computing the energy consumption of robotic cells. The test cell, comprising a high payload IR equipped with multiple sensors and different payloads, is firstly described. The testing procedures are then presented. Experimental results are analyzed providing novel qualitative and quantitative evaluations on the contribution and relevance of different power losses and system operating conditions, clearly depicting the nonlinear relation between the energy consumption and various freely programmable parameters, thus paving the way to optimization strategies. Finally, all the experimental tests data are provided in the form of an open research dataset, along with custom Matlab scripts for plotting graphs and maps presented in this paper. These tests, which are verifiable via the shared dataset, consider the overall measured IR energy consumption (as drawn from the electric network) and highlight that, in some industrially interesting case scenarios, optimization potentials for energy savings of more than 50% are possible.

Keywords: Energy optimization , Experimental campaign , Industrial robotics , Industry 4.0 , Sustainable manufacturing

As the society is already permeated by data, a data-driven approach to inform design for sustainable behaviour can help to identify misbehaviours and target sustainable behaviours to achieve, as well as to select and implement the most suitable design strategies to promote a behavioural change and monitor their effectiveness. This work addresses the open challenge of providing designers with a model for Human-Machine Interactions (HMI) that helps to identify relevant data to collect for inferring user behaviour related to environmental sustainability during product use. We propose a systematic modelling framework that combines constructs from existing representation techniques to identify the most critical variables for resources consumption, which are the determinants of potential misbehaviours related to HMI. The analysis is represented as a Behaviour-Inefficiency Model that graphically supports the analyst/designer to link user behaviours with a quantitative representation of resources consumption. The paper describes the model through an example of the use of a kettle and an additional application of the same approach to a washing machine, in order to point out its versatility for modelling more complex interactions.

Keywords: Behaviour Change , Big data , Process modelling , Product modelling / models , Sustainability

Design for Sustainability is a research area based on a multidisciplinary approach, which has become increasingly important in recent years. Great attention is paid to the design of products that can impact on users' behaviours, through embedded smart technologies, e.g. Internet of Things (IoT). In fact, IoT systems are able to "dialogue" with the users, supporting the identification of any misbehaviour, and suggesting more sustainable ones. This paper presents a research aiming at supporting users towards more conscious food consumption in their daily life to reduce food waste. As a case study, it has been developed an interactive system in which chicken eggs are used as main communication element. Indeed, the environmental footprint of the egg industry is very heavy, and eggs are one of the main wasted food. The interactive system consists of a physical product, an eggs tray, integrating sensors and actuators for handling the interaction with users. It is accompanied by an interactive application for monitoring eggs consumption, displaying eggs waste statistics, and an Augmented Reality part for children, aimed to improve their awareness about food waste and the impact on their food habits through an "edutainment" approach.

Keywords: Industrial design , Sustainability , Virtual reality