Designing Sustainable Products in 8 Steps

In the context of the European Union's Green Deal Circular Economy Action Plan, we are introduced to the concept of sustainable products. Within this framework, the existing Ecodesign Directive will be replaced by the Ecodesign Directive for Sustainable Products (ESPR). The ESPR Directive not only requires products to ensure energy efficiency but also makes it mandatory for them to comply with circularity rules.

In a circular economy, sustainable products are expected to have a long lifespan, be durable, repairable, reusable, recyclable, environmentally friendly, and energy-efficient.

Below are shared methods for sustainable product development, specially for electrical and electronic devices:

1. Platform-based Designs: 

Creating product families and platform designs instead of seperate designs ensures visual coherence among products. It shortens product development cycles, reduces stock needs for different models, and enhances energy efficiency in mass production, leading to lower carbon emissions. The experience gained from the initial product benefits later designs, contributing to increased product lifespan and durability.

2. Durable Designs:

Applying the following steps in product design processes not only increases product durability but also reduces post-sales service needs and production losses:

• Implementing relevant quality standards in production.
• Conducting design verification and field tests before product release.
• Performing risk and error analysis in design, applying correct measures from the beginning  (Failure Modes and Effect Analysis - FMEA).
• Strengthening cables and connection points.
• Properly conducting pre-design product comparison processes.
• Accurately defining design specifications from the beginning.
• Planning and documenting design stages accurately.

3. Reducing Spare Part Variety

Minimizing the variety of spare parts simplifies both production and post-sales processes, reducing complexity and costs. Communication and coordination between design teams in different locations are crucial to ensuring components are as similar as possible.

4. Lean Designs

Applying lean principles, which originated in Japan to avoid waste, aligns closely with circular economy principles. This involves eliminating unnecessary processes, rework, excess inventory, and other inefficiencies in production and workflow.

5. Design for Manufacturing (DFM)

Ensuring that the design is easily and quickly manufacturable is essential. Complex designs and situations requiring manual labor can increase costs, energy consumption, and carbon emissions.

6. Adding Standby Features to Designs

Adding standby features to devices that consume energy when not in use increases energy efficiency and reduces carbon emissions.

7. Reducing Power Source Losses

Implementing high-efficiency circuit topologies (e.g., resonant converters) and techniques like soft switching in power sources and converters reduces losses, increases energy efficiency, and lowers carbon emissions.

8. Implementing Technologies like IoT in Designs

Utilizing technologies such as the Internet of Things (IoT) provides more control through data collection from devices like sensors and cameras. This can enhance energy efficiency, user safety, and remote access capabilities, leading to savings in time and costs and reduced carbon emissions.