Applied Mechanics and Materials Vol. 660 (2014) pp 1067-1071
© (2014) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMM.660.1067
A Sustainable Product Realization Strategy using
Decomposition-based Approach
Lee Guang Benga and Badrul Omarb
Faculty of Mechanical And Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia,
86400 Parit Raja, Batu Pahat, Johor, Malaysia.
a
b
[email protected], [email protected]
Keywords: axiomatic design, sustainable product realization, design for EOL management, green
supplier selection, sustainable manufacturing
Abstract. To achieve sustainable product realization, three essential areas namely end-of-line
management, green supply chain and sustainable manufacturing have to be considered during the
design/development phase. A framework for product realization (presented as objective-mean
hierarchy) is proposed in this paper with the help of decomposition-based approach to serve as a
guideline for product development companies/firms to improve their environmental strategies by
prescribing the key areas and necessary considerations to be scrutinized.
Introduction
As a result of population growth as well as the improvement of quality of life, more products are
being manufactured to offer services or to be consumed directly by users [1]. This complicates
environmental sustainability challenge and hence, it is important to minimize environmental
footprints associated with these products in order to address environmental issues [2]. Mounting
environmental issues, coupled with public pressure and stricter regulations are the main drivers that
motivate worldwide firms/companies to change their ways of designing and releasing new products
[3]. Firms/companies are being held responsible for producing products in an environmentally
friendly way and seamless integration of sustainability into design practices is seen as an area of
future importance [2].
Principles of Axiomatic Design and Decomposition of Functional Requirements
Axiomatic design (AD) system is a design model based on product attribute in which two axioms
are utilized for design. The first axiom highlights the necessity to maintain independence of
functional requirements (FR) while the second one is to minimize the information necessary to meet
the FRs. In most design tasks, it is crucial to decompose the problem, because the FRs at top levels
are abstract and are not substantially detailed for direct realization by means of implementing DPs.
Using a structured and consistent method (“zigzagging” between the FRs and DPs) the FRs and DPs
at the top level have to be decomposed at a more detailed level in order to develop a feasible design.
First, the top level FR is satisfied by a DP. Then, this top level FR (denoted FR1) is decomposed to
the next lower level through zigzagging, leading to the definition of two or more subordinate FRs to
FR1. For these, corresponding sub-DPs are to be found. The sub-FRs and the sub-DPs
operationalize the FR1-DP1 pair. Decomposing is repeated until the appropriate degree of detail is
reached, so that the design can be realized at the operational level. The result of the decomposition
is a hierarchy of objectives-means: the FR-DP pairs represent the relationships between objectives
and means, which are structured and consistently connected across several levels [4].
Sustainable Product Development: The Key Areas
End-of-life management is described as a process of converting EOL products into re-marketable
products, components, or materials [2] and product design is the most important factor to achieve
profitable EOL management [2,5]. In this aspect, additional FRs can be introduced during problem
definition stage to differentiate design objectives that address environmental needs from product
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Advances in Mechanical, Materials and Manufacturing Engineering
FRs that are related to customer needs [6]. Chen proposed a series of FRs and DPs that favor
disassembly and recycling [7]. For instance, the author stated that “easier or more economical
disassembly of the parts in the product” should be one of the design requirements to fulfill in order
to enable product disassembly with less manpower and costs.
Other than end-of-life (EOL) management and recycling of products, sustainable product
development requires a shared responsibility to implement and realize sustainability throughout the
life cycle. The necessary considerations to be taken account during the design stage to attain
sustainable product development include downstream issues such as supply chain and
manufacturing [2]. Green purchasing can be defined as an environmentally conscious purchasing
practice that reduces sources of waste and promotes the recycling and reclamation of purchased
materials [8]. It is a boundary-spanning function within the supply chain [9-11]. Min and Galle [12]
also stated that incorporating a company’s environmental goals with purchasing activities is
essential because purchasing is at the beginning of the green supply chain. Humphreys et al.
proposed a list of environmental criteria which are divided into two broad groups i.e. quantitative
and qualitative criteria [13]. The pollutant costs (due to treatment of pollutants) and improvement
costs (related to improving environmental performance) are grouped under the quantitative
category. On the other hand, the criteria identified under the other environmental category grouping
are mainly qualitative criteria such as the environmental management system within a company and
its green image which require subjective decisions to be made during evaluation of these criteria.
Assuming that the buyer is practicing proactive environmental strategy, alternative/candidate should
fulfill both quantitative and qualitative criteria at desired level in order to be qualified as green
supplier [13].
Machining processes constitute a major manufacturing activity that contributes to the
development of the worldwide economy [14]. In the developed world, it is estimated that machining
processes contribute about 5% of the total GDP. Furthermore, the importance of machining is
anticipated to increase even further due to shorter product cycle and more flexible manufacturing
systems induced by economic factors [15]. Due to the above reasoning, machining is chosen to be
the focus of discussion in this paper. For easier visualization on the cause-effect relationship, FRs
and DPs in Table 1 can be used to represent types of parameters involved in optimization problem
(for sustainable machining) and their respective means of fulfilling the requirements.
Proposed Sustainable Product Realization Strategy using Decomposition-based Approach
Potentially, axiomatic design can be utilized to achieve the aforementioned purpose owing to its
advantages stated as follows (1) differentiates between objectives (or requirements) and means (or
solutions), (2) allows structured approach to decomposition, making possible step-wise, consistent
operationalization and specification of objectives and means, (3) allows cause–effect relationships
and objectives-means hierarchies to be systematized, and (4) aids visualization and communication
[16]. Fig. 1 shows potential areas that can be tackled by AD principles in order to attain sustainable
product development.
A sustainable product development framework (see Fig. 2) is proposed by rearranging essential
FRs and DPs discussed in the previous section in hierarchical manner. Note that the chart is
constructed by using machining as example of major manufacturing process. One should be aware
that this framework is applicable to but not limited to products manufactured by means of
machining. FRs and DPs being considered in Fig. 2 are listed in Table 2. The top-level requirement
for firms/companies to fulfill is to achieve sustainable product development (FR1). This can
potentially be attained by considering EOL management, green supply chain and sustainable
manufacturing process (DP1). Hence, FR1 is further decomposed to yield FR11, FR12 and FR13 which
dictate requirements for the three key areas.
Applied Mechanics and Materials Vol. 660
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Table 1: FRs and DPs for optimized machining solution.
Function Requirements
Design Parameters
FR1: To maintain cutting condition within manageable range
FR2: To attain satisfactory machining performance
FR3: To achieve process sustainability at desired level
DP1: Parameters of cutting condition must be set within
constraints
DP2: Employ adequate cooling method
DP3: All sustainability factors to satisfy respective requirement
Fig. 1: Application of AD into design for EOL management, green supplier selection and
optimization for sustainable manufacturing to achieve sustainable product realization.
To increase productivity and thus the profit of a product recovery process, the product must be
designed to accommodate simple refurbishment process (DP11) and in order to practice green supply
chain strategy, parts/raw material must be purchased from green supplier(s) (DP12). Finally, an
optimized manufacturing solution is required with the purpose of meeting process sustainability
(DP13). FR11 can be strategically decomposed to properly address requirements regarding product
function, customer needs and most importantly, requirements that concern product refurbishment
(FR111 and FR112). Ideally, all parts should be purchased from green suppliers in order to properly
address environmental issues. Therefore, FR12 is further decomposed to specifically impose such
requirement on each item (FR121 - FR12N). Then, suppliers of each item should meet the respective
quantitative and qualitative environmental criteria (FR1211 and FR1212). Likewise, all
parts/components of a product must be manufactured by means of environmentally conscious
process so as to maximize the product’s overall sustainability. Consequently, FR13 is decomposed to
another level to particularly state requirements related to sustainable process for each part (FR131).
As mentioned beforehand, this study uses machining process as illustrative example and should
therefore involve requirements related to cutting conditions and machining performance only
(FR1311 - FR1313). Other factors (e.g. molding parameters) shall be included should the product calls
for additional types of manufacturing techniques.
The chart serves as a general guideline for FRs and DPs related to sustainable product
development and therefore, the hierarchy can be expanded by further decomposing the FRs to
involve more detailed, assembly-specific requirements. By performing the procedure presented in
the previous section, with the aid of the set of proposed FR and DP hierarchy, an environmentally
friendly product that considers the recovery procedure, green supply chain and sustainable
manufacturing can potentially be developed.
Conclusion
The use of decomposition-based approach to produce a sustainable product development strategy
has been the main focus of this paper. The importance of considering design for EOL management,
green supplier selection and optimization for sustainable manufacturing has been highlighted in the
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Advances in Mechanical, Materials and Manufacturing Engineering
FR1
DP1
Design for EOL
Management
Optimized Sustainable
Manufacturing
Green Purchasing
FR11
FR12
FR13
DP11
DP12
DP13
FR111
FR112
DP111
DP112
FR1111 … FR111N
FR1121 … FR112N
FR121
DP1111
DP111N
DP1121
DP112N
DP121
⁞
⁞
⁞
⁞
…
FR12N
FR131
DP12N
DP131
FR13N
…
DP13N
⁞
⁞
FR1211
FR1212
FR1311
FR1312
FR1313
DP1211
DP1212
DP1311
DP1312
DP1313
⁞
⁞
⁞
⁞
⁞
Fig. 2: Hierarchy of FRs and DPs to achieve sustainable product development.
Table 2: Essential FRs and DPs to achieve sustainable product development.
Function Requirements
Design Parameters
FR1
FR11
FR12
FR13
FR111
FR112
FR121
FR131
FR1111
FR1121
FR1211
FR1212
FR1311
FR1312
FR1313
: To achieve sustainable product development
: Functional product that enables effective product
recovery
: Sustainable supply chain management
: Environmentally conscious manufacturing
: Media player to have small-sized body and simplistic
appearance (example)
: Product to have high recovery potential
: To purchase raw material for closed-back housing
from green supplier (example)
: To adopt optimized manufacturing solution for
closed-back housing (example)
: Closed-back housing to provide protection for
internal components (example)
: Easier or more economical disassembly of the parts
in the product (example)
: Supplier(s)
to
have
adequate
qualitative
environmental capability
: Supplier(s) to show satisfactory qualitative
environmental capability
: Manageable cutting conditions
: Satisfactory manufacturing performance
: Desired sustainability performance
DP1
DP11
DP12
DP13
DP111
DP112
DP121
DP131
DP1111
DP1121
DP1211
DP1212
DP1311
DP1312
DP1313
: To consider EOL management, green supply chain
and sustainable manufacturing during design stage
: Design for EOL management
: Purchase from green supplier(s)
: Adopt optimized manufacturing solution
: To use closed-back housing with overall
dimensions of 50mm×30mm×7mm and button-less
control (example)
: Fewer parts (or less material volume) in product
and more economical replacement of parts in
discarded product (example)
: Raw material supplier to be assessed based on
qualitative and quantitative environmental criteria
(example)
: Cutting conditions, sustainability and machining
performance to be considered during optimization
(example)
: Maintain substantial housing wall thickness
(example)
: Defective window to be replaced by minimal
recovery operations (example)
: Supplier(s) to meet pollutant and improvement
costs requirement
: Supplier(s) to have acceptable capabilities in terms
of management competencies, green image, design
for environment, environmental management
systems and environmental competencies
: Cutting
condition
to
be
set
within
realistic/achievable range
: Employ adequate cooling method
: All sustainability factors to satisfy respective
requirement
Applied Mechanics and Materials Vol. 660
1071
content. The last part of this paper presents a framework for sustainable product development
constructed using decomposition-based approach to provide a general guideline for firms to work
towards sustainable product realization by considering the three key areas.
Acknowledgement
The authors gratefully acknowledge the financial support from the Ministry of Higher Education,
Malaysia under grant no. ERGS Vot E024.
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