A Process-Based Approach for Cradle-to-Gate Energy and Carbon Footprint Reduction in Product Design

Interest in accounting for environmental impacts of products, processes, and systems during the design phase is increasing. Numerous studies have undertaken investigations for reducing environmental impacts across the product life cycle. Efforts have also been launched to quantify such impacts more accurately. Energy consumption and carbon footprint are among the most frequently adopted and investigated environmental performance metrics. The purpose of this paper is to serve two objectives — first, it provides a review of recent developments for carbon footprint reduction in manufacturing processes and supply chain operations. Second, a future vision is shared toward developing a method for reducing carbon footprint through simultaneous consideration of manufacturing processes and supply chain activities. The approach is demonstrated by developing analytical models for alternative manufacturing processes and supply chain networks associated in the manufacture of a bicycle pedal plate to realize its potential in assessing energy and GHG (greenhouse gas) emissions. The sustainable design and manufacturing research community should benefit from the review presented. In addition, a point of departure for concurrent consideration of multiple stages of the product life cycle for environmental performance is established for the research community to move current efforts forward in pursuit of environmental, economic, and social sustainability.