Integrated eco-design decision-making for sustainable product development

This paper presents an integrated eco-design decision-making (IEDM) methodology that is formed using three stages: life cycle assessment, an eco-design process (Eco-Process) model and an enhanced eco-design quality function deployment process. All product sustainability considerations are conducted within a special eco-design house of quality. This brings together the analysis of factors relating to manufacturing processes, product usage and end-of-life strategy. The concentration of environmental considerations in one place insures that product sustainability is central to any design development and that the implications of change are fully identified and justified. The IEDM methodology utilises of a set of Eco-Process parameters and their associated relationships to allow users with complementary knowledge to enter and access information in a timely and controlled manner. They are then able to contribute their expertise to support decisions with the aim of providing more sustainable products. An application of the approach is presented in the context of a case study considering the redesign of a single-use medical forceps. The materials and production methods used are investigated with a view to quantifying their environmental impact. The resulting IEDM methodology can be seen to be widely and easily applicable.     

An approach to conceptual and embodiment design within a new product development lifecycle framework

The design of new innovative products is the result of an accurate and precise management of knowledge sources all over its life cycle, such as technology, market, competitors and suppliers. The work contributes with a framework that shows how the knowledge sources influence in the state-of-the-art and market needs so that they become opportunities for innovating products addressing the whole product life cycle. It provides a systematic path from the early generation of ideas to the production of a new product proposal. Through a deep analysis of previous research works of new product innovation life cycle development frameworks and linking it with knowledge management, strategic planning and scorecards, we came out with a structured contribution. The result considers the concurrent activities and its relationships all the way through the product life cycle that can help in creativity and innovation, combined with a process management proposal. Managing the sources of knowledge in highly dynamic markets and technologies is one of the major difficulties involved in innovative products design and development. The emerging knowledge from external sources is confronted with organisation internal knowledge and experience in order to achieve the first product correct.     

Analytic hierarchy prioritisation of new product development activities for electronics manufacturing

New product development (NPD) is a managerial process, performed by many activities. The purpose of this paper is to present the application of the analytic hierarchy process (AHP) to prioritise activities of NPD for manufacturing companies of electronic products. Mathematical modelling was the research method adopted. An electronics cluster located in the southeast region of Brazil was studied. Therefore, 10 of the 42 activities from an NPD model were suggested to be excluded for the electronics companies. These activities have less than 0.5% overall priority. The results from the AHP application were welcomed by the companies’ NPD experts.     

Non-discrete ant colony optimisation (NdACO) to optimise the development cycle time and cost in overlapped product development

In order to expedite the process of introducing a product to market, organisations have shifted their paradigm towards concurrent engineering. This involves the simultaneous execution of successive activities on the basis of information available in rudimentary form. For this, cross-functional teams sporadically communicate to exchange available updated information at the cost of augmented time and money. Therefore, the aim of this paper is to present a model-based methodology to estimate the optimal amount of overlapping and communication policy with a view to minimising the product development cycle time at the lowest additional cost. In the first step of the methodology, an objective function comprising the cycle time and the cost of the complete project is formulated mathematically. To reach the optimal solution, a novel meta-heuristic, non-discrete ant colony optimisation, is proposed. The algorithm derives its governing traits from the traditional ant algorithms over a discrete domain, but has been modified to search results in a continuous search space. The salient feature of the proposed meta-heuristic is that it utilises the weighted sum of numerous probability distribution functions (PDFs) to represent the long-term pheromone information. This paper utilises a novel approach for pheromone maintenance to adequately update the PDFs after each tour by the ants. The performance of the proposed algorithm has been tested on a hypothetical illustrative example of mobile phones and its robustness has been authenticated against variants of particle swarm optimisation.     

Product service systems,after-sales service and new product development

After-sales service is a critical element in the successful marketing of many products. Capital goods, for example, manufacturing equipment, require after-sales service such as maintenance and repair in order for customers to get the full value from them. Some manufacturers have started to offer customers an integrated product and service, termed a product-service system in the academic literature. However, in order to deliver such integrated offerings, a different approach to new product development (NPD) is required. This is because the product design influences after-sales service requirements, and so this needs to be considered during NPD. However, researchers have largely ignored the relationship between NPD and service. To address this gap, six in-depth case studies were conducted at leading companies that offer a combined product-service offering, to identify how service requirements are typically evaluated at the design stage. The results show that at companies where after-sales is an important element of the business, service requirements are systematically evaluated during NPD through the involvement of after-sales personnel and the use of field service data to set design goals.     

An analytical technique to model and assess sustainable development index in manufacturing enterprises

Sustainable development (SD) will be the driving force to Twenty-first Century as automation was to the Twentieth Century and stream was to Nineteenth Century. There are two levels of sustainability: Macro-Level (country, cities) and Micro-Level (manufacturing enterprises and its town and regional areas). In this paper, Micro-Level of sustainability will be discussed. The major challenge of manufacturing enterprises is modelling and assessing the sustainable development performance. Introducing indexes for sustainable development assessment in manufacturing enterprises is important not only to enable them to quantitatively estimate SD, but also to determine the requirements of components for these enterprises to survive. The main objectives addressed in this paper is how to model the required components and how to introduce a new assessment framework for assessing sustainability from lowest levels, dimensions up to sustainable development level according to Micro-Level. The three pillars of sustainability (economic, social and environmental) are modelled, estimated and incorporated into a concept, the so-called ‘general sustainable development index’. Based on these concepts, the sustainable models will be analysed and presented through covering all aspects/issues of sustainability. The ultimate goal of this paper is considering the needs of manufacturing enterprise to be sustainable as well as to be globalised through introducing the concept of economic-social-environmental sustainable development and basic attitudes related to creating sustainable development value in engineering practices (economic), social (political) and environmental community. An industry-based case study is used to represent sustainability through aspects, performance metrics, indicators and pillars.     

Modelling engineering change management in a new product development supply chain

The changes within a new product development (NPD) process are handled differently depending on the stage of the project. The changes during the initial stages of the project are addressed by design iterations, while the changes after the product design is complete are addressed using a formal engineering change management (ECM) process. The ECM process is a complex process, especially under a collaborative environment, where various independent entities work together for a common cause of product development. The interactions between the NPD and ECM processes have rarely been investigated in the research community. In this paper, we attempt to study the interactions between the various NPD and ECM process parameters by modelling the processes and simulated the model to understand the parameter interactions. The organisations in a supply chain have been characterised based on their interactions with the original equipment manufacturer (OEM) during the NPD process. The organisation process templates representing the NPD and ECM processes of each type of organisation in the supply chain have been modelled. The templates have been used to develop a simulation model representing the NPD and ECM processes for a supply chain. The process variables, such as processing rates, resources, resource composition, resource allocation priority, processing quality and phase overlap, have been included in the model. The results indicate that most of the variables and interactions among the variables have a significant influence on the NPD lead time. By identifying the status of?the NPD process, the decision-makers can use these results to develop appropriate management policies to govern their product development projects.     

Role of traditional Chinese philosophies and new product development under circular economy in private manufacturing enterprise performance

The new product development (NPD) process–performance link has been sufficiently studied in academic research. However, recent NPD process is significantly different from the conventional NPD specifically with the inclusion of sustainability considerations under circular economy (CE) context. In theory, NPD with CE considerations (CE-NPD), compared with the conventional NPD, is associated with higher costs and longer development times. This study empirically examines the effect of the CE-NPD process on both time-to-market (TTM) and profit performance in the context of Chinese private enterprises. In addition, the role of traditional Chinese philosophies of Confucianism and Taoism in influencing the CE-NPD process–performance link is also investigated. We find that Confucianism positively moderates the relationship between the CE-NPD process and TTM performance. However, it negatively moderates the CE-NPD-profit link. On the other hand, the moderating effect of Taoism is negative on both the CE-NPD-TTM and CE-NPD-profit links. An interesting finding of this study is that the coexistence of Confucian and Taoist values in NPD workers has the strongest positive impact on the relationship between the CE-NPD process and performance. Our study provides insights on the way in which companies should plan to apply Chinese philosophies during the CE-NPD process to maximise the benefits.     

State-of-the-art technologies and methodologies for collaborative product development systems

In order to facilitate product realisation processes, presently, research is actively being carried out to develop methodologies and technologies to support geographically dispersed teams to organise collaborative design based on the quickly evolving information technologies. A number of research works and commercial systems have appeared to provide solutions for collaborative and distributed product development, and the practical applications are getting more pervasive and mature. In this paper, the recently related works are summarised from three aspects—visualisation-based collaborative systems, co-design collaborative systems and CE (concurrent engineering)-based collaborative systems. Around these aspects, about 100 papers and 30 commercial systems/international standards published or launched recently are discussed. The current research and development statuses and issues, underlying algorithms, mechanisms and system architectures, and the future trends and challenges are explained and compared in detail.     

RMS capacity utilisation: product family and supply chain

The paper contributes to development of RMS through linkage with external stakeholders such as customers and suppliers of parts/raw materials to handle demand fluctuations that necessitate information sharing across the supply chain tiers. RMS is developed as an integrated supply chain hub for adjusting production capacity using a hybrid methodology of decision trees and Markov analysis. The proposed Markov Chain model contributes to evaluate and monitor system reconfigurations required due to changes of product families with consideration of the product life cycles. The simulation findings indicate that system productivity and financial performance in terms of the profit contribution of product-process allocation will vary over configuration stages. The capacity of an RMS with limited product families and/or limited model variants becomes gradually inoperative whilst approaching upcoming configuration stages due to the end of product life cycles. As a result, reconfiguration preparation is suggested quite before ending life cycle of an existing product in process, for switching from a product family to a new/another product family in the production range, subject to its present demand. The proposed model is illustrated through a simplified case study with given product families and transition probabilities.     

Multi-generation pricing and timing decisions in new product development

When planning for the introduction of a stream of new products into the marketplace, managers must consider both the timing and dynamic pricing decisions to determine an appropriate entry strategy into the marketplace. Literature in new product development (NPD) typically addresses optimal timing and pricing decisions independently. We develop an analytical model of coordinated product timing and pricing decisions when there are two generations of a new product under consideration. Factors driving the timing and pricing decisions include the unit sales and cost relationships for each generation as well as NPD costs for introducing the next generation of products. We derive analytic results that characterise the optimal timing and pricing strategies for a single product rollover scenario. We analyse several numerical examples to illustrate the interplay between optimal pricing and time-to-market strategies under more general settings.     

Development of a collaborative product development framework based on centre-satellite system and service-oriented architecture

To increase competitive advantage for manufacturers, collaboration product development (CPD) has recently become an important issue. Based on the CPD concept, this study focuses on the centre-satellite system (CSS) with five major roles (i.e. centre factory) and their interactions and the technology of web services using service-oriented architecture (SOA) to propose a system framework, entitled the collaborative product development framework for centre satellite system (CPDF-CSS). The CPDF-CSS comprises five modules: CF-MA module, DH-MA module, ODM-MA module, OEM-MA module, and EC-MA module. Next, based on the CPDF-CSS, a generic communication component (GCC) is designed for the interoperability among five modules under heterogeneous contexts. Finally, this study presents a case involving the motorcycle industry for evaluating the implementation of CPDF-CSS. The contributions of this study to the CPD are discussed.     

Approaching lean product development using system dynamics:investigating front-load effects

Competing with successful products has become perplexing with several uncertainties and transmutes from time to time as customers’ expectations are
dynamic. That is why manufacturing firms exhaustively strive to look for a better competitive frontier using wellestablished and innovative product development (PD) processes. In this paper, we would like to answer three research questions: (i) What would be the effects of frontloading
in PD? (ii) Can we improve our PD process endlessly? (iii) When is the critical time that the firm should take remedial action for improvements? As a contribution to the vast numbers of improvement methods in new product development (NPD), this paper investigates the effects of front-loading using set-based concurrent engineering (SBCE) on cost and lead time. Models are developed and treated using a system dynamics (SD) approach. We assign a hypothetical upfront investment for SBCE and compare its effects on  total cost and lead time of the development process. From the research, it is found that the total cost of PD is reduced almost by half-although the front loading is higher in order to encompass multiple design alternatives. The total product lead time is reduced by almost 20 %. The model reveals the critical time for improvement of the PD process. We use SD tool (e.g., STELLA) for simulation and visualization of the complex PD model, using SBCE as one of several strategies to frontload activities in the NPD process.     

Design of smart connected manufacturing resources to enable changeability,reconfigurability and total-cost-of-ownership models in the factory-of-the-future

The fourth industrial revolution requires higher capabilities of changeability and reconfigurability (C–R) of the future factories (FoF), as well as a higher focus on business models that are based on total-cost-of-ownership (TCO) paradigm. Up to date, there are little scientific contributions to deploy C–R into TCO models, as well as to systematic plan and design manufacturing resources such as to facilitate FoF ecosystem. In order to address this issue, this paper introduces research results that show how to deploy C–R, connectivity, smartness and TCO requirements into the technical solutions of manufacturing resources of FoF. Contributions emerging from this research include an index to measure C–R capability of manufacturing resources, a model to assess economic feasibility of a FoF over its lifecycle, as well as a methodology and related tools to design smart connected manufacturing resources with embedded features to facilitate changeability and reconfigurability in a FoF. Theoretical contributions are explained through a case study of a fast reconfigurable robotic manufacturing cell. Preliminary results demonstrate that it is possible to rapid design smart connected manufacturing resources and integrate them into FoF architectures that support convertibility, integrability, modifiability, adaptability, serviceability, scalability, integration of resources from various producers, service clustering and cloud-based services.     

An evaluation framework for product planning using FANP,QFD and multi-choice goal programming

Technological innovation and satisfaction of customer needs are the keys to survival and success for firms, especially in global competitive high-tech industries. Since new products are usually a source of new sales and profits, the success of new product development (NPD) is essential to maintain a competitive edge and to make a decent profit in a longer term. Therefore, how to develop products that deliver the quality and functionality customers demand while generating the desired profits becomes an important task for the manufacturers. In this paper, a framework with two phases is constructed for facilitating the selection of engineering characteristics (ECs) for product design. In the first phase, quality function deployment (QFD) is incorporated with the supermatrix approach of analytic network process (ANP) and the fuzzy set theory to calculate the priorities of ECs with the consideration of the interrelationship among factors and the impreciseness and vagueness in human judgments and information. In the second phase, multi-choice goal programming model is constructed by considering the outcome from the first phase and other additional goals, such as NPD cost and manufacturability, in the attempt to select the most suitable ECs. A case study of the product design process of backlight unit (BLU) in thin film transistor liquid crystal display (TFT-LCD) industry in Taiwan is carried out to verify the practicality of the proposed framework.     

Systematic packaging design tools integrating functional and environmental consequences on product life cycle: Case studies on laundry detergent and milk

This study presents systematic packaging design tools integrating functional and environmental consequences on product life cycle. To design packaging for sustainability, the trade-offs between functional and environmental aspects of packaging throughout the product life cycle should be considered. However, it is difficult for packaging designers to understand the overall trade-offs because the extent of the design consequences on the entire life cycle of packaging and its contents is unclear. We developed two tools for packaging design: the Life Cycle Association Matrix (LCAM) and the Function Network Diagram (FND). The following three steps, based on literature reviews and interviews with industrial experts, were applied. Firstly, we listed the product functions and design variables related to the functions as the attributes allocated to the product life cycle. Secondly, the attributes were connected appropriately based on causal relationships. Lastly, we identified the factors to support decision making in the packaging design procedure. As a result, the LCAM depicts the design consequences on the life cycle, and the FND determines the stakeholders affected by the design consequences. Two case studies were demonstrated to analyze the trade-offs by using our tools. In the case studies, a liquid laundry detergent bottle and a milk carton were redesigned. The tools identified the design consequences and stakeholders affected by the redesign of the usability and protective function for the detergent and milk cases, respectively. The results showed the significance of understanding the design consequences on the product life cycle by integrating the functional and environmental aspects.     

Refurbishment or quality recovery: joint quality and pricing decisions for new product development

Refurbishment and quality recovery, as two important strategies of reverse logistics, have been widely used for consumer durables, especially consumer electronics. This trend is driven by manufacturers’ profit-seeking behaviours and the increasing environmental concerns of society. This study investigates and compares the optimal emergence of these two strategies when product quality is endogenous. Model analyses provide several notable insights. First, we find that the refurbishment strategy dominates the quality recovery strategy when the fraction of the recoverable quality-inducing components in the defective product is low enough. Moreover, when the refurbishment strategy emerges as the optimum, the quality and price of the new product as well as the total realised sales of both new and refurbished products are consistently higher than those with the quality recovery strategy. In addition, when either the refurbishment or quality recovery strategy emerges as the optimum, the overall consumer surplus is also enhanced. Finally, in the model generalisation, we show that a synthetic strategy with which some of the returned defective products are refurbished and others are remanufactured through quality recovery can certainly increase the manufacturers’ profit compared to either one of them when the fraction of the recoverable quality-inducing components in the defective product is moderate.     

Influence of market orientation on performance: the moderating roles of customer participation breadth and depth in new product development

ABSTRACT

With a greater number of B2B firms integrating customers into the new product development (NPD) process, how to utilize customer involvement in NPD is an important decision because it may be a double-edged sword carrying both bright and dark sides. Utilizing a sample of 193 B2B firms across various industries, we validate previous research that suggests market orientation positively influences NPD performance and subsequently examine how this relationship may either be enhanced or diminished contingent upon how customers are utilized in the NPD process. The results show that the market orientation–NPD performance relationship is enhanced by having customers participate in a greater number of activities throughout NPD (customer participation breadth) and diminished when customers are involved at deeper levels (customer participation depth). This research suggests that the exact involvement of customers is a critical decision and has clear implications for the dialogues about customer involvement and management of customer relationships.     

An empirical study of firm’s absorptive capacity dimensions,supplier involvement and new product development performance

Firms’ performance in their new product development (NPD) is believed to be positively related with involving suppliers in the process of new product development, and also with the organisation’s capacity and capability to absorb external and internal knowledge, namely absorptive capacity (AC). Addressing a gap in the literature, this study adopts the definition and structure for AC suggested by Tu et al. (2006) to examine relationships between AC’s sub-dimensions with NPD performance, and also their moderating effects on the relationship between supplier involvement and new product development performance, on both financial and nonfinancial aspects. Data from a survey of 161 manufacturing firms are used to test the developed hypotheses using structural equation modelling and hierarchical regression. Direct and contingent effects of supplier involvement and AC on new product development performance are studied. As a result factors determining AC are found of different level of effects on financial and nonfinancial performance of new products, which will have implication for theory and practice.     

Supply chain risk assessment during new product development: a group decision making approach using numeric and linguistic data

Companies strive to minimise supply chain related risks during new product development as any glitch while developing new products can lead to considerable delay in product launch with severe financial implications. However, many organisations face difficulty in properly assessing the vulnerabilities of their globally dispersed supply chains during the product development stage as no suitable procedure for that purpose seems to be readily available in the literature. The present research is an attempt to fulfil this requirement. A step-by-step approach for supply chain risk assessment during new product development, involving group decision making, is suggested. This approach can use both numeric and linguistic data and helps in determining vulnerability scores for various sub-systems and for each supplier of the most vulnerable sub-system. This is followed by failure mode effect analysis (FMEA) which helps prioritise failure modes of vulnerable suppliers and thus create specific control plans to mitigate supply related failures. Using this approach, organisations can devise control plans to alleviate the supplier related risks during new product development. Although, the methodology is illustrated through an application in aircraft manufacturing, it can also be used in other discrete and process manufacturing industries.