Product Redesign Research Articles

Redesign of workstations guitar product to minimize musculoskeletal disorders for workers

The production process of acoustic guitars in Indonesia involves 4 workstations and 17 distinct activities. Due to the nature of the work—8-hour shifts in seated positions with frequent bending, squatting, and repetitive movements—workers are at risk of musculoskeletal disorders (MSDs), particularly in the neck, shoulders, back, arms, and wrists. This study aimed to identify and analyze body posture conditions using the Nordic Body Map (NBM) and Muscle Fatigue Analysis (MFA) methods. The NBM method was used to record pain complaints across various body parts, while the MFA assessed muscle fatigue by considering the level of effort, work duration, and movement frequency. Results from the NBM showed that among the workers, 2 were at high risk, 3 at medium risk, and 7 at low risk for MSDs. The MFA further identified 3 workers with very high to high-priority fatigue concerns, specifically affecting the neck, back, shoulders, right arm, wrist, and legs. To address these issues, the study recommended redesigning work facilities and layouts using the SolidWorks application, along with implementing regular muscle stretching and exercise routines to minimize the risk of MSDs and improve worker well-being.

When user error calls for a product redesign: Poverty in the United States

When user error calls for a product redesign: Poverty in the United States

The Effects of a Firm’s Product Redesign and New Product Introduction Experience on its Performance

The Effects of a Firm’s Product Redesign and New Product Introduction Experience on its Performance

Re-design Requirements Research for Intangible Cultural Heritage Products in the Tourism Industry: A Case Study of Mianzhu New Year Picture

In response to the challenges faced by Mianzhu New Year picture, a national-level intangible cultural heritage in China, in the transformation of tourism, including issues of homogenization, lack of cultural content, and limited innovation, this study aims to optimize the design of tourism derivative products of Mianzhu New Year picture. The goal is to avoid issues that may impact tourism consumption and cultural development. To achieve this, a method for evaluating the redesign requirements of Mianzhu New Year picture tourism products based on the KANO-AHP hybrid model is proposed, with the intention of providing guidance for the development of derivative products of intangible cultural heritage.Focusing on the "cultural creative products" in the redesign of Mianzhu New Year picture tourism products, the KANO model is applied. Based on tourism marketing demands, the study focuses on three main intentions: enhancing tourism consumption, cultural communication, and artistic innovation of Mianzhu New Year pictures tourism products. These are further subdivided into specific contents of artistry, functionality, technology, safety, and culture. A total of 30 requirement indicators are identified, and their KANO requirement attributes are determined. The study then constructs requirements indicators for cultural creative products of Mianzhu New Year picture tourism through statistical analysis. Subsequently, the Analytic Hierarchy Process (AHP) is applied to determine the weights of the cultural creative product requirements indicators. By analyzing and organizing the comprehensive weights of the top 10 requirement indicators, an optimized solution for the redesign of Mianzhu New Year pictures tourism products is obtained.

Conceptual framework for identifying polymers of concern

With the increasing global concern over plastics' environmental and human health impacts, the urgency for effective regulatory measures is evident. The UN Environment Assembly's initiative to establish an international, legally binding instrument via the Intergovernmental Negotiating Committee (INC) on Plastic Pollution marks a significant step toward addressing this issue. However, the vast diversity of plastic types and their myriad applications present a complex challenge in pinpointing the most critical targets for regulation. This study builds on the existing body of literature to outline potential key criteria for identifying Polymers of Concern (PoC). We recommend a dual-focused definition of PoCs considering both (1) the type of the plastics and (2) their domain of applications based on the environmental and human health impacts throughout the polymer's life cycle. Recognizing the current gaps in our understanding of the full spectrum of plastics' impacts across their life cycles, we suggest adopting a precautionary approach that factors in the volume of plastics entering natural ecosystems alongside their life cycle impacts as reported in the literature. We then bring forward existing data on the assessment of some of the main polymer types and applications. We propose that policymakers examine a wide spectrum of strategies including not only bans and phaseouts but also economic incentives, innovation, and the redesign of plastic materials and products to mitigate the adverse impacts of PoCs. We further emphasize the importance of thoroughly assessing the feasibility, costs, and environmental, social and economic implications of alternative materials to avoid “regrettable substitution.” We conclude by identifying existing knowledge gaps and emphasizing the need for further research to refine the proposed criteria for identifying PoCs.

Debating (In)Justice of Energy Futures Through Design

This article presents a design investigation of how to address social justice concerns in participatory activities when debating energy futures. As the climate crisis grows and technological progress exacerbates environmental issues, the design field is increasingly committed to understanding and mitigating the impact of new products in the world. This is resulting in a conscious redesign of products or in developing strategies to nudge sustainable behaviours. Yet little methodological work exists on how to address social concerns when designing in the context of energy transitions. This paper explores this gap by delineating an energy scenario of Switzerland in 2030, designing two fictional artefacts and a participatory toolkit, and then hosting a world café with twelve participants. The results provide insights into the value as well as the methodological challenges of designing for debating justice in energy futures.

The circular supply chain: a paradigm shift towards sustainable resource

In light of recent studies, we find that the circular economy has become a key component in corporate strategies to promote environmental sustainability. In this regard, corporations are increasingly adopting the circular economy perspective to review their supply chain management practices in a sustainable manner. This paradigm shift suggests the need for a circular approach to supply chain management, moving from simple efficiency and waste reduction to a philosophy that promotes product redesign, reuse and transformation. The circular supply chain approach involves a number of interlinked elements, including product design for circularity, reverse logistics, remanufacturing (re-manufacturing), recycling and waste management. These components are integrated at different stages of the supply chain with the aim of maximising resource recovery and minimising environmental impact. Particular emphasis is placed on supply chain collaboration, which is considered one of the key drivers of the circular economy and circular supply chains. The analysis of the circular supply chain management concept highlights five dimensions of circular supply chain management: closed-loop supply chain management, reverse supply chain management, remanufacturing supply chain management, recycling supply chain management and industrial symbiosis.

Diagnosing remanufacture potential at product-component level: A disassemblability and integrity approach

The remanufacture of products is emerging as a key strategy in the circular economy, primarily due to its role in extending product lifespans and conserving product value. The efficiency of this process relies heavily on accurately determining the remanufacturability of products, especially at the component level. The article introduces the Remanufacturing Potential Index (RemPI) to address this issue. This diagnostic tool is based on two main characteristics: i) disassemblability, which is the ability of a product to be dismantled, and ii) integrity, referring to its physical condition upon return. Notably, RemPI provides a robust understanding by weighing the functional importance of each component in the remanufacturing process. Contributions of this research include: a detailed remanufacturability assessment at the component level, highlighting its role in the overall assembly; and a focus on balancing disassemblability with integrity, providing insights for potential product redesigns. The effectiveness of the proposed approach is validated through two case studies.

Implementing Circular Economy Principles to Enhance Safety and Environmental Sustainability in Manufacturing

The global manufacturing sector is confronted with mounting challenges related to safety hazards and environmental sustainability. In response, there has been a growing emphasis on adopting circular economy principles as a transformative approach to address these pressing issues. This review explores the implementation of circular economy principles within manufacturing processes to enhance safety and environmental sustainability. Circular economy principles prioritize resource efficiency, waste reduction, and the continual use of materials within closed loops. By shifting from the traditional linear "take-make-dispose" model to a circular approach, manufacturing facilities can significantly mitigate safety risks associated with hazardous waste generation and disposal. Moreover, the adoption of circularity fosters a culture of preventive measures, reducing the likelihood of workplace accidents and improving overall safety standards. Furthermore, integrating circular economy principles into manufacturing operations contributes to environmental sustainability by minimizing resource depletion and pollution. Through strategies such as product redesign for recyclability, remanufacturing, and waste valorization, manufacturers can reduce their reliance on virgin materials and curb emissions. This transition towards circularity not only diminishes the environmental footprint of manufacturing activities but also creates opportunities for cost savings and innovation. However, the successful implementation of circular economy principles in manufacturing requires a concerted effort from stakeholders across the value chain. Collaboration among manufacturers, suppliers, policymakers, and consumers is essential to overcome barriers such as technological limitations, regulatory constraints, and behavioral change resistance. Embracing circular economy principles holds immense potential for enhancing safety and environmental sustainability in manufacturing. Through systematic integration and collaboration, the manufacturing sector can pave the way towards a safer, more sustainable future.

Product Redesign and Innovation Based on Online Reviews: A Multistage Combined Search Method

Online reviews published on the e-commerce platform provide a new source of information for designers to develop new products. Past research on new product development (NPD) using user-generated textual data commonly focused solely on extracting and identifying product features to be improved. However, the competitive analysis of product features and more specific improvement strategies have not been explored deeply. This study fully uses the rich semantic attributes of online review texts and proposes a novel online review–driven modeling framework. This new approach can extract fine-grained product features; calculate their importance, performance, and competitiveness; and build a competitiveness network for each feature. As a result, decision making is assisted, and specific product improvement strategies are developed for NPD beyond existing modeling approaches in this domain. Specifically, online reviews are first classified into redesign- and innovation-related themes using a multiple embedding model, and the redesign and innovation product features can be extracted accordingly using a mutual information multilevel feature extraction method. Moreover, the importance and performance of features are calculated, and the competitiveness and competitiveness network of features are obtained through a personalized unidirectional bipartite graph algorithm. Finally, the importance performance competitiveness analysis plot is constructed, and the product improvement strategy is developed via a multistage combined search algorithm. Case studies and comparative experiments show the effectiveness of the proposed method and provide novel business insights for stakeholders, such as product providers, managers, and designers. History: Accepted by Ram Ramesh, Area Editor for Data Science and Machine Learning. Funding: This work was supported by the National Natural Science Foundation of China [Project 72071151] and the Natural Science Foundation of Hubei Province, China [Grant 2023CFB712]. Supplemental Material: The software that supports the findings of this study is available within the paper and its Supplemental Information ( https://pubsonline.informs.org/doi/suppl/10.1287/ijoc.2022.0333 ) as well as from the IJOC GitHub software repository ( https://github.com/INFORMSJoC/2022.0333 ). The complete IJOC Software and Data Repository is available at https://informsjoc.github.io/ .

Code and Data Repository Product Redesign and Innovation Based on Online Reviews: A Multistage Combined Search Method

Code and Data Repository Product Redesign and Innovation Based on Online Reviews: A Multistage Combined Search Method

Redesigning product line for integrated manufacturer-supplier ecosystem in a centralized supply chain: Case of an industrial consumer product

To produce quality products rapidly to derive competitive advantage, the original equipment manufacturer (OEM) must work closely with its suppliers in product redesign processes. Previous literature has emphasized that quality products can be produced effectively and will provide better customer service if product redesign is performed considering the broad OEM-supplier(s) ecosystem. To this end, we seek to develop a mathematical model focused on maximizing the objectives of the OEM-supplier(s) ecosystem considering a centralized supply chain in such a manner that operational-level financial objectives are mapped in terms of product line design decisions and attribute-level assignments. By including operational-level supply chain considerations such as service levels and consumers' preferences, we seek to capture key aspects related to customers’ requirements. This research links product-level technical decisions with enterprise-level business objectives, thus bridging engineering and enterprise-level financial nuances. The problem for the manufacturer pertains to the minimization of the manufacturing cost and maximization of the product premium. The problem for the suppliers pertains to maximization of salvage value, minimization of shortage cost, and maximization of sales revenue. These two problems are then sewed together, and a chemical reaction optimization (CRO) based solution methodology has been deployed. To solve and analyze the devised problem, a case study based on an industrial consumer product is conducted. We evolve a comprehensive mathematical framework that mimics the facets related to product line redesign encapsulating considerations pertaining to functional level design, supply chain dimensions, and manufacturer-supplier profitability. Several novel findings are reported based on the study. For instance, we demonstrate that product configurations for respective segments after the redesign process are contingent upon the service level. Further, we demonstrate that in the industrial consumer product market, higher profit for the OEM-supplier(s) ecosystem is achieved at a slightly lower service level as opposed to a higher theoretical service level. The study has important implications for design and product management.

Design for Circularity: A Framework for Sustainable Product Redesign

Implementing circularity presents a multifaceted and intricate challenge to address sustainability issues. With 80% of environmental impacts determined in the design stage, the product's design becomes paramount in enabling the product and/or material circularity. Transitioning from the current linear economy to a circular one requires enforcement of radical approach to the design process. Existing R-strategies frameworks for design are either too complex or overly simplistic to be incorporated organically into product development process. The lack of standardized perspective in different fields when incorporating circular design often led to multiple interpretations of circularity. This paper proposes a framework that supports the incorporation of the R-strategies as four design principles (Reduce, Reuse, Recover, Rethink) to enhance the circularity of the product. The framework will be applied to the redesign of a hybrid thumbdrive-name card design case study. These designs illustrate how the 4R design principles can generate strategies that can be applied to address the circularity of the product while maintaining the same design requirements. A comparative life cycle assessment is performed to each design against the original design and the results are discussed.

In search of a non-anthropocentric middle-range theory of the firm: On how the Patagonia Purpose Trust granted a controlling stake to nature

Patagonia, an outdoor clothing company thrust into the limelight by a New York Times full-page ad that in 2001 invited customers not to buy its own gear, has recently responded to the inherently low capacity of firms to supply ecosystem services. Since the firm is a generic term encompassing many different bundles of property rights, the specific mechanism of the Patagonia Purpose Trust is researched to find whether it has plausibly locked the company in on preserving ecosystems through its environmentally driven community investment, product re-design, and supply chain overhaul. A mechanism-based methodology is employed, organizing the units of observation in keeping with a formal ontology and benchmarking Patagonia's mechanism against the generic templates of a corporation and a charitable Trust to highlight what is distinct about Patagonia. The findings are that, in a nutshell, Patagonia's mechanism consists of: 1) increasing the opportunity cost of not redressing a breach of purpose by designating an ascertained beneficiary with an unequivocal interest in Nature's preservation; 2) offsetting fiduciaries' influence on asset management with a countervailing mechanism; and 3) designing a procedure centered on the renewal of credible co-trustees to keep checking on fiduciaries in the long run.

Challenges on the way to a circular economy from the perspective of the Austrian manufacturing industry

Circular economy has become a prominent topic in scientific discourse and has gained significant presence as a strategic factor for business and industry. Both, as crucial enabler of a sustainable economy, and as lever for overcoming resource dependencies. Previous studies have identified multiple benefits of implementing circular principles, as well as enablers for a transformation to circular economy. However, studies with a focus on a specific industry and regional context that offer practical guidance for the transformation to a circular economy are still somewhat underrepresented. This paper addresses this gap by analyzing major obstacles to a transformation to circular economy, in the context of the Austrian manufacturing industry. It is based on a literature review, in which 369 articles were reviewed, complemented by a structured online survey in which 229 managers from 192 companies in the manufacturing industry participated. In the survey, the obstacles were ranked according to their relevance on two levels: assessing 10 clusters of obstacles on a higher level, followed by a deep-dive evaluation of specific obstacles within the clusters. Based on the research findings, it is evident that the circular economy plays a significant role in long-term corporate success and most surveyed companies recognize its strategic importance. The results also reveal that market and customer demand are the biggest drivers of a transformation to circular economy, followed by general concerns about the environment and regulatory pressure. The biggest barriers on the way toward circular economy are the need for more financial government support, challenges with setting up an effective circular supply chain, economic challenges resulting from customer behavior and barriers in the redesign of products. The interdisciplinarity of the challenges leads to a high complexity in the transformation process. This means that most of the major barriers are external, and therefore companies cannot tackle these barriers by themselves. Governments should consider developing more incentive systems to support companies in their transition to the circular economy. To effectively navigate the transition, companies should adopt integrated strategies that encompass supply chain optimization, in-depth analysis of customer buying behaviors, and investment in sustainable and recyclable product design.

Redesign of Standard Paddock Motorcycle Products Using the Quality Function Deployment (Q.F.D.) Method

One of the two standard replacement aids for motorcycles is the Standard Paddock. The use of Paddock Standard itself was initially only used on sports or racing motorcycles because it did not have standards attached to the motorcycle. However, after the times and technology, leverage standards are in great demand by motorcycle lovers for daily activities and modifications. This research aims to design Paddock Standard tools that suit the wants and needs of consumers who are functional and able to provide safety, comfort, and convenience for their users. The design of the tool uses the Quality Function Deployment (Q.F.D.) method, which will later become a benchmark in making design concepts. There are two design concepts and one combined concept, where the selected is a combined concept A + B. After users test the concept and prototype of the design product as consumers, the average likes the product concept, which can provide more function than the previous tool. When asked if it can be implemented quickly and use the tool every day, most answer that they will probably use it more often every day.

Selection methodology for additive manufacturing processes considering design, material, and manufacturability

PurposeOne of the critical reasons for the nonacceptance of additive manufacturing (AM) processes is the lack of understanding and structured knowledge of design for additive manufacturing (DfAM). This paper aims to assist designers to select the appropriate AM technology for product development or redesign. Using the suggestion provided by the design assist tool, the user’s design alterations depend on their ability to interpret the suggestion into the design without affecting the design’s primary objective.Design/methodology/approachThis research reports the development of a tool that evaluates the efficacy values for all seven major standard AM processes by considering design parameters, benchmark standards within the processes and their material efficacies. In this research, the tool provides analytical and visual approaches to suggestion and assistance. Seventeen design parameters and seven benchmarking standards are used to evaluate the proposed product and design quality value. The full factorial design approach has been used to evaluate the DfAM aspects, design quality and design complexity.FindingsThe outcome is evaluated by the product and design quality value, material suit and material-product-design (MPD) value proposed in this work for a comparative assessment of the AM processes for a design. The higher the MPD value, the better the process. The visual aspect of the evaluation uses spider diagrams, which are evaluated analytically to confirm the results’ appropriateness with the proposed methodology.Originality/valueThe data used in the database is assumed to make the study comprehensive. The output aims to help opt for the best process out of the seven AM techniques for better and optimized manufacturing. This, as per the authors’ knowledge, is not available yet.

The CIRCULAR pathway: a new educational methodology for exploratory circular value chain redesign

The circular economy (CE) is gaining global relevance across countries and institutions as a tool to solve some of the most pressing global challenges derived from linear production and consumption systems. However, transitioning to a CE requires significant changes in how businesses and supply chains operate, including redesigning products, processes, and business models. These changes require that future professionals acquire knowledge and skills on the principles of CE, Life Cycle Thinking, and Systems Thinking. However, research on existing higher education programs signals a need for educational resources to develop these skills and knowledge in real-world settings. This paper outlines a new eight-step methodology to introduce students to the principles of CE through the exploratory redesign of a real-world product and value chain in a project-centered learning environment. This methodology was developed in four iterations and was used to teach 251 students from the BSc. Business Engineering at Maastricht University during the academic years 2020–2022. The findings indicate that this method supports students' understanding of complexity, linearity, and the importance of systemic change across the entire value chain, as well as their critical thinking, problem-solving, and decision-making skills. The methodology provided in this paper supports and encourages educational bodies to implement Education for CE in their curricula and further strengthens the complementary fields of Education for Environmental Sustainability and Education for Sustainable Development. Furthermore, educators, professionals and businesses can make use of this tested methodology for exploratory product redesign toward sustainable circularity transitions.

Microplastics in the environment: An urgent need for coordinated waste management policies and strategies

Microplastics (MPs) have become a prevalent environmental concern, exerting detrimental effects on marine and terrestrial ecosystems, as well as human health. Addressing this urgent issue necessitates the implementation of coordinated waste management policies and strategies. In this study, we present a comprehensive review focusing on key results and the underlying mechanisms associated with microplastics. We examine their sources and pathways, elucidate their ecological and human health impacts, and evaluate the current state of waste management policies. By drawing upon recent research and pertinent case studies, we propose a range of practical solutions, encompassing enhanced recycling and waste reduction measures, product redesign, and innovative technological interventions. Moreover, we emphasize the imperative for collaboration and cooperation across sectors and jurisdictions to effectively tackle this pressing environmental challenge. The findings of this study contribute to the broader understanding of microplastics and provide valuable insights for policymakers, researchers, and stakeholders alike.

Carbon reduction engineering through value chains intersection, product and process re-design, industrial processes’ scraps de-manufacturing

Composite materials use recently increased, although treatments at their End of Life are inexistent or highly inefficient (from the environmental perspective). Thus, openness to cooperation is needed, supported by methodologies for design for de-manufacturing. The approach proposed in the present work aims at transforming industrial processes’ scraps and off-specification pieces in primary materials, through re-design, without the risk of cannibalisation. It is mainly intended for industrial processes of composite materials; its objective is to find alternative applications to their invaluable final disposal and supports the merging of existing supply chains (Industrial Symbiosis). Nevertheless, it can be easily extended to non-composite and/or non-scraps. Re-design enables the establishment of waste-to-treasure composite scraps’ life cycles and is evaluated through Life Cycle Assessment. The application of the approach involved four Italian companies and results reveal that industrial symbiosis can reduce emissions (from −45% to more than −90%). Guidelines were outlined: involve End of Life operators to know how waste treatments, share information, favour networking and proximity, apply design for disassembly principles, consider simple shapes and modularity during (re)design. Future works will focus on off-the-shelf components and the economic evaluation of the proposed de-manufacturing actions and supply strategies.