An approach to identify the factors that affect a products life time energy consumption during the concept design stage

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28th 28th CIRP CIRP Design Design Conference, Conference, May May 2018, 2018, Nantes, Nantes, France France

28th CIRP Design Conference, 2018,a Francelife An the that affect products An approach approach to to identify identify the factors factors thatMay affect aNantes, products life time time energy energy consumption during the concept design stage consumption during conceptand design stagearchitecture of A new methodology to analyze the the functional physical a a S a*, S Kara a existing products for an assembly oriented product family identification SM M Ibbotson Ibbotson *, S Kara a Sustainable a

Manufacturing and Life Cycle Engineering Research Group, School of Mechanical and Manufacturing Engineering, Sustainable Manufacturing and Life Cycle Engineering Research Group, School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney NSW 2052, Australia The University of New South Wales, Sydney NSW 2052, Australia

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France * Corresponding author. Tel.: +61-2-9385-5757 ; fax: +61-2-9663-1222. E-mail address: [email protected] * Corresponding author. Tel.: +61-2-9385-5757 ; fax: +61-2-9663-1222. E-mail address: [email protected] * Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]

Abstract Abstract

Abstract Energy efficiency of products is one area of sustainable development that has gathered increased attention due to the increased cost of energy Energy efficiency of products is one area of sustainable development that has gathered increased attention due to the increased cost of energy and the associated environmental footprint. The responsibility to develop more energy efficient products rests largely with designers and and the associated environmental footprint. The responsibility to develop more energy efficient products rests largely with designers and Inmanufacturers. today’s business the in trend towardsthe more product variety customization is unbroken. Due step to this need of Theenvironment, design phase, particular conceptual design and stage is highlighted as a critical in development, determining atheproduct’s manufacturers. The design phase, in particular the conceptual design stage is highlighted as a critical step in determining a product’s agile and reconfigurable production systems emerged cope with available various products To design andThis optimize environmental impact and related costs. However, the to information is limitedand andproduct usuallyfamilies. of a qualitative nature. paperproduction presents a environmental impact and related costs. However, the information available is limited and usually of a qualitative nature. This paper presents a systems as well as to choose the optimal product matches, uses product analysis methods arestage needed. most information of the knownnormally methodsfound aim to novel approach linking qualitative features that a designer at the conceptual design withIndeed, quantitative in novel approach linking qualitative features that a designer uses at the conceptual design stage with quantitative information normally found in analyze a product or one product on the shown physicalcan level. however, mayindiffer largely inthe terms of theconsumption, number and the detailed design stage. Thefamily correlation be Different used to product develop families, a framework to aid calculating energy the detailed design stage. The correlation shown can be used to develop a framework to aid in calculating the energy consumption, nature of components. Thisassociated fact impedes and product family combinations for the production environmental impact and costsan of efficient a productcomparison concept over thechoice entire of lifeappropriate cycle. environmental impact and associated costs of a product concept over the entire life cycle. system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster © 2017 The Authors. Published by Elsevier B.V. 2018 The Authors. Published by Elsevier B.V. Ltd. This is an open access article under the CC BY-NC-ND license © 2017 these productsunder in new assembly oriented product families for the optimization existing assembly 2018. lines and the creation of future reconfigurable Peer-review responsibility of the scientific committee of the 28th CIRPofDesign Conference (http://creativecommons.org/licenses/by-nc-nd/3.0/) Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. assembly systems. on Datum Chain, the physicalofstructure the products is analyzed.2018. Functional subassemblies are identified, and Peer-review underBased responsibility of Flow the scientific committee the 28thofCIRP Design Conference consumption, Conceptual design,aProduct Cycle and physical architecture graph (HyFPAG) is the output which depicts the a Keywords: functionalEnergy analysis is performed. Moreover, hybridLife functional Keywords: Energy consumption, Conceptual design, Product Life Cycle similarity between product families by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Introduction Industry is largely seen as responsible for environmental ©1.2017 The Authors. Published by Elsevier B.V. 1. Introduction Industry is largely seen as responsible for environmental Peer-review under responsibility of the scientific committee of the 28th CIRPefficiency Design Conference [6]. In 2018. order for future generations to have the

It is predicated that by 2030 more than 3 billion people It is predicated that by 2030Family moreidentification than 3 billion people Keywords: Assembly; Design method; will enter the middle class leading to an unprecedented will enter the middle class leading to an unprecedented demand for goods and services. If this consumption is left demand for goods and services. If this consumption is left unchecked then by 2050 there will be a tripling in the unchecked then by 2050 there will be a tripling in the depletion of natural resources which will pose a severe 1.depletion Introduction of natural resources which will pose a severe threat to economic and human security [1]. threat to economic and human security [1]. Demand for energy such as electricity is one of the Due to for the energy fast development in the domain Demand such as electricity is one of theof resources in which consumption has greatly increased. communication and an ongoing trend of digitization and resources in which consumption has greatly increased. Unfortunately, the main energy source for the world’s digitalization, enterprises facing Unfortunately,manufacturing the main energy sourcearefor the important world’s electricity production comes from fossil fuels namely, coal, challenges in today’scomes market environments: a continuing electricity production from fossil fuels namely, coal, oil and natural gas. Such fuel types produce more than one tendency towardsgas. reduction of product development timesone and oil and natural Such fuel types produce more than third of global greenhouse gas emissions [2]. To curb this shortened product lifecycles. gas In addition, there an curb increasing third of global greenhouse emissions [2].isTo this demand, governments have introduced a number of energy demand customization, being at the same time of in energy a global demand,ofgovernments have introduced a number standards for appliances and equipment such as the competition withappliances competitorsand all over the world. standards for equipment suchThis as trend, the European directives on the Eco-Design of Energy-related European directivesthe on development the Eco-Design of macro Energy-related which is inducing from to micro Products [3], Energy End-Use Efficiency and Energy Products results [3], Energy End-Use andaugmenting Energy markets, in diminished lot Efficiency sizes due to Services [4] and in Australia the Greenhouse and Energy Servicesvarieties [4] and(high-volume in Australia to thelow-volume Greenhouseproduction) and Energy product [1]. Minimum Standards (GEMS) [5]. Minimum Standards (GEMS) [5]. To cope with this augmenting variety as well as to be able to identify possible optimization potentials in the existing 2212-8271 ©system, 2017 The Authors. Publishedtobyhave Elsevier B.V. knowledge production is important a precise 2212-8271 © 2017 The it Authors. Published by Elsevier B.V.

efficiency [6]. In order for future generations to have the same standard of living enjoyed today, manufacturers need same standard of living enjoyed today, manufacturers need to adopt an approach that minimises the impact their to adopt an approach that minimises the impact their products have on the environment as well as the broader products have on the environment as well as the broader society. To encourage this, tools and methods are required, society. To encourage this, tools and methods are required, particularly in the early stages of product development. of particularly the product inrange and stages characteristics manufactured the early of product development.and/or The traditional product development process consists of assembled in this system. In this context, theprocess main challenge The traditional product development consists in of designing a product from cradle to gate. However, this modelling anda analysis nowcradle not only to cope with single designing product is from to gate. However, this method is seen as obsolete and a more sustainable approach products, range existing product approach families, methodaislimited seen asproduct obsolete and or a more sustainable needs to be encouraged [7]. Implementing a cradle to grave butneeds also totobe to analyze andImplementing to compare products beable encouraged [7]. a cradletotodefine grave philosophy in the design stage will assist in reducing the new product families. It can be observed that classical existing philosophy in the design stage will assist in reducing the impact a product has on the environment. This is due to less product families are regrouped function of clients features. impact a product has on the in environment. This isor due to less dependence on the use of raw materials as well as a However, assembly are hardly dependence on oriented the use product of rawfamilies materials as wellto find. as a reduction in the amount of waste to landfill. Subsequently, On the product products differ mainly in two reduction in the family amountlevel, of waste to landfill. Subsequently, this system has the potential to increase profits and/or main (i) the number to of components and (ii) the thischaracteristics: system has the potential increase profits and/or improve a products competitiveness through appealing to improve a products throughelectronical). appealing to type of components (e.g.competitiveness mechanical, electrical, environmentally conscious consumers. environmentally conscious consumers. Classical methodologies considering mainly single products The product design process consists of three generic The product process consists of three generic or solitary, alreadydesign existing product families analyze the stages. The first stage is ‘Specification’. The second stage stages.structure The first is ‘Specification’. The second stage product on stage a physical level (components level) which causes difficulties regarding an efficient definition and comparison of different product families. Addressing this

Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. 2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/) 2212-8271 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of scientific the scientific committee theCIRP 28thDesign CIRP Conference Design Conference Peer-review under responsibility of the committee of the of 28th 2018. 2018. 10.1016/j.procir.2018.02.033

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concerns ‘Conceptual Design’. The final stage is known as ‘Detail Design’ [8]. It is well documented that 70-80% of a products cost and environmental impacts are determined at the design stage [9]. Furthermore, up to 60% of a products lifetime cost and environmental footprint is determined at the concept design phase [10]. Therefore, to have the greatest benefit, environmental considerations should be integrated into the first two stages of the product design process. To aid designers and manufacturers in determining a products environmental impact over its life cycle, Life Cycle Assessment (LCA) has been utilized [11]. The life cycle stages consist of raw material extraction, production, transportation, usage and End-of-Life (EOL). During a products development, LCA is usually performed during the detailed design stage. From an energy perspective, different types of products consume various energy levels in all life cycle stages. For instance, an active product has the highest energy consumption during the usage phase while a passive product’s material stage is the predominant contributor [12]. Additionally, there is still a gap between solutions that support energy assessment and industry adoption of those solutions [13]. The design tools and guidelines that have been developed to reduce energy consumption have focused on the Usage stage as it can be a dominant selling point [14]. Furthermore, previous studies have only considered energy consumption for a particular life cycle stage [12]. For instance, there is a lack of information relating to the energy utilized during the production phase, which contributes a significant proportion of a product’s energy consumption over its life cycle [15]. The research that has been undertaken into estimating the energy consumed over the product life cycle can be divided into two main approaches. The first is Energy Factor [16] which is a variable coefficient expressed as a mathematical model that can be used to calculate product or sub-assembly energy consumption over the life cycle stages. The second approach is to use CAD based systems [17]. Whilst these methods can help in determining energy consumption over a product life cycle, there are some limitations namely, they require either a CAD model or Bill of Materials (BOM) to input the data. This paper will demonstrate that CAD is used when the product is in the detailed design stage not the concept design stage. At the detailed design stage the product concept is locked in and changes can be very costly and add additional development time slowing time to market. Both approaches are mainly suitable for the redesign of an existing product. They cannot be applied to the design of a new product as they rely heavily on data, such as specific number of components, CAD models or BOMs to calculate the results. For the design of a new product, it is all most impossible to accurately know the specific number of components the product will consist of. Furthermore, they are dependent on the designer’s level of experience to obtain a more accurate result. As far as this research could establish, limited studies

have been undertaken to calculate the energy consumed by a product over its entire life cycle at the concept design stage. The concept design stage is identified as a critical stage for not only a products overall cost but also its environmental impact. It is at this stage that numerous iterations can be produced quickly without dramatically effecting the project cost or timeline. However, the information at this stage has traditionally been seen as qualitative in nature making it challenging to develop tools and methods that can easily quantify the impact a product has on the environment in relation to such factors as energy consumption, CO2 emissions and water usage. The aim of this paper is to identify the factors that affect energy consumption of a product and link these to the information available to a designer at the concept design stage. To achieve this the design process is defined from initial briefing through to the detailed design stage. Information available at the various stages is presented with a novel approach on linking qualitative to quantitative data. Through this link the information can then be used to develop a framework to assist in estimating energy consumption and the associated environmental footprint as well as product cost across the product life cycle. A detailed analysis of the design process is presented in Section 2. Followed by the factors that affect a products energy consumption and which of these are known at the concept design stage. Subsequently, the qualitative elements that affect energy consumption and how they can be linked to quantitative data is presented. A discussion of such information and how it can be utilized to develop a framework to estimate energy consumption is provided in Section 4 whilst Section 5 concludes the paper. 2. Design process The design process has been widely documented in literature as depicted in Table 1 below. These include the VDI2221: A systematic approach to the development and design of technical systems and products [18]. Pugh, S developed a four part Total Design Activity Model [19]. The first part of the model consists of six core design phases. A Product Design Specification is identified in the second part, the third part requires inputs from independent discipline methods needed to execute the central design phases and the final part consists of inputs from technology and discipline dependant sources. Pahl, G et al describe a design process that encompasses four main phases namely, planning and task clarification, conceptual design, embodiment design and detail design [20]. From an industrial design perspective Lesko, J provides a product design sequence that consists of six design phases [21]. The first is product identification/design teams formed, followed by product defined, concept development, concept presentation, product development and finally product presentation. During these phases, three considerations need to be taken into account, namely aesthetics, analysis and synthesis.



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Table 1. Design process. VDI guideline

Clarify and define task

Pugh, S.

Design specification

Concept design

Pahl, G et al

Task clarification

Concept design

Lesko, J

Product identification/ design team formed

Product defined

Concept development

Porsche Engineering.

Pre-Product development process

Definition phase

Design development and assurance

Determine functions and their structure

Search for solution principles and their combinations

Porsche Engineering provide an industry perspective on how they undertake the product development process [22]. From Porsche’s viewpoint there are seven stages starting from a pre-product development process, which includes defining requirements, competitors and target markets as well as product ideas and concludes with series production. Of the design processes mentioned above some are quite broad in nature. For example, the method developed by Pahl, G et al [20] lists the main stages only such as Phase I – Task Clarification, Phase II – Conceptual design, Phase III – Embodiment Design and Phase IV – Detailed Design. Whilst, some others provide more detail at what happens at each stage. For example, Pugh, S [19] provides a table of Product Development Specifications for part two of the Total Design Activity Model in which it lists information such as materials, aesthetics, ergonomics, quality and shipping. Lesko, J [21] also provides some detail at what occurs at the different stages. Specifically, sketches, manufacturability and ergonomics at concept development. Additionally, CAD/CAM, tooling and shipping/packaging occur at the detailed design stage. The design process developed for this research combines the information available at the various stages and the author’s industrial experience of 15 years. Figure 1 provides an overview of the design process from when the designer is briefed by the client or marketing all the way through to production.

Divide into realizable modules

Develop layout of key modules

Design proposal Concept/Early design development Detail design Production Figure 1: The developed design process

Whilst Production is not technically part of the design process, it is shown to illustrate what occurs once the detailed design stage is completed. The following sections

Prepare production & Operating instructions Detailed design

Embodiment design Concept presentation

Detailed design Product development

Product presentation Series development

explain in detail the information that is available across the various stages as shown in Figure 1. 2.1. Design Brief All design projects start with a brief whether it comes from an external client or in the case of ‘in-house’ design, from marketing. The project needs to begin with a purpose, generally to solve an identified problem or to fill a gap in the marketplace. Figure 2 lists the information that is provided during the design brief stage. Preliminary research needs to be carried out after the brief is given in order to confirm that the proposal has merit. Otherwise, resources could be allocated and expenses incurred for a project that is not justifiable. The brief is returned to the client for approval and if approved the project moves into the Research phase. If the client is not satisfied with the brief then an iterative process is undertaken until a solution is reached by both parties. Designer is briefed by Client Preliminary Research to support proposal

Brief revised until both parties satisfied

Brief documented and returned to Client with Proposal Approval to proceed received from the client

Design brief Research phase

Complete overall layout

Figure 2: Information available at the Brief stage

2.2. Research Stage Figure 3 depicts the information available during the Research stage. This stage is where user needs are investigated as well as the cultural and physical environments in which the product will be used. Competitive analysis and patent searches are conducted to ensure that any design developed does not infringe on another entities intellectual property. Analysis of competitor’s products can assist the designer to learn what has been done as well as what could be improved. Additionally, the Research stage is where sustainability issues that need to be addressed during the design process can be introduced. As well as the various environmental

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Figure 3: Information available at the Research stage

Design development and CAD modelling

2.3. Concept Development

Concepts evaluated against Specifications

Target Specifications established

Unit Production Cost estimated

Preparation of Marketing Materials

Design Presentation to Client Further development if requested by Client

Revision of Design Detail and Documentation Final Design Presentation to Client

Concept Sketching and 3D form Studies Select Concepts prepared for Client Presentation

Prototype(s) obtained for Evaluation

Evaluation of Form, Detail, Finish, Component Fit

Once the Research stage is completed the Concept Development can commence. Figure 4 shows the steps involved in developing a product concept. Target specifications can be established with the information collected from the Research stage. For instance, a vacuum cleaner specifications may include ‘Bin capacity’, ‘Motor Size and Power’ and ‘Filter size’. Concepts are then developed through the use of sketches and 3D form models to ensure they meet the Target specifications. This is an iterative process until one or several concepts are chosen that meet the specifications.

Tooling Evaluation and Costing

Research into Current Stateof-the-Art

Research into Sustainable solutions

Patent/Prior Art search

Research into User needs and desires

Research into Physical and cultural environments

Research phase

components and establish a BOM for production. A prototype is generally made that closely resembles the finished product. This prototype can be used to analyze fit and finish, for focus groups, obtain certification to sell the product in different markets, to evaluate tooling design and cost as well as in the preparation of marketing materials. At the completion of these steps the design is presented to the client for approval. If the client approves the design it is signed off and sent to production to be manufactured. Similar to the Concept Development stage, if the client requires some changes, the process is repeated.

Engineering Analysis and Certification

legislation and standards can be documented to ensure the design complies with these requirements.

User Evaluation/ Focus Group

226 4

Final Design Revision

Final Design Presentation to Client Design signed off and released for Production Further Concept Exploration if requested by Client

Concept Presentation to Client Concept selected by Client for Development Figure 4: Steps involved in Concept Development

Following on from this, the concepts are prepared for presentation to the client as well as product production cost estimates. With the information collated, the concepts are presented to the client for review. Subsequently, the client will either select one of the concepts to move onto the detailed design stage or request further concept exploration. 2.4. Embodiment and Detail Design With the concept selected the next stage is known as Embodiment and Detail Design. Figure 5 shows the steps involved in this stage. The concept will be refined using CAD modelling to determine the exact number of

Figure 5: Steps involved Embodimenttoand Detail Design Final DesigninPresentation Client

3. Data availableEvaluation at the concept design stage of Form, Detail, Finish, Component Fit oduction

A designer’s aim is to solve ill-defined or ill-structured design problems using various techniques. At the concept design stage this can include asking the client various questions to better define the problem or collecting more information through research. Furthermore, designers can utilize sketches, drawings and other representations to arrive at a solution [23]. When designing a product there a number of factors that influence the design as shown in Table 2 [24]. Through the use of sketches and other visual images the designer is introducing features such as form, proportions, orientation, material, colour, symmetry and contrast [25]. A number of these factors are present at the concept design stage. Whilst a sketch can be seen as general in nature it can be a powerful tool for a designer to use. Through sketching the designer is translating the literal requirements from the brief and any information they have gathered and converting it into a visual form. As when a designer sketches a solution they are by default realizing the form of the product. This in turn can dictate the material the product will be made from and subsequently the manufacturing process. An overall indication as to the



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size/dimension and shape of the product can also be obtained from the sketch. These factors are constant whether the product being developed is a redesign of an existing product or the design of a completely new one. Similar to the elements that effect a design there are a number of factors that influence the energy consumption of a product over its entire life cycle. These include: Material; Product shape; Manufacturing process; Weight; Number of parts and Usage time [17]. Table 3 shows that there is a correlation with information available to a designer at the concept design stage and factors that impact energy consumption. Some of this information that would traditionally be seen as qualitative can actually be converted to a unit of measure and quantified. For example, size and shape can be attributed to volume (cm3), material to embodied energy (MJ/kg) and usage to energy utilised by the product during operation (MJ). Table 4 expands on the information provided in Table 3 by looking at whether the information available is quantitative or qualitative in nature. A unit of measure was also provided to aid in validating the nature of the information. Table 2. Factors that influence design Factors that influence Form

Factors that influence Appearance

Factors that influence Expression

Material

Aesthetics

Lightness

Structure

Unity

Weight

Dimension

Proportion

Stability

Appearance

Visual Balance

Movement

Surface

Order

-

Table 3. A comparison between information available to a designer at concept stage and what affects a products energy consumption. Information Available to Designer at Concept Design Stage

Factors that affect energy consumption

Material

Material

Shape

product shape

Manufacturing process

manufacturing resources

Size

weight

Product Type

process plans

Number of components

no. of parts

-

usage Time

Table 4. Qualitative or Quantitative information at the concept design stage. Information Available to Designer at Early Design Stage

Unit of measure

Level of information

Material

MJ/kg

Quantitative, embodied energy

Shape

cm3

Quantitative, volume

Manufacturing process

Dimensionless

Qualitative, specified

Size

cm3

Quantitative, volume

Product Type

Dimensionless

Qualitative, specified

Number of components

n

Quantitative, binary

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From Table 4, ‘Product Type’ is referring to the actual product being designed. For example, a kettle, washing machine or vacuum cleaner. At the start of every project, a designer will be briefed on the problem that needs to be solved for a particular market segment. Utilizing the target specifications established at the start of the concept development stage, the size and shape can be determined through sketches and/or 3D mock-up prototypes. Traditionally, the term ‘Size’ and ‘Shape’ refer to qualitative information. However, if the size and shape can be illustrated, then a quantitative volume estimate can be calculated. Furthermore, when designing a product, a general idea is known in regards to material selection. This could not necessarily be in the form of a specific material but a more general category such as plastic, metal, wood or a combination of materials. Once a material is established then a manufacturing process can be defined. The information relating to the ‘Number of components’ refers to a broad understanding of the make-up of the product. It is not expected at this stage that every nut, screw and washer be specified. However, an overview of the major components that make up the product can be established. For example, the major components of a kettle could be sketched to include the heating element, PCB, kettle body, lid and power button. 4. Discussion In order to take into account energy consumption at the concept design stage, a scenario adopted from Pahl, G et al [20] in the design of a domestic hot and cold mixer tap that can be operated by one hand is presented. The design brief states the mixer tap should have the following characteristics: Throughput 10 L/min; Maximum Pressure 6 bar; Normal pressure 2 bar; Hot water temperature 60 C; Connector size 10mm. Attention is to be paid to appearance with the company’s trade mark to be prominently displayed. Release date for final product is two years time. Manufacturing costs not to exceed €30 at a production rate of 3000 taps per month. Based on this information the ‘Product Type’ is a domestic mixer tap. The designer could sketch a number of concepts and from this the size, shape and number of components can be determined. These factors all impact on a products life time energy consumption as the bigger the products footprint the more energy it can potentially consume due to more material required to make the product. As well as increased transportation costs caused by the weight of the product. Furthermore, the more components required to make it can lead to an increase in energy consumption due to more manufacturing processes needed to make the parts. Combine this with the increase in transportation needed to deliver the parts to be assembled into the final product and minimizing the number of components can play a key role in reducing a products life time energy consumption. The designer could also be thinking about the type of material to use to make the tap. As the type of material chosen can dictate the manufacturing process. Material

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selection can have a large impact on a products life time energy consumption. For example, if the designer decides to make the tap body from brass over stainless steel the embodied energy values are approximately 58MJ/kg and 85MJ/kg respectively [26]. Additionally, the way in which the tap is manufactured can impact on the energy consumed. The embodied energy to cast the tap in brass is 8MJ/kg compared to 11MJ/kg for stainless steel [26]. However, if the process was changed to a deformation procedure such as forging then the embodied energy value would fall to 1MJ/kg for brass and 8MJ/kg for stainless steel [26]. In terms of End-of-Life, Brass has an embodied energy recovery value of 13.5MJ/kg compared to Stainless Steel with 12MJ/kg [26]. By making designers aware of the choices they make at the concept stage, a potential framework can be established to assist in estimating the energy consumption over a products life time based on just a simple sketch. This would result in cost and time to market savings as more concepts could be explored and analyzed. The amount of time it takes a designer to sketch a new concept is considerably less than to model one in 3D CAD. Furthermore, trade-offs could be made before moving to the detailed design stage. 5. Conclusion As the demand for energy, products and services continues to increase, designers and manufacturers need to adopt a cradle-to-grave product development process. To achieve this new tools and methods need to be developed to make it easier to integrate such thinking in the product development process. Existing design processes were identified from an engineering design, industrial design and industry perspective. Adapting these approaches with the authors own extensive industry experience, an exhaustive design process was presented. From this process, a clear point of difference was established between the concept design stage and detail design stage. The information available at the various stages was also presented. The concept design stage was highlighted as a critical step in the design process as it is where changes can be made with minimal impact on project costs and the environment. With this established, a link between qualitative data traditionally found at the concept stage with quantitative data was demonstrated. Future work involves establishing a framework that could be used at the concept design stage to calculate the environmental impact a product can have over its entire life cycle. These impacts could include energy, CO2 emissions and water usage. The cost to produce the product could also be included. This would encourage the shift away from the traditional design thinking process to encompass the whole life cycle during product development. References [1] Putt del Pino, S., Metzger, Eliot , Drew, Deborah and Moss, Kevin Elephant in the Boardroom: Why Unchecked Consumption is Not an Option in Tomorrow’s Markets. 2017 March 2017 [cited 2017 24

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