A novel approach to include sustainability concepts in classical DFMA methodology for sheet metal enclosure devices

Nowadays sustainable design is a mandatory requirement in the product development process. For this reason, design methodologies are addressed to establish a close relationship between environmental, social and economic impact indicators and product features from early design stages, especially in those features related to its manufacturing. In this paper, the design for manufacturing and assembly—DFMA methodology is adapted to sheet metal enclosure devices, integrating functional and component relationships to minimize particular sustainability indicators such as energy consumption, carbon footprint, number of parts, required amount of material, assembly time and manufacturing costs. Savings with the proposed method are achieved following specific sub-tasks oriented to define new simplified product components, considering changes in manufacturing processes and re-defining mechanical connections between parts. Traditional DFMA approaches consider manufacturing and assembly issues related to a reduction of product complexity and economic savings. The proposed method aims to examine the benefits in life cycle stages such as raw material consumption, service, maintenance, upgrading and end of life—EOL. The methodology is validated through a redesign of a sheet metal industrial clock, in which the sustainability impacts are calculated from a comparison of an existent product vs. a new product development. The implementation of the method in the case study demonstrate reductions of more than 25% in product mass, consumed energy and CO₂ footprint, and more than 50% in theoretical assembly time and product complexity. Sustainability indicators of the proposed method are selected from literature analysis and taking into account attributes of sheet metal enclosure devices.