A new methodology for innovative product development based on the application of sustainability principles for the entire life-cycle of a product and beyond is developed. This involves an analysis of multi-life cycle material flow leading towards perpetual life products, making it truly sustainable. In order to achieve the function of such a sustainable product, it has to fulfill the concept of 6R (Recover, Reuse, Recycle, Redesign, Reduce and Remanufacture), which are composed of 6 stages of material flow in a products life, as opposed to the traditional 3R (Reduce, Reuse, Recover) concept. We apply the 6R concept in designing a new aluminum beverage can with much enhanced sustainability factors, especially in recycling processes.

Much has been written on the subject of sustainable development and the urgent need for society to understand and address human impacts on socio-ecological systems. Emerging from this broad context, the concept of sustainable product development (SPD) represents an important strategy to steer human society towards sustainability. This thesis investigates strategies for integrating sustainability concepts, through organisational learning and stakeholder management, into a new product development tool entitled ‘Touchpoint’. Built on prior research, specifically Methods for Sustainable Product Development(MSPD) and Templates for Sustainable Product Development (TSPD), this could help to eliminate product development approaches that lead to reductionism and ensure that SPD is adopted rapidly and widely.

The audience for this research is fellow researchers and others helping product developers to start including sustainability when they are selecting product concepts. The aims of the research were to understand the needs of product developers integrating sustainability into concept selection and what might be done to help them. The research approach was to iterate between the three studies of design research methodology. The first study focused on understanding the challenges that product developers face when integrating sustainability into concept selection. The aim of the second study was to identify potential support to help product developers to deal with the challenges.  And the third study was to try out the potential support to see if it actually helps product developers address the challenges they face. These studies were executed through reviewing literature and exploring two cases. The results led to a focus on supporting the decision-making process and supporting analysing with  respect to social sustainability.  Selecting concepts is a complex decision made under challenging conditions. Bringing in the complex, new and unfamiliar aspects of sustainability can make good decision-making even more challenging. When integrating sustainability, two particular barriers to good concept selection decision-making are errors due to illusory correlation and confirmation bias. Despite the challenges, how good you are at making decisions matters. And a good decision-making process drives good decisions. This is especially relevant when bringing in complex and unfamiliar aspects, such as sustainability.  A likely candidate for helping product developers achieve a good decision-making process when integrating sustainability is active, value-focused decision-support. In other words, structuring the process into bite-sized steps and using particular techniques to avoid bias. At each step, decision-makers’ focus is anchored by the things that stakeholders value as important.   Further research is required to investigate the details of how to employ these process-support approaches in the particular context of integrating sustainability into concept selection decision-making. In addition to a process, complicated selection decisions demand analysis. Support for analysing concepts with respect to social sustainability was identified as a gap. We explored a potential approach that might contribute to this analysis, but found that it was not useful for the particular decision in hand.  This opened up some interesting questions for further research.

Both the ecological and social system are systematically degrading, resulting in decreasing capacities to support human civilization. Product development and manufacturing companies play a key role in driving society’s transition towards a sustainable path. Besides moral arguments, the motivation for companies can be expressed as a matter of smart risk management, i.e. avoiding threats and exploiting opportunities. Such sustainability risks can be related to, for example, brand and reputation, legislative change, or attracting top-talented employees. But, more importantly, it is about understanding changes that are inevitable on markets to come. Based on Maxwell’s interactive qualitative research approach and following the structure of the Design Research Methodology, this thesis aims to contribute (i) to knowledge by increasing the conceptual understanding of what sustainability risks are; and (ii) to practice by researching decision-support for how sustainability risks can be managed in a product development company context. The first study reviewed existing literature and identified characteristics of sustainability risks, which make them particularly difficult to manage. A following exploratory and descriptive study investigated companies’ current risk management practices and preconditions for sustainability integration. It showed that the effects of uncertainty from the sustainability transition need to be identified, assessed, and managed in relation to how they can affect objectives anchored in both internal and external stakeholder value creation. In parallel, the Framework for Strategic Sustainable Development was applied as a lens to understand the implications of the sustainability transition for company risk management. This resulted in a new definition, stating that sustainability risks are threats and opportunities that are due to an organization’s contribution or counteraction to society’s transition towards strategic sustainable development. A questionnaire study then investigated some case companies’ challenges and preconditions to build sustainability capabilities. Finally, a workshop method is proposed that aims to support design teams in early sustainable product development. Future research will leverage on the findings to develop and test decision support for how product development companies can manage sustainability risks on different organizational levels in practice to increase competitiveness, while taking leadership in the transition towards a sustainable society.

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Simplified life cycle assessment (LCA) method quickly delivers an estimation of the product’s life- cycle impacts without intense data requirements, which are taken as a practical tool in the early stage of product development (PD) to support sustainable decisions. However, obstacles are to integrate the LCA tool efficiently and effectively into the designers’ daily workflows. To give a comprehensive overview of the potential challenges in integrating simplified LCA software to vehicle PD processes, the research conducts accessibility, intrinsic, contextual and representational data quality evaluation of the two vehicle-LCA software, Granta Selector and the Modular-LCA Kit, by the means of interviews, case studies and usability testing. From the four data quality evaluation, the results demonstrate (1) the importance of the company’s collaboration with the software developers to ensure the software’s accessibility; (2) the data accuracy constraints of the software due to the generic database and over-simplified methods; (3) the vehicle designer engineers reactions in the two software’s data fulfilments in conducting the complicated vehicle LCA models; and (4) the LCA results’ effectiveness in supporting sustainable design decisions. Overall, the two simplified LCA software’s reliability is sufficient merely in the very beginning stage of PD while the user satisfaction and effectiveness of the simplified LCA data are positive for the design engineers with a basic level of sustainability knowledge. Still, there is a need of systematic strategies in integrating the software into PD processes. A three-pillar strategy that covers the approaches of company administrative policy, software management, and promotion, and LCA and vehicle data life-cycle management could tackle the data gaps and limitations of the software and company. Based on this strategy, the research proposes an example roadmap for Scania. / Genom en förenklad livscykelanalys(LCA), kan man tidigt i produktutvecklingen få en indikation över ett fordons miljöpåverkan. Analysen kan agera som ett verktyg för att ge stöd till mer hållbara beslut i produktutvecklingen. En svårighet ligger dock i att integrera LCA i designers dagliga arbetsflöde på ett effektivt sätt. För att skapa en översikt av Scanias utvecklare och designers LCA- datakrav för hållbar fordonsutveckling genomfördes en datakvalitetsutvärdering (“accessibility, intrinsic, contextual, and representational”) av två LCA-programvaror, Granta Selector och Modular-LCA-kit. Från detta kunde en strategi och handlingsplan tas fram för implementering av LCA-programvara inom fordonsutveckling. Resultaten indikerar att programvarornas tillförlitlighet endast är tillräckliga i ett tidigt skede i produktutvecklingen. Dessutom varierar användarnas tillfredsställelse och effektiviteten av programvarans förenklade data utifrån designerns kunskapsnivå inom hållbarhet. För att ha en framgångsrik integrering av LCA-programvaran i fordonskonstruktionen, utvecklades en strategi med tre pelare. Dessa täcker Scanias företagspolicy och mjukvaruhantering samt hanteringen av livscykel inventariet och BOM-data, för att hantera brister i dataseten men även begränsningar hos programvaran och företaget. Baserat på denna strategi presenteras en möjlig handlingsplan för Scania.

I samarbete med Kungliga Tekniska Högskolan har uppdragsgivaren ÖMV AB utformat ett uppdrag som berör en av deras tidigare huvudprodukter, fiberfiltret. ÖMV AB ingår i OSTP Group Company. Genom engagemang och modern teknologi konstruerar, tillverkar och utvecklar ÖMV AB avancerad process utrustning som bidrar till en hållbar framtid. Företagets huvudprodukter är reaktorer, värmeväxlare, cisterner, tankar. Planer om att återuppta tillverkningen av fiberfiltret som är en av företagets tidigare produkter är aktuell, men det tidigare konceptet bör ses över och utvecklas för att uppfylla kundens önskemål. Det nuvarande konceptet anses innehålla brister och områden som potentiellt behöver förbättras, utvecklingen kommer att utföras med hänsyn till både konstruktion och även hur produkten anpassas för användarens säkerhet. Dagens fiberfilter används inom papper- och massaindustrin, dess syfte är att separera massa till fibrer och vatten för att förhindra fibrerna från att släppas ut i vattendrag. Målet med detta arbete är att ta fram minst tre alternativa lösningar för en förbättrad stödkonstruktion, även utveckla fiberfiltrets luckor som i nuläget anses utsätta användaren för risker, minst två koncept ska tas fram som uppfyller maskindirektivets föreskrifter. Utvecklingen av fiberfiltret kommer ske med hjälp av ett antal systematiska produktutvecklingsmetoder, de olika lösningarna kommer att analyseras och modelleras i ett datorstött designverktyg kallat Creo PTC. / In collaboration with the Royal Institute of Technology, the commissioner ÖMV AB has designed an assignment relating to one of their former main products, the fiber filter. ÖMV AB is part of OSTP Group Company. Through commitment and modern technology, ÖMV AB designs, manufactures and develops advanced process equipment that contributes to a sustainable future. The company's main products are reactors, heat exchangers, cisterns and tanks. Plans to resume fiber filter manufacturing as one of the company's previous products are current, but the previous concept should be reviewed and developed to meet the customer's wishes. The current concept is considered to contain shortcomings and there are areas that may need to be improved, development will be carried out with regard to both design and also how the product is adapted for user safety. Today's fiber filters are used in the paper and pulp industry, its purpose is to separate pulp into fibers and water to prevent the fibers from being released into watercourses. The aim of this work is to develop at least three alternative manufacturing methods for an improved support structure, including developing the fiber filter gaps that are currently considered to expose the user to risks, at least two concepts must be developed that comply with the Machinery Directive. The development of fiber filters will be done using a number of systematic product development methods, the different solutions will be analyzed and modeled in a computer-aided design tool called Creo.

Sustainable design is often practiced and assessed through the consideration of three essential areas: economic sustainability, environmental sustainability, and social sustainability. For even the simplest of products, the complexities of these three areas and their trade-offs cause decision making transparency to be lost in most practical situations. Additionally, the models and tools available to consider social sustainability are severely underdeveloped. This thesis is separated into three parts: 1) a design tool to consider all three aspects of sustainability simultaneously, 2) a literature survey to characterize social impact as it relates to products, and 3) interviews with engineering professionals regarding how social impact is currently considered in product design in industry.The existing field of multi-objective optimization offers a natural framework to define and explore a given design space. In chapter 2 of this thesis, a method for defining a products sustainability space (defined by economic, environmental, and social sustainability objectives) is outlined and used to explore the trade-offs within the space, thus offering both the design team and the decision makers a means of better understanding the sustainability trade-offs. This chapter concludes that sustainable product development can indeed benefit from trade-off characterization using multi-objective optimization techniques “ even when using only basic models of sustainability. Interestingly, the unique characteristics of the three essential sustainable development areas lead to an alternative view of some traditional multiobjective optimization concepts, such as weak Pareto optimality. The sustainable redesign of a machine to drill boreholes for water wells is presented as a practical example for method demonstration and discussion. In these efforts it became apparent that the tools for considering social impact were lacking and needed to be further developed.While efforts have been made to identify social impacts, academics, and practitioners still disagree on which phenomena should be included, and few have focused on the impacts of products specifically compared with programs, policies, or other projects. The primary contribution of chapter 3 of this thesis is to integrate scholarship from a wide array of social science and engineering disciplines that categorizes the social phenomena that are affected by products. Specifically, we identify social impacts and processes including population change, family, gender, education, stratification, employment, health and well-being, human rights, networks and communication, conflict and crime, and cultural identity/heritage. These categories are important because they can be used to inform academics and practitioners alike who are interested in creating products that generate positive social benefits for users.Though academic research for identifying and considering the social impact of products is emerging, additional insights can be gained from engineers who design products every day. Chapter 4 explores current practices in industry used by design engineers to consider the social impact of products. 46 individuals from 34 different companies were interviewed to discover what disconnects exist between academia and industry when considering a products social impact. These interviews were also used to discover how social impact might be considered in a design setting moving forward. This is not a study to find the state of the art, but considers the average engineering professionals work to design products in various industries. Social impact assessments (SIA) and social life cycle assessments (SLCA) are two of the most common processes discussed in the literature to evaluate social impact, both generally and in products. Interestingly, these processes did not arise in any discussion in interviews despite respondents affirming that they do consider social impact in product design. Processes used to predict social impact, rather than simply evaluate, were discussed by the respondents and tended to be developed within the company and often related to industry imposed government regulations.The combined work reported in this thesis is a significant step forward in being able to handle the unwieldy nature of social impact in product design in the larger context of sustainability. Not only do these efforts provide a basis upon which future tools can be developed, they are also immediately useful in providing a basic framework upon which to consider the full spectrum of social impact of products during design.

Many specific methods and tools have been developed to deal with sustainability problems. However, without a unifying theory it is unclear how these relate to each other and how they can be used strategically. A Framework for Strategic Sustainable Development (FSSD) is being developed to cover this need for clarity and structure. It includes backcasting from a principled definition of sustainability as a key feature. The aim of this thesis is to study how this framework can guide the use and improvement of detailed methods and tools, in particular to support sustainable product innovation (SPI). First, a new strategic life-cycle management approach is presented, in which the selection of aspects to be considered are not based on typical down-stream impact categories, but on identified major violations of sustainability principles. Ideas of how this approach can inform various specific methods and tools are also presented, as a basis for an integrated “toolbox” for SPI. As part of such, a new “template” approach for sustainable product development (TSPD) is developed through a sustainability assessment case study of TVs. That study indicates that this approach can create a quick and strategically relevant overview of critical sustainability aspects of a product, as well as facilitate communication between top management, product developers and external stakeholders. Based on such an assessment, it is sometimes necessary to go deeper into details, including the use of specific engineering methods and tools. To facilitate a coordinated assessment of sustainability aspects and technical aspects, an introductory procedure for sustainability-driven design optimization is suggested trough a water jet cutting case study. Equally important, to get a breakthrough for SPI, it is essential to integrate sustainability aspects into the overall decision-making process at different levels in companies. An approach to assessing sustainability integration in strategic decision systems is therefore also developed through a case study involving several companies. Finally, the integration between the FSSD and general systems modeling and simulation (SMS) is discussed and tested in another water jet cutting case study. It is shown feasible to start with the FSSD to create lists of critical flows and practices, ideas of long term solutions and visions, and a first rough idea about prioritized early investments. After that, SMS can be applied to study the interrelationships between the listed items, in order to create more robust and refined analyses of the problems at hand, possible solutions and investment paths, while constantly coupling back to the sustainability principles and guidelines of the FSSD. This research shows that the combination of the FSSD with detailed methods and tools cohesively provides decision-makers with both a robust overview and, when needed, a more coordinated and effective detailed support. To utilize its full potential, this approach should now be integrated into decision processes, software and manuals for SPI.

This thesis explores the conditions under which traditional Small and Medium Enterprises (SMEs) can be involved in the design of sustainable Product Service Systems (PSS). The integration between design and Information and Communication Technologies (ICT) in the context of sustainable business development was used to define the space for this exploration. The research was carried out through a case study with a group of Colombian Manufacturing SMEs. As a result of the case study a business framework was developed to guide the design of sustainable PSS. In order to establish the basis of the research a review of the literature on sustainable business development, ICT, design, product service systems and SMEs was carried out. This review brought to light the main features of a sustainable PSS and the challenges associated with its design. These challenges were further investigated in the context of SMEs with a scoping study involving a group of 38 Colombian SMEs. Additionally, 36 PSS already on the market were analysed to identify the possible relationships between design and ICT, and to determine how they could contribute to develop sustainable PSS. The scoping study and the analysis of the 36 PSS gave structure to the case study with a second group of Colombian Manufacturing SMEs. This case study aimed to build understanding of the connection between the characteristics of these SMEs and the main features of a sustainable PSS. As a result of this case study a set of concepts, drivers and barriers to take into account to design sustainable PSS formed the basis of a business framework developed and validated in the final part of the research. The business framework proposed can help to understand the resources and changes needed to develop a sustainable PSS, reducing the uncertainty that it may cause. The integration between product and service design and ICT is used in the framework to outline the areas of opportunity in the design of sustainable PSS. This business framework developed as a result of the research promises to be a helpful tool for organisations working to support the transformation of SMEs toward competitive and sustainable business models using as a basis the integration between product and service design and ICT. Despite the Colombian context the results and outcomes of this research are described in general terms to be applicable in other contexts around the world working with SMEs in the design of sustainable PSS.