Improving sustainability performance in early phases of product design: A checklist for sustainable product development tested in the automotive industry

In the early phases of product development, it is important to both reduce costs and improve a product's sustainability performance. Insufficient data are available on the costs and sustainability aspects of innovative concepts such as automotive lightweight design, which require the application of new materials and processes. The lack of information and high degree of uncertainty hinder the use of traditional sustainability evaluation tools such as Life Cycle Assessment during these early phases. Tools used in eco-design and sustainable design have disadvantages since they either focus on only one sustainability dimension, require quantitative data about materials and processes, or cannot be applied by designers and engineers. To overcome these disadvantages, a new checklist for Sustainable Product Development (CSPD) was developed in close collaboration with practitioners. The CSPD allows the qualitative assessment of environmental, economic and social aspects during the early phases of product development while considering a full life cycle perspective. It provides the methodological foundation for an iterative process, in which improvement tasks related to sustainability are defined that must be completed by the engineers. The applicability of the CSPD with reference to a wide range of technologies was evaluated and tested in a case study that included nine automotive lightweight technologies. This case study revealed that the developed tool helped designers and engineers assess and improve the sustainability performance of a technology and that it stimulated processes of collaboration and information exchange within and between organizations.