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Welding is a widely used technology that allows the joining of thick metal plates for the development of large structures (e.g. piping, tanks, vessels). Many industries are intensively using welding for manufacturing and assembly activities. Sustainability assessment of welded structures is currently performed with misleading information in terms of data heterogeneity (nature) and quality (source). The data required to carry out a robust environmental analysis are spread among different documents and become available only when the project is finalized. This paper aims to define a data framework for a life cycle inventory of metal arc welding processes to preventively assess the environmental performances of different processes for comparison and decision-making analysis. The framework is presented as innovative solutions for life cycle inventory that provide (i) a common data structure (model), (ii) necessary data (input/output), and (iii) physical allocation/placement of data (project design documents). This study was performed in accordance with the international standard organization ISO 14040/14044 by using an attributional life cycle assessment (aLCA). Two structures (an oil and gas riser and a ship hull) were investigated considering the same functional unit: the manufacturing, use, and disposal of a welded structure able to guarantee the engineering requirements (according to a specific standard) in terms of strain, stress, and corrosion allowance over the expected lifetime of 20 years. In both cases, the share of welding process in respect to an overall product/structure life cycle impact assessment is strictly dependant on the project design choice and can be negligible for high-corrosion-resistance materials (e.g., Inconel alloy). On the other hand, the use of traditional metals (e.g., carbon steel) allows a large decrease of the environmental load, and the influence of the welding process becomes significant in a life cycle perspective.

Several implant materials are used in cranial surgery. Still, each one has its drawbacks, such as the risk of infections, low mechanical strength, or low osseointegration. Implants with a porous surface are considered more effective than a smooth and rough coating. The porosity density and structure also influence the mechanical properties of the final implant. Moreover, the implant properties depend on the manufacturing method.

Lightweight engineering is a current topic in mechanical industry. The mass reduction is a common design objective to reduce product cost and environmental impacts. Virtual prototyping tools are widely applied to study new lightened solutions and check the compliance with regulations and standards. However, an integrated approach, involving simulations and life-cycle analysis, is necessary to support design optimization and decision-making. The scope of this study concerns the definition of an Ecodesign approach to support the lightweight engineering of cast iron parts through the redesign of the product shape. In particular, this paper deals with the optimization of a ductile cast iron manhole. The test case shows a redesign method which considers structural analysis with environmental impacts. The structural analysis has been evaluated using a finite element method tool. In particular, the simulation results have been compared and validated with physical tests. The environmental analysis is based on the methodology provided by the standardized ISO 14040:2006 and ISO 14044:2006. The proposed LCA study considers the phases of manufacturing and transport related to one ductile iron product. The described manufacturing phase is related to a Chinese foundry which produces roughly 12,000tons of ductile cast-iron castings. The results show the possibility to achieve about 20% of mass reduction for one casting. Considering such mass decreasing, the related reduction in terms of carbon emission is about 7%. Summarizing, this paper shows a design approach to integrate the structural improvements with the reduction of the environmental impacts related to a lighter weight casting.

Circular economy (CE) is a new business model that is pressing manufacturing companies to think about closed loop scenarios for materials and products. Design for End-of-Life (DfEoL) and Design for Disassembly (DfD) are key enabling methods for the effective application of this model. The paper presents a time-based method for the calculation of disassembly sequences, adopting basic theories and techniques in this topic and integrating new concepts for the assessment of the disassembly time. The method consists of five steps and starts from the documentations (e.g., CAD model) generally available early in the product development process. The first three steps encompass the product analysis by including (i) the definition of target components from the general assembly, (ii) the analyses of the virtual model, and (iii) the assessment of the so-called level matrix, which is based on the concept of disassembly levels and liaisons characterization among components. The last two steps allow for the assessment of the time-based disassembly sequence by including (iv) the analysis of feasible sequences and (v) the generation of the best disassembly sequence for target components. The method mainly overcomes two issues highlighted in the literature regarding the reliability of the disassemblability analysis using a time-based approach and the quality of results accounting for the real condition of the product at the time of disassembly. The calculation of the effective disassembly time is grounded on a specific repository developed to gather knowledge about the disassembly tasks and related disassembly time. This is the main contribution and novelty of the proposed approach. By using the proposed method, different target components of a washing machine are analysed with the aim of demonstrating the robustness of the method and its consistency in the estimation of disassembly time. A maximum deviation of 10% between the estimated and measured disassembly times is noticed.

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.

Many foot pathologies are prevented or treated with Custom Made Insoles (CMIs). Although a strong computerization has characterized the shoe development process during the last decade, the CMI sector still lacks a software platform integrating the design and diagnosis tools used by the stakeholders of this area. Moreover, the prescription of CMIs is only based on the experience of skilled podiatrists rather than on a common and shared knowledge (e.g. guidelines, best practices, rules, etc.). This paper presents a multi-users and knowledge-based platform, called Smart Prescription Platform ( SPP ), covering the whole CMI development phases, from foot diagnosis to the production, involving clinicians, patients, manufacturers and controllers. The web-based platform is fully integrated with the technologies available in the orthopaedic sector, which are 3D/4D scanners, baropodometric platforms, footwear virtual catalogues, plantar pressure simulators, Augmented Reality devices and 3D CAD systems. The use of standard file formats (e.g. .stl , .bmp , .xml ) allows an electronic dataflow among the tools. The main module of the platform, called Prescription System (PS), is used for prescribing custom-made insoles for patients with different health conditions, satisfying the needs of all actors and optimizing the data exchange. PS is a knowledge-based prescription system integrating the best practices related to the prescription of CMIs. The PS output is a XML file representing the electronic order, used to exchange data with the other tools of the SPP . The proposed platform has been tested with a twofold aim: to validate the usability of the Prescription System and the inter-operability of the platform tools. The positive results gathered during the validation, led the experts to start using the web platform for their daily work.

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 cas...

This paper presents an approach for the product multi-objective optimization by associating the Response Surface Methodology (RSM) and the Design of Experiments (DoE) technique with the CAD/CAE/DfC integration. The goal of this study is to empirically identify the relationships existing between the design features and the product response (stress, strain, cost, etc.). This approach integrates three different levels of analysis: optimization problem definition, virtual prototyping and design optimization. The optimization problem definition concerns in choosing the design variables, setting constrains that have to be observed and goals that have to be achieved. The virtual analysis allows defining the principal parameterization of a geometric model and simulating the performance of each configuration, at a specific working condition, while evaluating the manufacturing cost and time. The proposed approach investigates the effect of the defined parameters and noise factor on the experimental results....

During the last 10 years, manufacturing companies have faced new challenges for improving their value proposition and being more efficient and effective on the market, satisfying the customer needs. According to this trend, several technologies have been developed and applied in different sectors and with different aims, in order to support such the companies in their reconfiguration. For example, the recent advances in Information and Communications Technologies (ICT) could give also to manufacturing industries the competences required to develop novel sustainable products embedded with a dedicated infrastructure able to provide more service functionalities to customer. In this context, the application of Internet of Things (IoT) have allowed developing the so named Product Service Systems (PSSs). Moreover, the cross-fertilization between such the technologies with the development of other ones have fostered the application of these novel ICT technologies inside the manufacturing companies also at process level. This approach has encouraged the study and development of Cyber-Physical Systems (CPSs). The present paper deals with a real industrial use case, where the application of ICT technologies and specifically the adoption of IoT at a plant of plastic extrusion pipes have allowed optimizing the production process in terms of energy efficiency.

Design for Assembly (DfA) is a well-known technique that supports in the reduction of manufacturing costs. Traditional DfA methods are generally focused on the product design lacking of a holistic view. The proposed 4 M approach takes into account all the most important aspects involved in the manual assembly: Method, Machine, Man and Material. The final goal is to provide a means for the concurrent improvement of the product design, the workstation ergonomics, and the assembly tasks. Results obtained with the electric spindle motor case study confirmed the usefulness of the approach in optimizing the manual assembly.

With increased acknowledgment of global climate change and warming, governments, consumers, and firms are responding collectively to create today's low-carbon economy. The eco-design of products is a crucial factor in the Community strategy on Integrated Product Policy. As a preventive approach, designed to optimize the environmental performance of products, while maintaining their functional qualities, it provides genuine new opportunities for manufacturers, consumers and society as a whole. This article presents an approach to support the designers during the energy labeling phases of products. The study starts with an analysis of the Eco-design regulations and proposes the virtualization of such tests. A case study on the application of the proposed method is described. The study results show that, the use of numerical simulations not only for product design but also during the testing and labeling phase, allowing a significant reduction in time to market and provides the company competition and economic, energy, and time savings

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.

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.

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.

The present paper aims at the definition of an analytical model for the cost estimation of the High Pressure Die Casting (HPDC) process. The model is based on two main pillars: (i) knowledge formalization and (ii) cost estimation algorithms. The novelty of this approach is the link between the analytical model (algorithms) and the geometrical features of the product under development. The relationship between geometrical features and cost items gives an accurate result in terms of cost breakdown, supporting designers for the application of Design-to-Cost rules in HPDC sector.

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.

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 ...

End-of-life (EoL) modelling in life cycle assessment has already been broadly discussed within several studies. However, no consensus has been achieved on how to model recycling in LCA, even though several approaches have been developed. Within this paper, results arising from the application of two new EoL formulas, the product environmental footprint (PEF) and the multi-recycling-approach (MRA) ones, are compared and discussed. Both formulas consider multiple EoL scenarios such as recycling, incineration and landfill. The PEF formula has been developed within the PEF programme whose intent is to define a harmonized methodology to evaluate the environmental performance of products. The formula is based on a 50:50 allocation approach, as burdens and benefits associated with recycling are accounted for a 50% rate. The MRA formula has been developed to change focus from products to materials. Recycling cycles and material losses over time are considered with reference to material pools. Allocation between systems is no longer needed, as the actual number of potential life cycles for a certain material is included in the calculation. Both the approaches have been tested within two case studies. Methodological differences could thereof be determined, as well as applicability concerns, due to the type of data required for each formula. As far as the environmental performance is concerned, impacts delivered by MRA are lower than those delivered by PEF for aluminium, while the opposite happens for plastic and rubber due to the higher share of energy recovery accounted in PEF formula. Stainless steel impacts are almost the same. The application of the two formulas provides some inputs for the EoL dilemma in LCA. The use of a wider perspective, better reflecting material properties all over the material life cycle, is of substantial importance to properly represent recycling situations. In MRA, such properties are treated and less data are required compared to the PEF formula. On the contrary, the PEF model better accommodates the modelling of products whose materials, at end of life, can undertake the route of recycling or recovery (or landfill), depending on country-specific EoL management practices. However, its application requires more data.

PMI annotations are widely used to support the Model Based Design within modern companies. In particular, the introduction of digital annotations marks the transition from the 2D drawings to the 3D representation in many manufacturing and design companies. However, today the implementation of the PMI technology presents some limits, such as the lack of functions to generate structure templates to be applied to similar CAD models. The proposed approach aims to overcome the limits of traditional tools which are not able to add a PMI annotation’s structure from one model to another one. The paper describes a method to reuse digital PMI annotations in a new model during the design phase, where the annotations are inherited from similar CAD documents. The proposed approach is based on two levels of geometric analysis: the searching of similar template models from an XML database, and the identification of the related geometric entities, which are used as associated objects for the definition of 3D annotations. The test case is focused on the automatic generation of PMI annotations for exhaust duct items used in oil & gas applications. The proposed tool has been developed within a software program called Duct Designer, which is used for the CAD automation of duct items. Particularly, the test case enhances the retrieval and reuse of sizing schemes from previous 3D models in order to obtain an automatic rebuilding of the geometric annotations.

The purpose of this study is to perform a new literature review of the principal ecodesign methods and tools published in the literature over the last twenty years with the objective of understanding the main obstacles that limit their actual and effective implementation in industrial companies. The main research studies on ecodesign issues are presented and classified in a structured framework on the basis of the scope perspective. Then, an exploration of the main barriers, according to the literature, that prevent the implementation of ecodesign approaches in industrial companies, is presented and compared with possible strategies that allow these barriers to be overcome. © 2016 Elsevier Ltd. All rights reserved.

A growing interest toward the adoption of a lifecycle perspective in product design is characterizing current industrial trends. The cooperation of global manufacturing actors is fundamental to retrieve information from each lifecycle stage. From this background, a lifecycle based platform is proposed to efficiently set up feasible design configurations by including global manufacturing information. Starting from a set of input parameters, the idea is to collect lifecycle information in a customized XML structure in order to draw up the environmental profile. Such platform can also be adopted as an organized “knowledge repository” enhancing information sharing among the global manufacturing network.

This study presents an approach based on Design of Experiment (DoE) technique for the optimization of an energy recovery ventilator (ERV). This system is one of the efficient ways to enhance the thermo-hygrometric comfort without increase excessively the thermal load in domestic kitchen. However, there is a major concern, which energy recovery cannot trade off ERV's fan power consumption. The goal of this study is to obtain the information about the relation between factors and response in an empirical way. This approach integrates three different levels of analysis: the virtual prototyping, Design of Experiment (DoE) and rapid prototyping. The virtual analysis allows to define the principal parameterization of a simplified model and to simulate the performance of each configuration at working condition. The proposed approach investigates the effect of the defined parameters and noise factor on the experimental results. In particular, the applied method for DoE analysis is based on virtual experiments in according to the necessity to reduce time and costs during the early design phase. The optimum parameters configuration, which is defined by the previous step, is useful to define the geometry and the working condition of a reliable virtual model. The final level is the realization of a 3D ERV with a rapid prototyping printer. The obtained component is now evaluable at the test bench to investigate the air flow rate and the electric power consumption.

Design-for-Assembly (DfA) and Conceptual DfA criteria are used in the generation of cost-effective assembly sequences for complex products. The design freedom suggests optimal solutions in the assembly time minimization problem regardless costs and issues about materials and manufacturing processes selection. The goal of this approach is to investigate how the application of the conceptual DfA affects the material and manufacturing costs (Design-to-Cost). A complex product (tool-holder carousel of a CNC machine) is used as a case study. The outcome is an approach to support designers and engineers in the re-design process for the product development and cost reduction.

The present study proposes a new method to manage adaptation behaviour of adaptive system according to the output information provide by a user model based on Bayesian Belief Network (BBN). Such method has been applied in the development of smart interfaces for cooking and kitchen management, such as meal preparation and interaction with the major kitchen appliances, pandering the user's skills, expertise and disabilities. Nevertheless, this method is flexible and suitable enough to be used in other application contexts. The validity of the decision making algorithm has been tested through simulation of real user case scenarios.

For modern manufacturing companies, the combination of physical products and intangible services (called Product-Service Systems or PSS) has been proved by time to be useful to enhance the product features by adding value throughout new functionalities, and bringing competitive advantages in a specific target market. Through PSS, companies create new business opportunities, extend the market share, differentiate the product portfolio, and improve sustainability. The PSS approach shifts the company attention from producing physical products to offering integrated systems. However, ideating and designing a PSS is a complex and multifaceted process, which requires multiple competences and cross-functions cooperation within the manufacturing company. In fact, the design phase requires to simultaneous dal with the characteristics of the physical product and of the intangible services, the last ones being by their nature fuzzy and difficult to define. Furthermore, the two entities have to be synergistically delivered and strategically managed thanks to the adoption of a PSS lifecycle management methodology and tools, in particular for the creation of a proper PSS infrastructure to delivery and maintain all the components from the design to the end of life phases. Several methodologies to design PSS can be found in literature. Most of them focus on technical development stages, while some of them face also the innovation aspects and sustainability. However, traditional product-centered approaches are not able to fully support the processes that manufacturing companies have to put in place for creating PSSs. This paper presents a new approach, based on the combination of the Open innovation method with IT solutions supporting information sharing and intra-team cooperation, in that any manufacturing company could adopt to manage the design process of a PSS. In particular, the methodology and the tools are focused on the early stages of the PSS design process, as Ideation and Concept definition that have been developed within the European FP7 project FLEXINET.

End-of-Life Tires (ELT) are one of the main source of waste in End of Life Vehicles (ELVs). Textile fibers represent about 10% in weight of the ELT and every year, in Europe, about 320,000 tons of dirty fibrous material must be disposed as special waste. Studies show that the fibrous material can be used in second life applications, reducing the environmental impacts of tires disposal, but none of these researches quantitatively evaluate the achievable benefits. This study presents a comparative evaluation of the environmental impacts of the tires considering different scenarios for the end of life of the textile fibers material.

Market competitiveness forces companies to explore novel methods and tools to make the overall product development (PD) agile and flexible and to reduce time to market. Accurate and fast cost estimation during design represents one of the most promising strategic actions to achieve these goals. In this context, a knowledge-based system that analyses the 3D CAD model of the product and automatically determines the manufacturing operations is developed. It consists of a scalable platform implementing “Design for Costing” paradigm. It is actually able to recognize geometric and non-geometric features from the 3D model and its attributes and calculate the final cost as the sum of raw materials, production cycles and setting operations thanks to the application of a set of knowledge-based rules mapping manufacturing processes and modeling features. While previous research works deepened the main technological issues of system development, this paper presents a practical case in ball valves industry to illustrate a structured methodology based on systematic engineering approach to apply the platform at the different stages of the product lifecycle and to verify the reliability of the implemented rules and the efficiency of the achieved process. The obtained results are compared to the traditional PD process to calculate product costs in order to highlight the main benefits.

Conceptual design is a crucial activity in the product development process. The design freedom must consider a trade-off analysis among several aspects such as assembly, manufacturing, and costs. The goal of this approach is to define a multi-objective design approach for the determination of feasible design options. The approach is grounded on the concept of functional basis for the analysis of product modules and the theory of Multi Criteria Decision Making (MCDM) approach for the assessment of the best design option. A complex product (tool-holder carousel of a machine tool) is used as a case study to validate the approach.

Smart Objects (SOs) market offers a wide variety of products apparently similar but characterized by different features that the average users fail to perceive. Consequently, their purchasing is often based on price and brand affection. In this context, users need a tool able to guide them in choosing the most suitable object to satisfy their expectations. To this purpose, this paper proposes a new systematic method to assess SOs in a comprehensive way: it allows to objectively assess and compare products and provides evaluation results tailored on users’ needs. A first validation is carried out on three different SO typologies.

In recent years, the Cyber-Physical Systems (CPSs), have become a new trend to increase and to enrich the interactions between physical and virtual systems with the goal to create a truly connected world in which smart objects interact and exchange data with each other. The CPS is the core of the new industrial revolution called “Industry 4.0”, which promotes the computerization of manufacturing to make decentralized decisions. Within the modular structured smart factories, Cyber-Physical Systems monitor physical processes, create a virtual copy of the physical world, simulate parts of process and implement sophisticated control policies in order to take optimized decisions. This research proposes the modelling and simulation of an induction heating process for aluminium-steel mold, which is used in the production of footwear soles. The modelling supports the simulation of a CPS model related to the use of a multi-use LGV (Laser Guided Vehicle) which transports aluminum-steel molds from a mechanized warehouse to the final rotary production line, used for the soles foaming. In detail, a thermal model and an induction heating electronic circuit model have been studied to describe the whole mold heating system and they have been simulated using Simulink/MATLAB. In addition, two types of controllers, an induction preheating control technique based on a Model Predictive Controller (MPC), and another one based on PID, have been developed in order to analyse the different behaviour of the system.

This study presents an approach for the evaluation of the energy efficiency and environmental impacts of a new modular and integrated system of renewable electricity generation and intelligent electrochemical storage systems, that allows auto-production and self-consumption of electricity in residential buildings. Homes with installed these renewable energy production systems are compared from an environmental and economic point of view, to the traditional ones, that draw electricity energy directly from the grid. In this context different scenarios are considered together with different configurations of power production and storage capacity, in order to compare different use cases. To this end, the environmental impact along all the life cycle of these systems is examined with the help of the SimaPro software simulation tool and quantitatively assessed.

Over the last years the sustainability issue has grown exponentially and it has involved several engineering areas, starting with the product sustainability, then to the factory sustainability, up to reach the entire Value Chain sustainability. Due to the continuous increasing of complex relations among factories, suppliers, and customers, a new method for investigating the entire Value Chain, considering its key partners, their requirements in terms of materials usage and energy consumption, and how these requirements influence the Value Chain sustainability is presented. This model will aim companies to define the criticalities inside the Value Chain relations and to develop possible improved scenarios.

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 presents a method to evaluate the environmental and economical sustainability of a manufacturing line/plant along its whole life cycle. The concurrent analysis of LCA and LCC allows the process engineers to estimate the production sustainability during the design of a new production line. The method considers costs and environmental impacts of the initial deployment (i.e. initial investment and set-up), use (i.e. workload or maintenance required by each machine) and end of life (i.e. retirement) of the analyzed system. The approach has been tested in a company that manufactures extruded pipes with the aim to evaluate the relative benefits.

Current CAD systems have dedicated functionalities to model weld beads, but it is often cumbersome to use these systems. This study presents a method to analyze the geometry of assemblies of B-Rep models to automatically identify possible welds among the parts using prediction rules. Adjacent faces are detected, and Boolean operators on planar loops are used to identify bead paths. Beads are then split in homogeneous portions based on the topology of the connected parts. The main goals of this study are to increase the speed of the welding definition process and to benefit applications such as the cost estimation of steelwork products. Cost estimates are based on the shape, the length and the dimension of each weld bead. Some industrial examples are presented to show the benefits in terms of time savings and accuracy to the estimation process.

The academic and industrial literature presents a lot of innovations to improve the energy efficiency of the home appliances around the world. However, few methodologies are able to combine innovations and eco-sustainability, during the design phase of green products.In this context, the paper defines an approach to analyse the relationships between different types of innovation and the relative environmental impacts, during the product lifecycle. The analysis has been performed by defining innovations categories and comparing the product Life Cycle Assessment before and after their implementation. This approach represents the preliminary phase of the innovation process, required to support the product manager.The approach has been experimented within a household appliances company, highlighting that there are innovations able to reduce the energy and water consumption respectively of 25% and 30%.

Generally a part of electric vehicle diffusion is still based on marketing of cars and vans suitable for specific use like work vehicles. A flexible design methodology is required to support rapid prototyping and product customization in the market of tailored EV/PHEV. The research focuses the cooling simulation for a PHEV Li-Ion battery. The thermal analysis is based on the physical parameters of the single cell and on the experimental data. The proposed methodology concerns firstly an analytical approach which evaluates the average heat generated by a single cell during working condition. Then the proposed virtual prototyping analysis has been divided into two levels: the thermal simulation of one cell, and the CFD analysis of a battery module. This workflow has been applied to support the design of a battery pack for a prototypal ecological hybrid vehicle. That test case vehicle is a small van, used for the curbside collection, which has in parallel an internal combustion engine and an electric motor supplied by a LFP battery with small cylindrical cells. The analysis concerns one of the four module which constitutes the whole battery pack. The virtual model has been parameterized and the behavior of air cooling system has been evaluated through virtual tools.

Cost estimation is a critical issue for many companies concerning both offers generation and company strategic evaluations. In this paper, a framework for early cost estimation has been proposed to some firms for an assessment of its main features. The aim of the industrial survey is to promote a discussion on the needs and the expectations regarding cost estimation in order to obtain feedbacks to be addresses in the implementation of a software tool. Gather data has led to a ranking of the main characteristics the tool should have.

The scope of the present research is the reduction of cost and time related to the design, prototyping and testing of a Li-ion battery pack, which is used in commercial full electric vehicles using tools for rapid product configuration and simulation. This objective is particularly important for small companies that produce many different batteries in small lots. To develop the product design support system, a preliminary study was necessary. A 3D model was analyzed to simulate real thermal behavior, reproducing a real electric load using a standard ECE-15 cycle. Experimental tests have been conducted on the vehicle and battery to validate the model. An analytical thermal model was developed to evaluate the heat generated by electrochemical reactions inside a Li-ion cell. The outcome of this analytical model was used as the boundary condition in the CFD simulation of the battery model to evaluate the cooling behavior. The rules and results deduced from these studies have allowed the implementation of an easy-to-use knowledge-based configuration tool that supports the designer in the definition of the layout of the battery pack to save time and evaluate costs. As a test case, the battery for an urban freight vehicle was designed using the proposed approach. The achieved results show good performance and robustness of the simplified approach in terms of temperature distribution evaluation and design process efficiency.

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.

Cost Estimation for offer generation in ETO companies is a critical and time-consuming activity that involves technical expertise and a knowledge base. This paper provides an approach to acquire and formalize the design and manufacturing knowledge of a company. The method has been described as a sequence of steps, which moves from the data acquisition of the past projects to the definition of a cost function based on dimensioning parameters. This approach has been experimented on a family of cranes for plants in collaboration with an industrial partner.

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.

Search engine efficiency is an essential prerequisite to ensure a satisfactory on-line purchasing experience. Despite powerful tools available today, search engine is limited to a semantic elaboration of keywords and they do not allow users finding product categories that do not belong to their knowledge sphere. In this context, in order to make an effective search engine it is necessary to provide tools able to understand what the user is looking for and suggest the products that best satisfy their needs, regardless of users’ background. To this aim, this paper proposes an innovative smart search strategy, based on artificial intelligence technologies. In order to highlight the system potential, the smart object market case study has been considered. The SOs market is grown so quickly to disorient the average user and it offer a wide variety of products apparently similar, but that are characterized by different features that the average user fails to perceive.

Circular economy is largely recognized as the univocal economic model that guarantees a long-term sustainability, decoupling the economic growth and the finite resources consumption. As a prerequisite, it requires to realize product closed-loop lifecycles. However, the management of the EoL phase during the design process is a complex task, due to the fact that it is the most far away phase, in terms of time, from the moment of the product conception. For this reason, usually, manufacturers and EoL stakeholders do not actively collaborate in optimizing the product lifecycle performances. This paper wants to overcome this lack proposing a method to formalize, collect and classify the EoL knowledge. The main outcome is a structured database containing positive and negative knowledge about best practices and disassembly problems faced during dismantling activities. The knowledge classification rules are based both on product characteristics (e.g. product families, target components, assembly methods, etc.) and on other more general aspects (e.g. motivations of the disassembly, handling difficulties, etc.). Through the sharing of this knowledge, the gap between design departments and EoL stakeholders can be reduced with the aim to improve EoL performances and the overall resource efficiency. This work is focused on an out-of-service washing machine case study. The product has been manually disassembled by expert operators, observing and rating the significant problems. Their interpretation has allowed to create a set of specific design guidelines, organized according to the defined rules. The classified knowledge has been used by non-expert designers (undergraduate students) as a tool to guide the re-design activities. Different design solutions (e.g. homogenization of screws, reduction of component number, etc.) have been implemented to configure a new washing machine version, improved from the disassemblability point of view. The obtained results have confirmed the usefulness of the disassembly knowledge sharing in supporting Design for EoL activities and, furthermore, in non-skilled operators training. In conclusion, this research work contributes to the state of the art linking stakeholders involved in the Beginning of Life (BoL) with stakeholders responsible of the EoL management. Furthermore, the proposed work leads to relevant improvements in product lifecycle performances. The proposed knowledge database represents the needed resource to effectively extend the producer responsibility and to close the current gap between manufacturers and dismantlers.

Nowadays, the energy factor is growing in importance because it really affects the production costs of factories. Not least, energy regulation and rules are stricter as time goes by. Tools for energy monitoring are needed. The objective of this work is to propose a tool aimed to assess the energy value flowing in a production system, according to the Energy Value Stream Mapping method (EVSM). The final goal is to increase the sustainability of the processes through identification of energy wastes, aiming at eliminating them. The tool is a lean graphic instrument; it permits to represent explicitly the energy flows along the process with respect to the concept of value creation. The tool permits to clearly identify and quantify different types of energy flows concerning different carriers, even in a complex production plant where multiple energy carriers act at the same time. Finally, it will be shown the testing of the tool in a household appliances production system.

In the last few years, the environmental problem has become a very serious issue and the research world has answered to this growing interest with the development of a high number of ecodesign methods and tools. However their use in real contexts is still quite low, due to their complexity, time consuming and need for specific knowledge. From this reason, it comes the need for tools that support designers in the implementation of ecodesign strategies. This paper presents the Case Based Reasoning (CBR) methodology and tool, which represents the knowledge and the best practices for manufacturing products. It supports designers in the re-design process of products, by allowing them to gradually acquire knowledge and to solve problems in a rapid and simplified way, through the collection and sharing of ecodesign knowledge in a structured Database. The tool has been tested into two industrial companies to verify its potentialities, evaluate its usability and identify its limits.

A product is chosen by users not only for the features it offers but also for the perceived experience of use. This statement widely recognized in literature highlight that key issues for the success of interactive products are the practical, experiential, affective, meaningful and valuable aspects of interaction. In the last years, gesture-based interfaces have been introduced to make the experience of interaction more emotional, intuitive and natural. For this reason, the design and development of products integrated gesture-based interfaces represent a challenging issue. In this context, a User-Centered Design (UCD) method to implement novel interaction paradigms into traditional consumer products is proposed. Its application in a real case study addresses the development and prototyping of a system exploiting gesture-based interaction to train aspiring conductors of orchestra. If a young musician wants to play a guitar, it is usually no great problem to find one, but if a musician wants to learn the ins and outs of being a conductor, the problem shifts to search for an electronic device managed by hands as used by conductors. The developed system provides three main functionalities: tempo control, velocity control and instruments activation. It represents both a use case to validate the proposed UCD method and an innovative solution in the context of aspiring conductor’s training.

Electric motors are one of the most common electrical components used both in industrial and household applications. In order to reduce world energy consumption and environmental impact, electric motors need to be improved in terms of efficiency and eco-sustainability. For this reason it is necessary to improve environmental consciousness, favouring the application of eco-design guidelines in the design phase, which is the most important stage where “green” solutions can be rapidly ideated, evaluated and optimized. Different aspects have to be concurrently considered in order to achieve a high quality product in a short time to market. In this context, the present paper describes an innovative web-based software platform to configure and simulate customized energy efficient electric motors. The core of the platform is a knowledge-based system which aims to standardize the design process according to the rules which represent the company know-how and best practices. The platform integrates different software tools to support the development from conceptual design to detailed design, and from the configuration of design solutions up to environmental impact assessment and manufacturing cost evaluation. It also provides a collaborative area in order to improve the collaboration among remote users involved in the design process, thanks to the sharing of important design data and models. The presented practical case studies demonstrate the effectiveness of the platform application. The achieved results demonstrate the improvement of the configured solutions in comparison with the traditional adopted motors. The new motors exhibit both a considerable increase in energy efficiency and at the same time relevant improvement in product sustainability combined with acceptable production costs.