Modeling and analysis of sustainable product development

Abstract

In this thesis, a methodological approach for sustainable product development is proposed. It consists of three fundamental phases which employ Life Cycle Assessment (LCA) and Life Cycle Costing (LCC), Quality Function Deployment (QFD), and Data Envelopment Analysis (DEA). The life cycle analysis of the current system is the first phase. The processes which occur along the life cycle are separated, and their inputs and outputs are detected. These identified elements are analyzed with LCA from an environmental viewpoint, and with LCC emphasizing the economical issues. Customer requirements are identified, design alternatives are generated and compared with QFD in the second phase. From sustainability point of view, customer term is classified as external customer, internal customer, and society. Product design alternatives are then compared based on technical specifications and requirement satisfaction levels. In the last part of the methodology, DEA model based on critical criteria of sustainability is constructed. In accordance with this model taking into account inputs, desirable outputs, and undesirable outputs, each design alternative is evaluated and the most sustainable option is selected. Based on the proposed approach, a case study is conducted for glass beverage containers. 24 design alternatives are constructed from the most crucial technical attributes based on the customer requirements. They are analyzed and assessed in accordance with the proposed methodology. As a result, four options are selected as more sustainable than the others. It is demonstrated that selection and evaluation of product design alternative can be performed in a systematic way. The integrated methodology provides a roadmap for modeling and analysis for sustainable product development to strengthen the competitive power of manufacturing companies.