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Procedia CIRP 122 (2024) 271–276

31st CIRP Conference on Life Cycle Engineering (LCE 2024)

Supporting Sustainable Product Design with Engineering Data Management

Capabilities
Sebastian Webera, Sven Fortea*, Thomas Dickopfa, Lucas Kirschb, Christo Apostolova
a
CONTACT Research, CONTACT Software, Martin-Luther-Str. 8, 67657 Kaiserslautern, Germany
b
CONTACT Research, CONTACT Software, Boxhagener Straße 71c, 10245 Berlin, Germany

* Corresponding author. E-mail address: [email protected]

Abstract

Today, innovations are no longer defined just by technical progress but also, in particular, by environmental aspects (such as carbon gas
emissions). The issue of reuse is also becoming increasingly central to purchasing decisions and is forcing manufacturing companies to deal
transparently with environmental impacts. This is also receiving a lot of political attention and is underlined by increasingly far-reaching
regulations on sustainability, such as CSRD, Product Declarations, Transparent Supply Chains, Substance Compliance, etc. Since 80% of the
environmental impact is already determined in the early product development phases, there is a high potential for improvement. This is where
engineering data management approaches (such as PLM) come into play as a systematic approach to data, document, and information
management. Many KPIs for determining the environmental impact are often already available in PLM. Still, it is necessary to bring them into
context in a targeted way to support early qualitative and quantitative evaluations in the engineering phases regarding the current environmental
impact of the design. The paper, therefore, presents a concept based on PLM-available data along the product engineering process for assessing
ecological impact. This includes the product life cycle (and the supply chain) as well as the prototypical provision of environmental information
and is demonstrated using platform technology by CONTACT Software.
© 2024 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 31st CIRP Conference on Life Cycle Engineering (LCE 2024)

Keywords: Type your keywords here, separated by semicolons ;

1. Motivation design, also known as Design for Sustainability (DfS) or

sustainable product development, aims to support the
Climate change has emerged as one of the greatest transformation to a greener and sustainable future. DfS could
challenges [1]. There is an increasing urgency to reduce global and should play an important role in the transition towards
greenhouse gas emissions and the growing awareness of sustainable design, production and consumption and serves as
climate change, transparency of environmental impacts [2] of a fundamental component in generating value for society.
products and services and their circularity potentials [3]. The Transparency and traceability across the entire product life
foundations for this have to be established in the early stages of cycle are essential to effectively address sustainability
product development. In fact, 80% of the environmental impact challenges. These elements are crucial for understanding
is already determined in this early product development [4]. In environmental impacts and identifying potential risks. In the
general, sustainable development is defined, that „Sustainable context of environmental impact, the carbon footprint of an
development meets the needs of the present without average automotive component, for example, is almost half
compromising the ability of future generations to meet their accounted as a result of materials and transport, a further third
own needs.“ [5]. In the context of product design, sustainable is accounted for by production, and just under 20% is accounted

2212-8271 © 2024 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 31st CIRP Conference on Life Cycle Engineering (LCE 2024)
10.1016/j.procir.2024.01.039
272 Sebastian Weber et al. / Procedia CIRP 122 (2024) 271–276

for by use and recycling [6]. However, the composition of the considers the entire life cycle of a product or project, including
value chain also plays a decisive role for companies [7] when it its production, use, and disposal phases. The goal is to balance
comes to designing and producing their products more human needs, the natural environment, and future generations.
sustainably. This is where Product lifecycle management Thus, within the DfS approach, various DfX approaches can be
(PLM) comes into play as a systematic approach to data, found in the dimensions. For example, a taxonomy of DfS
document and information management that can be used to techniques can be found in Arnette et al [10]. For the
document and manage all documents that arise during the economical dimension, DfX techniques in the context of supply
product life cycle. This includes in detail material management, chain, manufacturing and/or assembly, and logistics can be
substance compliance, product design, product structures (e.g. applied. Ecology is focused with techniques in the context of
Bill of Materials), production planning, manufacturing, energy environment, material usage, recycling, reuse and so on. Social
management, usage phases, and change management and other aspects are supported with techniques which aim to support
processes. Impacts can also be broken down into the material, social responsibility in the design process. R-strategies in the
process, and logistics clusters, which fit well with the PLM context of sustainability and circularity aim to generate more
concept. To be able to carry out suitable lifecycle assessments products or benefits from existing resources to minimize the
(LCA) following [8] and [9], it is essential to utilize PLM- environmental footprint and promote sustainable use of natural
available data in an automated way to facilitate a resources.
comprehensive assessment of the product footprint in the
context of a LCA [8]. In this context, it’s important to explore 2.2. Regulations in the context of product sustainability
the key capabilities of PLM that support sustainable product
design, delivering value to companies and society. Sustainability initiatives, including various regulations,
strongly influence product development and have an impact on
2. Environmental impacts along the product design both the company and its processes. In particular, the focus is
lifecycle on the recyclability of products and materials as part of the EU
Green Deal [3]. The Corporate Sustainability Reporting
A comprehensive understanding of the product is becoming Directive (CSRD) [2] imposes far-reaching reporting
increasingly important against the backdrop of sustainable obligations on companies that ensure that companies directly
product development. A holistic perspective is essential here. and indirectly affected in the value chain must maintain and
Various approaches can be pursued in development, which report sustainability-related information. Product development
vary in their approach and focus. National and international itself is exposed to a wide range of requirements, for example
regulations, which need to be managed and effectively handled from the Sustainable Product Initiative (SPI) [4] and the related
in an engineering data management system, provide an Ecodesign for Sustainable Product Regulation (ESPR) [14],
important framework for this. including, among other, in the areas of reliability, material
selection, and energy efficiency. Regarding material selection,
2.1. Design Approaches there is an increasing number of material-related environmental
regulations [15] and an associated increase in the complexity
Design for X (DfX) [10] can be understood as an umbrella of design and development activities and decisions, which
term, representing serval design methods focusing on various poses a challenge. Thus, material selection and the associated
aspects along the entire lifecycle and for specific desired material compliance (MC) are increasingly important to
properties, e.g., manufacturing design or recycling design. companies. MC can be defined as "…the conformity of
Several of these different DfX approaches involve systematic products with all relevant requirements regarding their
consideration of sustainability in the design of products, composition, as well as the conformity of materials and
processes, or resources. Design for Sustainability (DfS) or substances with all relevant requirements regarding their use
sustainable design evolved from the foundation of ecodesign within products." [16]. Among other, the most important
[11]. Ecodesign is a proactive strategy that seeks to minimize material-related regulations are REACH regulation ((EC) No.
the environmental impact of a product throughout its entire 1907/2006) and RoHS directive (2011/65/EU).
lifecycle under considerations about economic factors. This is
done based on LCAs and their determination of environmental 2.3. Product Data and Lifecycle Management
impacts and statements on cost efficiency [12]. While
ecodesign is a specific approach that focuses on integrating Especially in the early stages of product development, the
environmental and economic considerations into processes of foundation for a sustainable development is laid and key
design and development of products, DfS is an approach to decisions regarding material selection, design and the
creating products, buildings, systems, and processes that manufacturing process are made in this phase. This is where
prioritize and balance environmental, social, and economic PLM [17] as an enterprise data management capability comes
sustainability [12]. Elkington's notion [13] of the Triple Bottom into play as a systematic approach to data, document, and
Line (TBL) also describes these three pillars of sustainability. information management during the entire product lifecycle.
In this sense, a perfect product design concept should consider From the concept phase to disposal, PLM capabilities enable
all three pillars of sustainability [12]. It aims to minimize a sound and structured consideration and optimization of
negative impacts on the environment and society while products' sustainability on a single source of truth data basis
maximizing positive contributions. Sustainable design along the life cycle.
 Sebastian Weber et al. / Procedia CIRP 122 (2024) 271–276 273

as it provides access to all relevant information. In addition to

identifying sustainability information via LCA, sharing this
information for downstream processes and reporting
requirements must also be possible. This can happen, for
example, via the digital product pass or in a company report.

2.4. Environmental impact breakdown by product instance in

the context of sustainable calculations

Fig. 1: Sustainability effort dimension on the example CONTACT Elements An LCA provides a process-based analysis of the
Taking CONTACT Elements (CE) [18] as an example, the environmental impact during the entire life cycle of a product,
central fields of action for sustainability capabilities that can be while the key element of a PLM system (in most cases) is the
supported by a PLM system (Figure 1) include material and BOM. Therefore, the elements of an LCA, such as the life cycle
substance management, (product) bill of materials inventory, must be brought into a product-centered view within
management, calculations in the sense of a database for a LCA, the PLM system in the form of a bill of material.
and the derivation of product declarations [14] (or, in the future, The approach shown in Figure 2 is proposed for this
a digital product passport [19]). Bills of materials (BOM) are purpose. This approach enables analyses at different levels and
central to a PLM system. They are used to record all thus a comprehensive evaluation of individual components
components and materials of a product in a structured manner, right down to the company using the PLM system. On the one
which enables efficient product development, manufacturing, hand, BOM items are enriched with process-related
and maintenance by providing a clear overview of the product information from the LCA, including information on material
structure and easily managing changes. The materials used and procurement and work schedules. On the other hand, the BOM
the substances they contain for the products maintained in the is also the key element for the calculation, as it is the carrier of
PLM system can be stored and managed. The control and relevant information. An example of this is the linking of
tracking of the material composition of products, already at an material selection and components, which makes it possible to
early stage of the life cycle, is supported by the BOM estimate the environmental impact of the product development
management. The product's structure is visible, and materials process at an early stage.
are assigned to the BOM items. In the PLM system CE, The individual assemblies with the corresponding
Material and Substance Management is responsible for components building the product, while each assembly and
bundling all material parameters and evaluating them in line each component can be a part manufactured in-house or a
with the MC, providing sustainability-relevant material supplied part. Sustainability-related factors are increasingly
information and making it available to the product engineer in included in strategic procurement and supplier selection,
the decision-making process. This ensures product compliance particularly at company level. In order to pass on
with regulatory requirements, such as REACH, RoHS, conflict environmental factors, for example, Environmental Product
materials and manages the associated certificates. Declarations (EDP) of supplier components with their material
Furthermore, initial environmental impacts of the decisions and environmental parameters are imported into a engineering
made regarding material selection are disclosed. The BOM is data management system and made available for downstream
a key input for calculating environmental factors within a LCA, processes. This data is integrated via a supplier and producer

Fig. 2: Hierarchical sustainable impact breakdown from component to product

274 Sebastian Weber et al. / Procedia CIRP 122 (2024) 271–276

management systems combining information from third-party compared early in the product planning phase, baselines can be
sources and self-managed data sources. In addition, compliance established based on design decisions and the environmental
with regulations and social responsibility for the markets in impact of products under development can be assessed.
which the respective products are to be sold is of crucial Regarding the focus of the materials, recording them in an
importance. Fields of action for the sustainability assessment engineering data management system makes it possible to
here are the description of work plans and the associated evaluate the materials used in terms of their circularity and thus
material and energy expenditure, operating and production also the products. As products that are still under development
resources of the technical resources used. In energy have not been finally defined, only an initial assessment of the
management, the energy consumption of production can be environmental influences is possible. In the design phase, an
recorded, and its emissions assessed. Packaging materials and initial assessment of the material category (e.g. aluminum,
the environmental factors of internal- and cross-company steel, etc.) is possible. This only becomes more concrete when
transport are also factors that must be considered in the supplier information is included, and a specific selection is
calculations. The environmental factors determined in this way made.
can be allocated to the respective items in the bill of materials Another building block is energy monitoring. Energy
and transported with the help of the product structure. For a monitoring enables dynamic life cycle assessments in ongoing
comprehensive sustainability assessment, all environmental production as well as the recording and optimization of CO2
factors are finally aggregated along the nodes of the product emissions based on energy data from production machines. It
structure and collected at the respective levels, thus enabling an represents a critical use case within a sustainability-oriented
assessment at different levels. cost perspective [20]. In addition, the optimization of energy
This information must then be able to be communicated and generation and use can support resource-efficient production.
shared to fulfil reporting requirements in the form of company
reports or within the value chain. For this purpose, the 3.1. Engineering data management use case implementation
information is used as the basis for deriving an EPD or will be
provided as a Digital Product Passport (DPP) in the future. Based on the environmental impact breakdown of a product
instance with the associated structure and taking into account
3. Potential Key Use Cases in the context of sustainability the potential use cases, an exemplary implementation was
assessments driven by engineering data management carried out on the CE platform. The focus of the selected
example is on the early phases, in which initial estimates are
Several use cases are of interest for a breakdown of the made possible and optimization potential is identified. The
sustainability factors. These range from the design of the value product structure of a bicycle was used as an application
chain to the optimization of design and downstream example. The data aggregation within an engineering data
production. Examining sustainability in each scenario provides management system and the exemplary implementation takes
a nuanced perspective on how environmental, social, and place from the material declaration (Fig. 3-A1-2) to the product
structure, environmental influences and the provision and
economic considerations can be integrated and optimized
integration of supplier information (Fig. 3-B1-3) as well as a
throughout the product lifecycle. This holistic approach
prototypical visualization of product declarations (Fig. 3-C).
enables companies to make informed decisions that are in line
The material management of an engineering data management
with sustainability principles and improve overall operational system forms the basis in the early phase. The Material
and environmental performance. At this point, the focus of management is shown in Fig. 3-A and includes the creation of
implementation is on component, material, process, and energy new materials (Fig. 3-A2), the material properties together with
components of a sustainability assessment. suppliers that can be added (Fig. 3-A1) as well as the
Against the backdrop of increasing reporting requirements connection to environmental databases (Fig. 3-A3). The
and the provision of sustainability-related information through material properties that can be mapped in this way enable the
regulations and within value chains, the pressure to provide MC and its contribution to circularity and can facilitate the
sustainability information has increased considerably. To this development of sustainable products. By connecting to
end, the data bases and available data points must be identified environmental databases, missing supplier information on
and made available in the established engineering data materials can be compensated for and made available in the
management systems. Furthermore, the evolving regulations development process. The "ProBas" environmental database
and requirements for the design of the value chain and the [21] was used for the prototype implementation. Central carrier
selection processes are leading to a paradigm shift at company of relevant information is the product structure as described
level. In addition to traditional cost considerations, above (Fig. 3-B1). In this product structure, it is possible to
sustainability factors are now also being integrated. This means classify the components contained as assemblies and individual
focusing on the adaptability and reconfigurability of value parts as well as in-house production and external procurement.
chains to improve overall sustainability. In the case of externally sourced parts, the information situation
The inclusion of sustainability-relevant information in the is blurred. Equivalent to the material information,
planning and design phase lays the foundation for sustainable environmental information can also be fed into the
product development. Consequently, integrating sustainability development process for entire components (individual parts or
assemblies) via an environmental database or directly via the
factors throughout the product development process provides
supplier. By using the product structure as an aggregation
crucial insights for engineers focused on developing
framework, both process-related factors such as work plans and
sustainable products. In this way, concept alternatives can be
transportation factors can be added to the product structure as
 Sebastian Weber et al. / Procedia CIRP 122 (2024) 271–276 275

components and considered as parameters for the calculation environmental parameters (sustainable attributes) can be
of environmental factors. A product sustainability data sheet is determined and made available in the form of a life cycle
created by summarizing the relevant environmental aspects of inventory [8]. With these results, the product developer is able
the products (Fig. 3-B2). If these environmental aspects are to identify the causes of negative environmental impacts at both
aggregated via the product structure, the resulting product and component level and further optimize them in the

Fig. 3: Hierarchical sustainable impact breakdown from component to product

276 Sebastian Weber et al. / Procedia CIRP 122 (2024) 271–276

ongoing development process. Not only the integration of Climate Action (BMWK) based on a decision by the
information from the value creation network is of interest, but German Bundestag (Grant 01MN2301).
also the transfer of own product information. For example, data
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