Calculator for Sustainable Tradeoff Optimization in Multi-Generational Product Family Development Considering Re-X Performances

Michael Saidani, Xinyang Liu, Dylan Huey, Harrison Kim, Pingfeng Wang, Atefeh Anisi, Gul Kremer, Andrew Greenlee, Troy Shannon

Research output: Chapter in Book/Report/Conference proceedingChapter

Abstract

Design for Re-X (reuse, remanufacturing, recycling) in a multi-generational product family setup is a challenging task that requires new and more advanced, quantitative, and user-friendly tools to ensure environmental savings and economic profitability for product makers. Through this REMADE-funded project, state-of-the-art Re-X, reliability, and lifecycle-based models are combined within a new design tool in order to generate and compare designs for Re-X alternatives. This newly developed Calculator aims to assess the potential of reliability-informed analysis of longterm benefits/costs of Re-X in product family design to enable substantial reductions in embodied energy and carbon emissions. To do so, three integrated modules are working together: (i) the LCA/LCC module; (ii) the reliability module; and (iii), the Re-X policy optimization module. Notably, the lifecycle-based module allows testing and comparing the impact of different material alternatives, part designs, and sub-assemblies. In addition, the Re-X and reliability analysis modules enable to compare and optimize different designs based on, e.g., material composition, the percentage of remanufactured components, the energy consumption, or the remaining useful life of critical components. In particular, for the reliability module, the inputs are the following: the shape/scale from reliability info or estimated using warranty claims, the warranty length (provided from the product or part information), the total number of new and used parts, and the weight (initial weight of product/subassembly being evaluated). The outputs enable the user to estimate the additional units for warranty claims, the reuse rate, and the adjusted weight. The Re-X policy optimization module includes: the bi-objective function (as of now, minimize cost and energy consumption), the Pareto front exploration, the impact of component reliability, the impact of warranty length, the impact of return rate, and the impact of remanufacturing cost. This new Re-X Calculator is being tested, finetuned, and validated based on two complementary product family categories (utility tractor product family design problem and mobile phone design and recovery problem) provided by the industrial partners, John Deere and Global Electronics Council.

Original languageEnglish (US)
Title of host publicationTechnology Innovation for the Circular Economy
Subtitle of host publicationRecycling, Remanufacturing, Design, System Analysis and Logistics
PublisherWiley
Pages159-170
Number of pages12
ISBN (Electronic)9781394214297
ISBN (Print)9781394214266
StatePublished - Jan 1 2024

Keywords

  • Circular economy
  • Computation tool
  • Design performance
  • Impact quantification
  • Life cycle assessment
  • Product reliability
  • Product sustainability
  • Remanufacturing

ASJC Scopus subject areas

  • General Engineering

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