An Integrated Approach for the Sustainable Development of an Automotive Component Using CAD/CAE, DFE and DFMA Concept

Abstract

In order to render cost effective and environmentally friendly products, sustainability is gaining importance in contemporary manufacturing organizations. The rapidly changing marketplace also means that organizations are in search of integrated approaches for creating sustainable product. In this context, this paper reports a case study carried out in an automotive component of single cylinder four stroke petrol engines. The candidate product is connecting rod. The existing handle of connecting rod has been modeled using computer-aided design (CAD). Then, the sustainability analysis has been carried out on the existing component for determining the environmental impact. This is followed by the engineering analysis of the component using computer aided engineering (CAE). Then the redesign of the handle performed by using design for manufacture and assembly (DFMA) principles. The sustainability factors have been measured in terms of carbon footprint, air acidification, energy consumption, and water impacts. It has been found that the redesigned product possesses minimal environmental impact. It could be knew from the results of the case study that the implementation of DFE (design for environment) and DFMA concept could initiate new developments in sustainable product design with minimal impact on the environment. This integrated approach is considered to be valuable for its implementation in similar product development situations to achieve business benefits such as reduced cost and time which would in turn improve the profitability.