Design for sustainability

In this paper we describe the design of a smart alarm clock, conceived as a persuasive system to foster a sustainable urban mobility. Automatically retrieving and elaborating information available on the web, such as means of transport and weather forecast, the device is able to suggest to the user the most sustainable travelling solution, to help him/her to wake-up and reach the destination on time. Following a user-centered design approach the elaboration of the best travelling solution takes also into account, together with his/her next day appointments, user's needs and habits such as: The time he/she needs to get ready in the morning; his/her travelling preferences. A functional prototype has been built to test the effectiveness of the device using as a context the city of Milan.

Keywords: Design for sustainable behaviour , Multisensory product experience , Smart mobility , Sustainability , User centred design

The great impact played by Product/Service-Systems (PSS) on industry and academia can be motivated by the need for modernizing business models, carrying out internal companies' reconfiguration, enhancing environmental sustainability. Despite the large number of objectives pursued by PSS, sparks of criticism have recently emerged, as well as the results ensuing from PSS adoption have not been rigorously assessed. In particular, the authors highlight a lack of quantitative analysis concerning the service aspects of PSS and hurdles in service modeling and evaluation. The paper's objective is to contribute in this field by individuating factors, advantages and disadvantages that are not directly measurable in monetary terms by companies. This kind of assessment might result crucial, as the implementation of PSS-oriented strategies require a not negligible amount of commitment, besides propensity to risk. A first activity was carried out thanks to a pilot group of firms that have not implemented any PSS initiative so far, which have been exposed to business reconfiguration scenarios underpinning PSS. A model for generalizing pros and cons of future PSS implementation has been subsequently experimented by a larger group of industrial organizations. Such a model has represented the backbone for the creation of a tentative quantitative estimation tool, which assesses and forecasts the added value of services featured by the introduction of PSS and hence represents a candidate criterion for undertaking decisions concerning the implementation of PSS strategies. The paper clarifies which assumptions are introduced in order to achieve this result.

Keywords: decision-making , Product Service-Systems , quantitative service estimates , service modelling , value forecasting

As creativity is increasingly important in order to achieve differentiation and competitiveness in industry, designers face the challenge of conceiving and rating large numbers of new product development options. The authors' recent studies show the effectiveness of ideation procedures guided by stimuli that are submitted to designers in the form of abstract benefits. A rich collection of said benefits has been created to this scope; more specifically, the authors have performed a detailed clustering of the categories described in TRIZ ideality, i.e. useful functions, attenuation of undesired effects and reduction of consumed resources. Aspects related to sustainability and environmental friendliness manifestly appear in the list of stimuli and these issues are reflected in several ideas emerged in initial experiments. However, many promising product development objectives conflict with sustainability or, at least, their adherence to eco-design is arguable. The paper assesses the share of ideas that are supposed to comply with sustainability in experiments described in recent literature. Subsequently, it intends to stimulate a discussion about the introduction of measures to attract attention of designers on sustainability in the critical early product development stages also when green aspects do not represent the fundamental driver to achieve greater customer value. As well, it discusses which sustainability aspects are worth being considered adequately during the very early design phases and which ones could result as exceedingly constraining.

Keywords: Idea generation , Product value , Sustainability , TRIZ , Very early design phases

In Europe, kitchen hoods currently come with an energy label showing their energy efficiency class and other information regarding the energy consumption and noise level, as established by the European Energy Labelling Directive. Because of recent regulations, designs of cooker hoods must consider new issues, such as the evaluation of the energy efficiency, analysis of the energy consumption, and product lifecycle impact. Therefore, the development of eco-driven products requires Ecodesign tools to support eco-innovation and related sustainability improvements. The scope of the proposed research is to define a method and an agile and affordable platform tool that can support designers in the early estimation of product energy performance, including the calculation of energy efficiency indexes. The approach also considers the use of genetic algorithm methods to optimize the product configuration in terms of energy efficiency. The research context concerns large and small productions of kitchen hoods. The paper describes the methodological approach within the developed tool. The results show a good correlation between real efficiency values and calculated ones. A validation activity has been described, and a test case shows how to apply the proposed approach for the design of a new efficient product with an A-class Energy Efficiency Index.

Keywords: Ecodesign , Energy label , Knowledge-based engineering , Optimization , Product configuration , Virtual prototyping

During recent years the European Ecodesign Directive has introduced big changes in the design methodology of several energy-using products including consumer goods such as ovens, washing machines and kitchen hoods. Additionally, the introduction of the Energy Labelling Directive pushes manufacturers to implement new energy-saving features in many energy-related products sold in Europe. As a consequence, several companies have been encouraging the improvement of their energy using products paying attention to the related selling cost. Eco-driven products require eco-design tools to support the eco-innovation and the related sustainability improvement. The main scope of the proposed re-search is the reduction of the time-to-market for the energy-using products such as kitchen hoods. In this context, the paper aims to provide an approach to support a pre-evaluation of the energy labeling related to kitchen hoods. A prototypical software tool has been developed in order to simulate the energy performance of new kitchen hood configurations in term of energy efficiency. The approach also considers the introduction of virtual experiments in order to calculate the performance of virtual modules. This tool makes the product-engineer more aware in the decision-making about the energy-saving. As a test case, different product configurations have been compared analyzing the energy labelling and the overall energy performance.

Keywords: Ecodesign , Energy efficiency labeling , KBE , Kitchen hoods , Virtual prototyping

The article presents a model to support designers and stakeholders when selecting the best product concepts, from among those in the course of development, assessing them from the sustainability point of view. The main aim of the article is to give the designer a road map, by which to collect and organize data, perform environmental analysis and compare different design alternatives, before the embodiment phase is completed. The model integrates different approaches: the use of a simplified life-cycle assessment to assess concepts when the information is poor or rough, performing the evaluation according to a set of environmental indicators; the employment of an augmented version of a design structure matrix, used to manage product components and functionalities; the use of a multi-criteria decision-making method to compare the environmental characteristics of design alternatives and a Pareto approach to select the most promising concepts. Finally, the design alternatives are expressed in terms of three dimensionless coordinates related to material wastes (α), energy dissipation (β) and environmental characteristics (γ) of the concept and are positioned in a three-dimensional environmental efficiency space to allow designers to visualize the position of each concept solution. The employment of an aggregate objective function and its geometric interpretation in the environmental efficiency space allows the designer to have a deeper knowledge of the choices to be made and how these can be taken more consciously. Furthermore, this final step can help designers and stakeholders in their reasoning about the environmental potentialities and drawbacks of the products in the phase of development. The whole model is applied to a case study where a group of five concepts of orange juicers are analysed and all the steps of the model are described in detail and discussed.

Keywords: design structure matrix , environmental assessment , environmental indicators , multi-criteria decision-making methods , product design

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.

Keywords: closed-loop scenarios , Design for EoL , EoL indices , EoL management

This paper aims to analyze the attitude and the awareness of environmental sustainability issues within diverse Italian industrial companies. A survey has involved a balanced sample of companies operating in different industrial sectors. Considering the survey's results it can be concluded that: (i) environmental sustainability is an opportunity and a current market requirement, (ii) environmental sustainability is not formalized, since specific methods and tools are not used in technical departments, and (iii) environmental decisions are mainly made by specific key figures (i.e. energy/environmental manager). This analysis can be considered as a useful starting point for the framework formalization of eco-design approaches and tools able to bring eco-design principles into the work of technical departments with the aim to foster the future development of green and sustainable products and services.

Maritime vessels have long service life and great costs of building, manning, operating, maintaining and repairing. Making a consistent lifecycle model among the different vessel typologies, repeatable with the same level of detail and comparable for the implementation of decision-making strategies, remains an open question. This paper aims to define a suitable lifecycle model in the context of maritime vessels to cope with the current limitations of ad-hoc and fragmented methods. The model considers the main aspects involved in the vessel lifecycle such as building materials, manufacturing and assembly, maintenance/service, operational activities, use, etc. The model provides a common structure for the lifecycle assessment (LCA) and lifecycle cost analysis (LCCA) including the way to retrieve and to collect the data necessary for the analysis starting from the available project documentation and the design models. The method is flexible and it is able to cover a large variety of maritime vessel typologies. As example, a luxury yacht has been analysed using the developed method, demonstrating the applicability of the proposed model in one of the most critical vessel typology.

The goal of sustainable development through the product innovation is a global challenge that Academia and Industries are addressing. The regulatory pressure and the growing demand of eco-friendly products by consumers are two of its main drivers, especially in the household appliances sector. For this aim, manufactures need to change the design approach in order to extend the boundaries of the benchmark analysis of possible innovations: (i) multi-objective criteria should be taken into account such as the environmental issues, costs, technical performances, etc., and (ii) a life cycle thinking has to be adopted to consider long terms benefits or impacts. However, the literature highlights the lack of structured methods able to support the R&D activity according to these perspectives. For this aim, the present paper provides a systematic approach, which exploits lifecycle and innovation tools to effectively support designers in the development of sustainable solutions in a long term perspective. The proposed approach has been applied in real case study to increase the energy efficiency of a domestic refrigerator. In particular, the insulation module has been redesigned by comparing several alternatives in terms of environmental performances and costs over the product lifespan to effectively evaluate the consistency of the developed eco-innovations.

This paper proposes an approach of sensitivity analysis for LCA of building retrofit measures aiming to establish the impact of input data uncertainties on the output variance. The approach includes the quantification of data input uncertainties in terms of their Probability Distribution Functions (PDFs), their sampling and the uncertainty propagation through Monte Carlo (MC) methods. A sensitivity analysis through Variance based decomposition (Sobol' method) techniques are used to point out the key parameters uncertainties that mostly affect the LCA results distributions. The paper presents a building case-study where the MC-based uncertainty and sensitivity analysis method is applied considering different design options (XPS and Cork internal insulation measures) and different scenarios for the assessment of the building energy need (use phase). Results obtained highlight that the differences on the Climate change environmental impact between the two design options is quite limited (about 12%) and this is mainly due to the use phase which is the more relevant input parameter on the overall result. Concerning the Sensitivity Analysis, when the building energy need is considered as a "deterministic" input in the LCA assessment, the unitary impacts of the design options materials uncertainties are the most influential parameters. On the other hands, when the building energy need is represented by a PDF, the quantity of energy carrier consumed and its unitary environmental impact are the most influential parameters on the output variance. .

Keywords: Internal insulation , MonteCarlo simulation , Probabilistic LCA , Sensitivity analysis

Electronics plays an essential role in many products and this leads to a larger production of e-wastes, currently recovered through impactful recycling processes. This paper proposes a web-based platform to implement reuse scenarios for electronic components. The objective is to create a structured portal where all the stakeholders can collaborate to extend the components lifespan and implement new circular business models. The final goal is to "close the gap" between the beginning and the end of life. The case study (industrial application) shows relevant benefits for the involved electronics manufacturer both in terms of environmental impact and economic savings.

Keywords: Collaborative platform , Decsion support system , Electronics reuse , EoL mangement

The paper presents a lifecycle approach and the related software tool for the analysis and management of resource consumptions and environmental impacts of manufacturing plants. The approach, based on the industrial metabolism model, takes into account all the production and assembly aspects. The tool is able to assess the optimum working conditions for the minimization of resource consumptions (e.g. electricity) or environmental emissions (e.g. CO2). It provides a tangible support to guide decision-making strategies to move manufacturing towards sustainability. A manufacturing plant has been analysed for the model validation and the management of production scenarios, optimizing environmental and energy loads.

Keywords: Environmnetal impacts optimization , Plant lifecycle management , Resource consumption optimization , Software tool , Sustainable production

A growing interest towards smart manufacturing is focused on sustainable development at both industrial and policy level. In particular, an effective sustainable development incorporates three fundamental pillars: environment, cost and society. While environment and cost have been already faced by numerous studies so far, society is still the less considered in manufacturing. Social sustainability comprises specific relapses on humans that are quantifiable through social assessment methods. This research work proposes a new Social Life Cycle Assessment (S-LCA) methodology, based on the United Nations Environment Programme and the Society for Environmental Toxicology and Chemistry (UNEP/SETAC) framework, to support enterprise modelling and knowledge management to assess company sustainability by solving current issues and uncertainties regarding the evaluation of social impacts in the context of smart manufacturing. The analysis is settled into a LIFE +2012 European Project, named LIFE GREEN SINKS. The project concerns the introduction of innovative materials for a new generation of kitchen sinks. The S-LCA methodology proposed embeds a detailed inventory method tailored on real data, collected directly from the field of application thanks to customised surveys that allow modelling the enterprise and integrating data available from the manufacturing process. This method is designed as a supporting tool for enterprise modelling and strategic company decision-making. Specifically, it intends to help companies in understanding and, consequently reducing, social impacts of all processes related to a certain product from a life cycle perspective, to achieve an effective “smart” manufacturing for a sustainable development.

In recent years, the growing attention to environmental challenges has shown that these issues are becoming of more and more interest to both research and industry. Companies are expected to ensure their products are fully traceable and more sustainable, which requires the involvement of all of the actors in the production network. According to this aim, this study proposes a structured approach that uses the traditional traceability concept as a means to identify the main information needed to assess environmental impacts along the whole supply chain (SC). The proposed approach is composed of four main steps: (i) SC modelling to identify all stakeholders and their inter-relations, (ii) data sharing to collect all relevant data, (iii) data elaboration to calculate performance at different levels of detail and (iv) result interpretation to optimise the SC. The distributed implementation of the approach at different SC steps represents a useful means to practically realise a sustainable SC management. A case study involving a leather shoe SC is used to demonstrate the effectiveness of the approach in identifying criticalities, supporting the selection of the most appropriate suppliers and correctly setting a management strategy towards the optimisation of internal and external traceability and environmental sustainability performances.

Keywords: Collaborative network , Environmental sustainability , Sustainable supply chain , Sustainable supply chain management , Traceability

Nowadays the efficient use of energy has acquired a significant importance in the industrial sector. Moreover, stringent regulations on environmental impact lead companies to tread a path towards energy efficiency in short terms to avoid penalties. The goal of this work is to propose a structured method to perform fast and simplified energy assessments. The latter starts from a proper classification of process data, passing through an effective mapping in order to identify criticalities that have to be solved by innovative action plans. Method will be tested on a real case study.

Keywords: data management , energy efficiency , process innovation , sustainable manufacturing

Circular economy is recognized as the most effective economic model to face issues related to waste management and resource scarcity. This requires to efficiently manage the End of Life (EoL) phase, which represents the joining link to close the product lifecycle. The objective of this paper is the definition of a framework to monitor product EoL during the most affecting phases. It is founded on the concept that it is better to prevent issues, by designing optimized products and creating favourable operative conditions, other than solve problems related to EoL. The EoL-oriented framework integrates three innovative resources: (i) a Design for Disassembly Tool to identify product criticalities, (ii) a Disassembly Knowledge Database to support the redesign phase and (iii) a Collaborative EoL platform for the sharing of relevant data and materials. The final aim is to provide companies with a set of integrated methodologies and tools able to support the decision-making process at different levels (from conception to EoL management), in order to design product with improved performances in terms of disassemblability, maintainability, de-manufacturing and EoL.

Keywords: Circular economy , Design for X (DfX) , Product lifecycle management (PLM) , Sustainability

The topic of digital manufacturing is increasingly emerging in industry. One of the main scope of data digitalization is achieving more efficient factories. Different techniques and tools under the Industry 4.0 paradigm were already discussed in literature. These are aimed mostly at boosting company efficiency in terms of costs and environmental footprint. However, from a sustainability point of view, the social theme must be equally considered. While energy flows or costs can be already monitored in a production plant, this is not valid for data related to human effort. Monitoring systems aimed at supervising factory social sustainability were not already discussed in literature. The aim of this paper is to propose a method to acquire social related data in a production plant. The method is supported by a smart architecture within the concept of IoT factory. Such architecture permits to monitor the parameters that could influence social sustainability in a production site. After a discussion on production plants facilities and features, the parameters that need to be considered to guarantee socially sustainable manufacturing processes are identified. A set of sensors controls these data taken from different sources, including operator vital signs. Operations as well as humans are monitored. Data acquired by sensors are collected by a central server. A decision maker can interpret the data and improve the production system from a social point of view, implementing corrective actions. Data can be exploited not only for social assessments but even for other analyses on the production system. Guaranteeing social sustainability could boost the factory productivity. A case study is included in the paper: smart sensors are implemented in a production line to understand the operations efficiency in terms of social sustainability.

Keywords: digital manufacturing , smart sensors , social sustainability

Sustainability is becoming one of the main drivers of the modern product and system design. However, sustainability assessments are usually carried out at the end of the design process to check the validity of the decisions already taken. As a consequence, when targets are not achieved, numerous time-consuming iteration loops are necessary to optimize the initial solution. The paper merges functional-based and design-to-cost approaches to propose a CAD-based platform able to assess product lifecycle costs and impacts from the earliest design stages by configuring and assessing feasible design solutions. It considers both economic expenses and environmental impacts during all phases of product lifecycle on the basis of the company knowledge.

Keywords: CAD , Design-to-cost , functional design , lifecycle approach , sustainability

Although factories are becoming smarter and more and more automated, thanks to ICT penetration, process performances still highly depend on 'humans in the loop' who have to carry out their tasks by perceiving and understanding increasingly complex multidimensional data sets. Forecasting the human behaviours and assessing how human factors affect the process performance are very difficult but fundamental for strategic decision-making and sustainable manufacturing. In this context, the research highlights the need of predictive methods to design human-centred smart manufacturing systems from the early design stages as an important part of the overall assessment of process sustainability. The paper defines a model to early assess human factors to be integrated with other existing models (i.e., cost estimation and lifecycle assessment) to evaluate manufacturing process sustainability. The proposed integrated method can be fruitfully used to support the design of sustainable manufacturing systems by taking into account also the impact on workers. An industrial case study focusing on packaging machines design is presented to demonstrate the validity of the proposed method and its adoption to propose re-design action promoting sustainability.

Keywords: Design for sustainability , Human factors , Key performance indicators , KPIs , Sm , Sustainability assessment , Sustainable manufacturing