International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391 Online ISSN 2198-0810

https://doi.org/10.1007/s40684-019-00052-1 Print ISSN 2288-6206

REVIEW PAPER

Trends and Perspectives of Sustainable Product Design for Open

Architecture Products: Facing the Circular Economy Model
Jaime A. Mesa1,3 · Iván Esparragoza2 · Heriberto Maury1

Received: 7 December 2017 / Revised: 25 April 2018 / Accepted: 30 April 2018 / Published online: 28 February 2019
© Korean Society for Precision Engineering 2019

Abstract
The purpose of this paper is to perform the analysis of literature review regarding the design of open architecture products
(OAP) and their potential benefits within the circular economy (CE) model. The analysis involved studying more than 80
research articles during the last two decades in engineering journals. The articles were gathered through a bibliometric
analysis using the most relevant keywords concerning product design, sustainability, OAP, and CE. Main trends, challenges
and future scopes of research opportunities and development were identified. The study provides a framework to designers
and researchers involved in the design of OAP to enhance their sustainability performance for a CE model, which integrates
lifecycle considerations (reuse, remanufacturing, repair, and recycle), resource optimization, and emissions reduction. The
findings include the need for design methods focused on the design of OAP to guarantee an effective circularity of resources
during the whole lifecycle of products and the need of integrating manufacturing processes and material analysis to design
products capable of adapting to the CE model.

Keywords Sustainable design · Open architecture products · Circular economy · Research opportunities · Trends

Abbreviations 1 Introduction
AD Axiomatic Design
DFS Design for sustainability Design for sustainability (DFS) is considered nowadays as a
OAP Open architecture products remarkable topic in the product development processes for
CE Circular economy both design and manufacturing companies. The increasing
LCA Life cycle assessment of legal, market and financial pressures on manufacturing
DFMA Design for manufacturing and assembly industries to develop sustainable products pushes towards
QFD Quality function deployment the mandatory consideration of sustainability requirements
EOL End of life and the use of tools and strategies aimed to reduce environ-
mental, economic and social impacts from the product devel-
opment process [1–3]. As a result, it is common to find many
approaches focused on diminishing adverse effects of prod-
uct development in the end of life (EOL) phases of product
lifecycle including design for recycling, design for remanu-
facturing, and design for reuse among others. Authors like
* Jaime A. Mesa Kulatunga et al. [4]. and Harper and Thurston [5] establish
jmesa@utb.edu.co that approximately 80% of sustainability impacts from the
1
Department of Mechanical Engineering, Universidad del product are decided in the product design and development
Norte, Km 5 Vía Puerto Colombia, Barranquilla 081007, stages, where future implications related to emissions, mate-
Colombia rial and energy consumption can be predicted. Therefore, the
2
Department of Engineering, PennState relevance of design is critical since once a product has been
University-Brandywine, 25 Yearsley Mill Road, Media, developed and manufactured its sustainability attributes are
PA 19063, USA largely fixed [6]. Several methods have been developed to
3
Department of Mechanical Engineering, Faculty enhance the sustainability performance of products during
of Engineering, Universidad Tecnológica de Bolivar, Km 1 the design phase. These include quality function deployment
Vía Turbaco, Cartagenade Indias 131001, Colombia

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378 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391
(QFD) [7, 8]; life cycle assessment (LCA) [9–11]; tools
based on computed aided design (CAD) [12, 13], and
Design for Manufacturing and Assembly (DFMA) [14–16],
axiomatic design (AD) [17], decision support methods [18]
among others. These works have remarkable significance
during conceptual and primary design stages due to their
contribution to the selection of materials, the reduction of
complexity in assembly/disassembly task for dismantling,
recycling, reuse, and remanufacturing.
According to the methods mentioned previously, it is pos-
sible to identify two main approaches to consider sustain-
ability into the lifecycle of any product: the reactive and the
preventive approaches. While the reactive approach focused
on minimizing adverse impacts in the EOL phases associ-
ated with the minimization of waste and emissions gener-
ated in the recycling, reuse and remanufacturing [19]; the
preventive approach aims to consider sustainability impacts
from early design phases. Despite the plenty of works and
methods related to design and final disposal phases, the
vast majority of them are established and validated without
considering the manufacturing paradigm that defines the
architecture of products, the volume per product variant,
and the product variety. The most important manufacturing
paradigms identified are mass production, mass customiza-
tion and mass individualization. Mass production is related
to a high volume of unified architecture products, while
mass customization is associated with the use of modules to
reconfigure partially products. Lastly, mass individualiza-
tion is characterized by the use of modules in reconfigurable
systems to enables adaptation capability respect to particu-
lar customer requirements to achieve highly personalized
products [20].
Nowadays, the development of products and devices is
dominated by a mass customization and individualization
models, which are characterized by a manufacturing strategy
based on shorter useful lifetimes and a rapid replacement of
old product versions to increase product sales and economic
profits [21]. According to Koren et al. [20], the mass cus-
tomization model is being replaced by a new emerging man-
ufacturing paradigm denominated mass individualization,
which involves the particular customer requirements from
the design stage to create highly personalized and upgrada-
ble products, also denominated open architecture products
(OAP). The OAP paradigm requires then a robust product
platform to generate personalized product families and prod-
uct variants to satisfy each set of requirements from the cus-
tomer. From the perspective of sustainability, this manufac-
turing paradigm is not desired in a sustainable development
due to the increase in population and the resource depletion
expected during its implementation.
One of the most feasible solutions to the sustainability
issues involved in the mass individualization is the circular
economy (CE) [22]. This model entails important strategies
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to (a) facilitate the interaction and supply chains among EOL
phases, and manufacturing and use, (b) extend the useful life
of products, and (c) improve the use of resources through
the adaptability of products to requirements dependent on
changes in the market. Therefore, this work aims to pro-
vide a framework based on an analysis of literature review
for future trends and research opportunities regarding both
sustainable product design and current product tendencies
framed in open architecture and CE strategies. For this pur-
pose, a systematic and particular literature review based on
bibliometric analysis is developed to identify the methods
related to the product development process considering
attributes of both OAP and the CE models.
This article is structured in six sections. Section 2 pre-
sents the motivation of this research and the concerns asso-
ciated with the consideration of the manufacturing system
and the CE model into the development of products. A lit-
erature overview is included in Sect. 3. The methodology
employed to identify, classify and analyse the related works
is described in Sect. 4. Section 5 summarizes findings and
results from the implementation of the methodology. Finally,
conclusions are described in Sect. 6.
2 Motivation
The analysis of existing literature reveals the opportunities
to advance in the studies of several critical aspects of DFS
in product design for open architecture platforms. Most of
the review articles related to DFS are focused on classify-
ing existing contributions based on the type of approach,
the lifecycle stages, the design phase associated, and other
issues related to distribution of works by region, year, jour-
nals, authors, and institutions. Several works are oriented
to compare approaches using advantages and limitation
analysis, while other works include particular criteria such
as actors involved in the lifecycle and barriers among others.
Table 1 summarizes the analysis of the most relevant review
works in the last decade concerning sustainable product
design. Such works were identified from a literature search
using the following keywords: review, sustainability, DFS,
method, and eco-design.
From the analysis of reviewed papers included in Table 1,
the following research opportunities on sustainable product
design were identified:
• The integration of socio-economic issues with environ-
mental aspects. The environment is the most relevant
dimension studied according to the results and discussion
of review papers analysed regarding sustainable design.
Several works [23, 25, 28] consider the economic dimen-
sion and just a few the social dimension.
 Table 1  Analysis of reviewed works related to DFS in products
Author Type of work Aim-motivation Criteria analysed
Type Life Design phase Distr. Distr. Another specific criterion
of tool/ cycle per per
method stage year region

(Ramani et al.) [23]
(Bovea and Pérez-Belis) [24]
(Arnette et al.) [25]
(Buchert et al.) [26]
(Brones and Monteiro de Car-
valho) [27]
(Pigosso et al.) [28]
Review of Eco-design tools
Review and classification of
tools
Review of DFS techniques
Analysis and Categorization of
tools for Sustainable Design
Synthesis of theoretical contri-
butions in Eco-design
Review of existing Ecodesign
tools and methods
To provide an overview and
decision support as an impor-
tant strategy
To provide to the designer a
guide to selecting the best
eco-design tool
To provide an overview of DFX
tools for sustainable product
design
To provide a framework which
combines the advantages of
different methods
Integration of more effective
Eco-design tools
To identify trends and research
opportunities in the next
decade
X X – – – DFX tool classification
X X X – – Method basis
X X – – – Primary design considerations
Potential performance outcomes
X – X – – Dimension of sustainability, Type
of processed data, User of the
method, layer of abstraction
X – – X X Journals systemic levels
X – – X X Paper per author
Papers per institution
Evolution of eco-design tools
Most used keywords
International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391

(Ceschin and Gaziulusoy) [29]
(Rossi, et al.) [30]
(Schöggl, et al.) [31]
Evolution of DFS tools and
methods
New literature review of the
principal eco-design tools and
methods
Summarizing of checklist tools
for sustainable product devel-
opment
To provide a framework of X – – – – Main Limitations
evolutionary works Future research directions
Understanding the main obsta- X – – X – Barriers
cles that limit their actual weakness
implementation in industrial Possible improvements
companies strategies
To provide a quantitative X X – – – Analysis of actors involved
assessment of environmental, Sustainability dimension
economic and social aspects Advantage
during early design phases disadvantage

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380 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391
• The development of multiple lifecycles and CE strat-
egies is highlighted as potential trends [23, 28, 30].
Optimization of products during lifecycle interactions
in manufacturing, use, and final disposal are remarked
as important issues to enhance the sustainability per-
formance of products and industrial companies.
• Practical case study applications of DFX tools concern-
ing sustainability. The vast majority of approaches has
not been validated in the industrial field, despite most
of the works are validated through particular case stud-
ies. Most remarkable research opportunities concerning
sustainability in product design are listed also after the
analysis of the literature considered in Table 1. These
opportunities are associated with the design of OAP,
product families, and the improvement of the product
lifecycle.
• Approaches and trends highlighted in the review arti-
cles analysed are focused on the study of secluded
works and do not consider the product families and
product portfolios models, which are currently
employed as critical strategies in the optimization of
design and manufacturing resources in the industry.
• Authors exposed a common concern about the need
of research efforts in support of product design for the
CE model. Works analysed in the reviewed articles are
oriented to seclude approaches such as design for recy-
cling, design for reuse, and design for remanufacturing.
However, it does not exist a decision-making approach
to provide a selection hierarchy to define which one is
more suitable depending on the needs of the case study.
• It is possible to identify an absence of research efforts
regarding the design of OAP. Despite the organization
and rigor in the review and analysis of the literature,
existing works do not take into account the type of
manufacturing paradigms (mass, flexible or reconfig-
urable), and the existing challenges regarding OAP and
CE. These concepts have been mentioned since early
2000s [20]; however, the methods and tools do not con-
sider them formally in the design process.
Analysis from review articles regarding DFS provides
relevant information about interesting criteria related
to the type of work, geographical distribution, journals,
design phases, and authors among others. Nevertheless,
several emergent topics related to the type of manufactur-
ing paradigms, product architecture, and feasibility to face
CE are not formally considered in the works analysed.
Nowadays, this situation requires holistic approaches
capable of integrating all lifecycle stages of products,
involved actors (material producers, manufacturers, cus-
tomers, and final disposers), and the conditions to establish
a CE model. Trends and research opportunities identified
13
motivate to address efforts in consideration of OAP and
CE in the DFS approaches.
3 Overview
This section aims to define and illustrate the main attributes
of the product manufacturing paradigms and to describe the
implications of CE concerning sustainable product design
and its impact during the product lifecycle. The product
manufacturing paradigms defined by Koren et al. [20] are
detailed and compared below taking into account the most
relevant features concerning product design.
3.1 Product Design Paradigms
It is possible to identify three main product-manufacturing
paradigms, which have established the relationships between
design, manufacturing, selling tasks, and the customer and
manufacturer roles into the product development process.
These are mass production, mass customization, and mass
individualization. As mentioned before, mass production is
associated with the massive manufacturing of products with
unified or fixed architecture. Mass customization employs
modular product architecture characterized by modules
designed and manufactured to generate different optional
product choices to the customer. Finally, mass individualiza-
tion involves the use of product platforms with a large vari-
ety of product variants resulting from the use of modules
designed with compatible interfaces. In this last model, the
customer can select the modules even from the design stage
and generate personalized product variants. Table 2 shows a
comparative summary of the main features of product manu-
facturing paradigms according to the definition of Koren
et al. [20], including several examples of products to each
paradigm.
According to Table 2, product design paradigms are
widely differentiated by the type of architecture, the manu-
facturing system, and the historical moment depending on
the evolution of manufacturing technologies. Additionally,
the roles of manufacturer and customers have also been
changing the product design paradigm. Mass production
and mass customization do not consider any participation
of customer in the product development stages beyond the
overall customer requirements. In contrast, the mass indi-
vidualization model includes the customer requirements
participation at an individual level from early design
stages to achieve highly personalized products. It is even
possible to reconfigure the product functional architecture
in further stages such as use/operation, maintenance, and
upgrading. Cost-effectiveness of manufacturing paradigms
is also very different. The mass production is based on
economy of scale that is subject to the production volume.
International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391 381

Table 2  Comparison of product manufacturing paradigms Adapted from Koren et al. [20]
Feature Mass production Mass customization Mass individualization

Product architecture Unified or fixed Modular Modular Open-Platform

Product built Identical product Product built with one option Customer designed
Time line 1913–1980 1980–2010 2010–Nowadays
Manufacturing System Dedicated manufacturing line Flexible manufacturing systems Reconfigurable manufac-
turing systems
Milestone CNC technology raise Globalization matures –
Examples of product Nut, manufactured in millions of Portfolio of cars. Personalized PC
units. Portfolio of TV. Personalized surfing table
Components manufactured using
extrusion
Profit based on Economy of scale Covering several market segments Exclusivity of products

In this case, the fixed configuration product is manufac- 3.2 Circular Economy‑CE

tured in large batches, and the profit depends directly on
the number of units sold. Mass customization takes advan-
tage of the modularity and sharing of constructive compo-
nents to reduce the manufacturing cost and aims to cover
several market segments through differentiation of prod-
ucts in the number of functions and capabilities from a
modular product platform. Finally, mass individualization
achieves profitability through the added value of person-
alized products. The customer can pay for a personalized
product due to the perception and feeling of exclusivity.
Regarding the differences of manufacturing paradigms
from the lifecycle stages, it is possible to highlight the
level of participation of both manufacturer and customer.
Figure 1 describes the differences between tasks for
design, manufacturing, and use for each manufacturing
paradigm.
The CE concept can be defined as a model in which the
flow of energy, materials, and resources are related in loops
to minimize emissions during the whole lifecycle of prod-
ucts and services. Unlike the traditional or linear economy
models that have not loops among the lifecycle, the design
for sustainability is closely linked to circular product
design. This is due to the common aim of increasing posi-
tive impacts, and reducing negative impacts derived from
any product development process such as adverse outputs
(e.g., emissions and waste released to the environment in
the air and landfills). Figure 2 shows a graphical compari-
son between linear and CE models. Recycling, reuse and
remanufacturing are highlighted as feasible tasks to reduce
adverse impacts during the lifecycle of products. According
to the information existing in the literature, five main strate-
gies can be identified concerning CE:

Fig. 1  Comparison of strategi- Mass Mass Mass Individualization

cal tasks in different product Production Customization (OAP)
manufacturing paradigms
Design of the set of modules
Design of single Design of product variants –
Design Phase product product families
capable of generating product
families and product variants

Manufacturing Manufacturing and assembly of Manufacturing and assembly of a

Manufacturing and
and assembly of product variants and product particular set of modules to
Assembly Phase single product families generate individualized products

Customer acquires a customized Customer acquires a highly

Customer acquires
product from the options offered. personalized product. The
a product with a
Use Phase fixed functional
The functional configuration is Functional configuration allows
adjusted but fixed to the customer to reconfigure the product
configuration
needs operational performance

EOL Manufacturer
not considered by
traditional approaches Involved Actors Customer
Manufacturer and Customer

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382 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391
Fig. 2  Comparison between
Linear and CE model
Material
Production/
Extraction
EOL Manufacturing
USE
(a) Linear Economy
• Design for circular supplies: focused on the thinking of
generating similar cycles to biological process in which
the resources are obtained and returned to their natu-
ral cycle without harming the environment [32]. This
strategy also involves the generation of internal supply
chains between stages of the product lifecycle, which
extend the useful time of products and components.
• Design for resource conservation: oriented to develop
products using the minimum possible resources from a
preventative approach [33]. This goal can be achieved
through an optimized selection of materials and a
robust design process to provide suitable geometries
and manufacturing materials.
• Design for long life use of products: aimed to extend
the utilization of a product during its use phase through
activities such as reuse, repair, easy maintenance and
upgrading [34]. This strategy involves a robust product
design oriented to manufacturing, assembly and dis-
assembly; and the modularization and standardization
of components and interfaces, which entails an easier
removal or reassembly [35].
• Design for multiple cycles: focused on the use and cir-
culation of material and resources in multiple cycles
[33, 34]. This strategy involves the remanufacturing,
reuse and product sharing. The multiple useful cycles
allow taking advantage of the full useful time expected
from the design phase, and components can be helpful
for their partial or complete failure.
• Design for systems change: associated with the whole
spectrum of value creation for both biological and tech-
nical cycles; this includes the development of inno-
vative solutions to adapt product features to market
changes [36].
13
Material
Production/
Extraction
Recycle
Re-Manuf. Manufacturing
EOL
Re-use
USE
(b) Circular Economy
3.3 Relationships Identified
After the overview of product manufacturing paradigms and
CE, it is possible to identify several relationships between
OAP and CE strategies. The attributes of OAP regarding
modularity, reconfiguration, and product family are highly
related to the strategies of the CE. Therefore, some attrib-
utes of OAP provide feasible solutions to the needs involved
in the implementation of a CE model. Consequently, the
synergy of both concepts is a robust approach to improve
the sustainability of products considering the current trends
in the manufacturing paradigm of mass individualization.
Figure 3 shows the identified relationships among OAP and
CE attributes according to the literature review of this paper.
In this subsection, the relationships identified between
OAP and CE are described in detail, each relationship is
grouped according to Fig. 3.
3.3.1 Modularity: EOL, Lifecycle Thinking
Modularity entails substantial benefits to the CE from the
perspective of EOL through the simplification of assembly/
disassembly task to facilitate the separation and removal of
components. Regarding upgrading, the modularity allows
upgrading the number of functionalities and operational
ranges of the product centring the modularization on par-
ticular functional component responsible for functions and
operational levels. Additionally, in the whole lifecycle, the
modularization provides easier maintenance, repair, and
exchange of components through the standardization of
interfaces. Modularity is highly associated with the prod-
uct architecture, which is considered as a crucial factor that
International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391 383

Fig. 3  OAP and CE Relation-

EOL
ships
strategies
Modularity

Open Useful Life

Extension and Circular
Architecture Reconfiguration
closing material Economy
Products flow

Product Family
Approach
Lifecycle
Thinking

connects product design to the decision making during any Analysis of Existing
lifecycle stage [36]. Review Articles

3.3.2 Reconfiguration: Useful Life Extension and Closing

Material Flow, Lifecycle Thinking Identification and clustering of
Review Parameters
The reconfiguration of products consists of the change of
constructive and functional components to adjust to new
operational requirements, such change of configuration can General Search
be considered an upgrading to achieve a new product variant. (Literature Search Engines)
The concept is associated with the optimization of resources
and the comprising of product family functionalities into a
single product; therefore, the useful life of the product can be
Detailed Filtering
diminished due to the intensity of use required. The recon-
figuration also entails an enhanced lifecycle management of
products and constructive components due to the existing
modularization among them. Related Works

3.3.3 Product Family Approach: Useful Life Extension Fig. 4  Methodological Approach employed
and Closing Material Flow

The design of a product family provides the implementation
of modules sharing among each product variant when the
customer requires to increase the operational range of the
product or to add new functionalities to the product. The
standardization and commonality among products facilitate
the extension of the useful life of products through the reuse
of modules; this scenario is possible when the product fam-
ily is designed to operate as a modular product platform to
the user.
4 Methodology
Methodology consist of three main steps which are proposed
to recognize and select the most relevant papers concern-
ing OAP products and CE strategies. The methodology
aims to separate non-related from related works regarding
the relationships established previously between OAP and
CE. Figure 4 shows the three-step proposed methodological
approach. The first step consists of identification and clus-
tering of review parameters according to the most relevant
search keywords selected from the literature review analysed
in Sect. 2. The second step consists of searching the litera-
ture using specialized databases from publishers including
Science Direct, Springer and Verlag, Taylor and Francis,
Inderscience, SAGE, Emerald Insight, Wiley and Google
Scholar. Once the search is done, articles are identified from
each cluster of keywords established using a detailed filter-
ing consisting of a comprehensive reading of abstracts in
step 3. The output of step 3 includes the most relevant works
concerning open architecture products and CE.
The literature search was developed taking into account
combinations of sets of most representative keywords
associated with both sustainable product design and
eco-design in OAP and CE concepts. Keywords are cat-
egorized into two groups: primary keywords, related to

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384 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391

sustainable product design and eco-design; and second-
ary keywords, concerning open architecture and CE con-
cepts. Primary keywords were selected from Pigosso et al.
[23], which includes an extensive bibliometric analysis
of 350 papers regarding sustainability and eco-design
until 2016. The most representative words identified in
this field are: “Eco-design,” “Life Cycle Assessment,”
“Design for Environment,” “Sustainability” and “Prod-
uct Design.” The four secondary keywords selected are:
“reconfigurable,” “open architecture products,” “circular
economy” and “product family.” To generate a systematic
and organized information gathering, the most representa-
tive words found in the literature are separated in four
groups of keywords (Set of primary keywords), meanwhile
keywords associated with OAP and CE are included in
a second set of words (set of secondary keywords). The
combination of each set of primary and secondary key-
words are considered as search clusters. Figure 5 shows
the flow of information developed in this research using
the reviewing parameters, the sets of keywords and the
generated clusters. Different colours are implemented to
discern each cluster.

Set 1 Set 2 Set 3 Set 4

Primary keywords Primary keywords Primary keywords Primary keywords
Ecodesign Life Cycle Assessment Design for environment Sustainability
Product Design Product Design Product Design Product Design

Secondary Keywords
Reconfigurable
Open Architecture Products
Circular Economy
Product Family
Search Cluster 1
Search Cluster 2
Search Cluster 3
Search Cluster 4
Literature Search Engines
Science Direct, Springer & Verlag,
Taylor & Francis, Inderscience, SAGE,
Wiley, Emerald Insight
Google Scholar

Articles identified Articles identified Articles identified Articles identified

for further analysis for further analysis for further analysis for further analysis
n=41 n=25 n=22 n=18

Total Articles
n=106

Number Included after

reading Abstract
n=37

Fig. 5  Literature search flow

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International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391 385

5 Findings and Results
After the revision of the relevant works regarding OAP and
CE, six main improvement fields related to the enhancement
of sustainability of products during its lifecycle. Table 3
shows each improvement field with a brief description of
each one and also an identification number for further analy-
sis. Table 4 summarizes a brief definition and aims of rel-
evant works obtained from the literature review using the
bibliometric approach. The concepts and tools employed in
each work are described as well.
Most relevant topics regarding sustainability, OAP and
CE attributes are analysed in this section taking into account
the selected works obtained from the bibliometric analysis.
Three significant topics are listed: the approach concerning
the important categories for sustainable product develop-
ment, the applicability of methodologies on open architec-
ture products, and the absence of research in key concepts
for the integration of OAP and CE.
5.1 Important Categories
The EOL stage is the most common focus of study in rel-
evant works obtained from the literature review. Thus, recy-
cling, reuse and remanufacturing are widely studied by many
authors not only in CE models but also in OAP. However,
the positive impact of these activities is low compared with
the potential impact obtained from the product design phase,
in which the lifecycle impacts of materials, manufacturing
processes, parts and components can be improved drasti-
cally. In the second place, the resource efficiency related to
consumption of raw material, energy and consumables is
considered in less proportion by the works analysed. Exten-
sion of operational life also represent an important propor-
tion of analysed works. Few works include the multiple life-
cycle generations, the reduction of emissions and the use
of low-impact materials. Figure 6 shows the distribution of
important categories consideration among analysed works.
It is important to clarify that the works studied are com-
prised by methods oriented to improve sustainability from
the design stage. According to authors analysed in Table 4,
the relevance of EOL stage concerning adverse impacts
in sustainability is very high; however, it is necessary to
include with the same importance impacts on sustainability
derived from manufacturing and the use/operation stages.
Therefore, it is necessary from a holistic view to designing
not only for EOL but also for all further stages to provide a
robust minimization of waste and adverse emissions.
5.2 Applicability of OAP and CE
Despite the fact that works identified integrate several con-
cepts of both OAP and CE, it is necessary to measure the
applicability of each design approach regarding all the attrib-
utes required for OAP in a CE. In this work applicability is
defined as the degree of consideration of main topics regard-
ing both Open Architecture and Circular Economy. There-
fore, a qualitative valuation scale is proposed and applied to
the most relevant works; Low, Medium and High levels are
established to differentiate the works analysed. A matching
of attributes of OAP and CE previously examined is devel-
oped to generate the hierarchy of High, Medium and Low
applicability proposed. In this way, works with four or more
Open Architecture and Circular Economy topics denote a
high applicability (H). On the other hand, works with three
topics denote medium applicability (M). Finally, works with
less than three topics denote low applicability (L).
Table 5 describes the applicability levels obtained for the
most representative work associated with methodological
approaches. The lack of works on reconfigurable design ori-
ented to OAP is observed. This provides research opportu-
nities concerning to the facilitation of changing functional
configuration of products during its use.
From the perspective of the CE conception, the following
research issues are identified: (a) the absence of considera-
tion of upgrading as a critical strategy to reduce the needs
of different product variants to comprise a wider functional

Table 3  Important categories for sustainability in a CE model Adapted from Schöggl et al. [26]
Improvement field Description Identifier

Resource efficiency
Use of low impact materials
Optimization of the EOL phase
Upgrading of products to
extend operational life
Reduction of emissions
Multiple lifecycles
Reduction of raw material, energy consumption, and resources involved during product lifecycle 1
The inclusion of low impact manufacturing materials considered. This is related to low carbon 2
footprint and less-hazardous materials
Consideration of strategies to enhance reuse, remanufacturing and recycling of products and com- 3
ponents
Use upgrading (removal and addition) of components to extend operational product life. Compo- 4
nents are designed to be removed in short useful periods
Reduction of solid, liquid and gas emissions generated during any lifecycle stage 5
Design components and products to achieve several lifecycles through the implementation of reuse 6
and remanufacturing strategies

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386 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391

Table 4  Characterization of authors in Sustainable Product Design in OAP

Author Method/approach Aim

Vanegas et al. [37] eDiM–ease of disassembly metric Method for measuring and facilitating disassembly to
improve reuse, recycling and remanufacturing
Paterson et al. [38] End of life decision tool for remanufacturing A tool for supporting the making decision concerning EOL
strategies
Kim and Moon [39] Sustainable platform identification To identify the sustainable platform for a product family
Favi et al. [40] Design for EOL approach To help designers in the evaluation and subsequent
improvement in product EOL performance
Yu et al. [41] QFD and Modularity for EOL of product family To develop a design method for eco-issues and product
family issues
Wang et al. [42] AHP-based eco-design model To help designers to decide for evaluating eco-design
options
Sakundarini et al. [43] Modular design method To optimize EOL strategies by using an excel-based
approach
Pialot et al. [44] Eco-innovative method based on upgradability To explore upgradability possibilities and to specify and
assess upgradable systems
Osorio et al. [45] Product design approach based on DFX guidelines To gather the main product design requirements for devel-
oping sustainable mass-customized products
Chou [46] ARIZ-based life cycle engineering model for eco-design To restructure a set of new product models through modu-
of products lar analysis, to develop an effective assessment method,
and to search for improvement opportunities
Mascle [47] Methodology for product rebirth To enables product design according to objectives defined
by its end of life (EOL)
Zwolinski et al. [48] Design Method for re-manufacturable products To propose an approach for integrating remanufacturing
constraints throughout the design process
Gu et al. [49] Method and guidelines for adaptable design To provide a framework concerning adaptable design and
its benefits
Kimura et al. [50] Product Modularization Strategy To design based on product functionality, commonality and
lifecycle similarity
Koga and Aoyama [51] Method for design of modular products based on its To design the optimal modular structure considering
lifecycle life-cycle calculation based on the sales of the line-up
products in the product family
Umeda et al. [21] Function behaviour state modelling To define candidates of modification of the function
structure and configuration of a upgradable platform for
modular products
Yang et al. [52]. Method to design eco-product families through modular- To provide a systematic method to develop an eco-product
ity family is proposed to improve the reusability and recycla-
bility of waste products
Wang and Tseng [53] Method to manage product end-of-life strategies through To help designers apply modular design methodologies
modular design based on the measurement of product modular architec-
ture from an end-of-life perspective
Martinez and Xue [54] Method to model adaptable products from modular To propose an overall evaluation index for adaptable
design products considering weighting factors from the whole
product utilization span
Amaya et al. [55] Life cycle analysis To help the environmental assessment of product service
systems using LCA during early design phases
Mestre and Cooper [56] Multiple loops life cycle design Establishes different circular economy approaches to
generate guiding strategies to improve sustainable design
solutions

range, and indeed to reduce the material and energy con-
sumption incurred from the product development of addi-
tional product variants. (b) The lifecycle thinking related to
the holistic consideration of further lifecycle stages from the
design phase and the alternatives of reintegration to another
lifecycle (through reuse, recycling or re-manufacture). (c)
Finally, lack of research efforts against the programmed
obsolescence to optimize the selection of materials and the
durability of components associated with the useful life
expected in case of reuse and remanufacture.

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International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391 387

The next topic in coverage is the product family concept

that is addressed by almost half of the works examined. This
topic is also very close to the idea of modularity. Product
families are designed to create alternatives for different mar-
ket segments varying the functional attributes or levels of a
basic product. Finally, reconfiguration and circular economy
concepts are studied only by a quarter of the works studied.
Therefore, the design for generating different functional con-
figurations from the same product and the formal considera-
tion of circular paths among product life phases provide new
study fields for future research efforts.

5.4 Future Trends Expected

Fig. 6  Important categories distribution in identified works Future trends are divided into two categories: the first one
related to the CE as a general model to design, manufacture
and dispose of products, and the second one associated with
5.3 Weakness‑Degree of Uncovered Topics
the trends in OAP facing the CE model. Future trends and
associated issues are listed below:
From all the works analysed, it is possible to affirm that
none of them integrates the attributes of open architecture
and CE concepts completely. Such absence of integration 5.4.1 Future Trends Regarding CE
is measured and described in this subsection to provide a
wide perspective of future research opportunities to improve • To integrate more manufacturing companies in the imple-
the sustainability of more complex products integrating mentation of product lifecycle strategies to achieve a
OAP, product family, modularity, reconfiguration, and CE. robust CE [31].
Figure 7 presents the percentage of coverage of the topics • To promote the eco-design for the development of re-
aforementioned. It is observed that modularity is the concept manufactured products [42].
with more coverage in the literature reviewed. The use of • To consider the economic perspective in the design of
platform-based products and common modules to generate new products for achieving competitiveness [47].
product variants is a topic highly studied to achieve more
market segments, and customers in a cost-effective manner. Issues identified

Table 5  Characterization of authors in Sustainable Product Design in OAP

(Sakundarini, et al., 2015)43

(Mestre & Cooper, 2017)56

(Koga & Aoyama, 2008)45

(Martinez & Xue, 2017)54

(Zwolinski, et al., 2006)48

(Wang & Tseng, 2011)53

(Paterson, et al., 2017)38
(Vanegas, et al., 2017)36

(Kimura, et al., 2001)50

(Kim & Moon, 2017)39

(Umeda, et al., 2005)21

(Amaya, et al., 2014)55

(Osorio, et al., 2014)45
(Wang, et al., 2015)42

(Pialot, et al., 2015)44

(Yang, et al., 2014)52

(Favi, et al., 2017)40

(Gu, et al., 2004)49

(Yu, et al., 2015)41

Main Topic
(Mascle, 2013)47
(Chou, 2014)46

Reconfiguration
Architecture
Open

Product Families

Modularity

EOL

Life Cycle Thinking

CE

Useful life Extension

and closing material
flow

Applicability M H L H H M L L M M L L M L L M H H H H M

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388 International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391
Fig. 7  Lacks/weakness of critical concepts regarding OAP and CE
• Lack of integration among industrial companies in the
sharing of supply chains from manufacturing to use, use
to EOL, and EOL to remanufacturing.
• Products are not commonly designed to be re-integrated
to another lifecycle.
• Sustainable products can be expensive due to the exter-
nalities (e.g., cost of transportation, management, re-
manufacturing) contemplated when the product is fol-
lowed during its whole lifecycle.
5.4.2 Future Trends Regarding OAP
• To increase efforts in the EOL of modular products and
the decision-making strategies involved in it [52].
• To integrate sustainability into the product development
of complex product families according to variable cus-
tomer needs [33].
• To study and analyse the trade-off between sustainability
and mass customization and individualization products
[39].
Issues identified
• Modularity is mainly considered from the design to
enhance functional attributes during the manufacturing
and use of products.
13
• Product families are designed from customer require-
ments. However, once the product family is designed it
is hard to upgrade and to adapt the product functionalities
according to new incoming customer requirements.
• Sustainability is often applied to single products with-
out considering the manufacturing paradigm involved in
reconfiguration, customizable and personalized products.
5.5 Socio‑Economical Challenges
This subsection includes the most representative challenges
facing the implementation of an integrated model of OAP
and CE. Such challenges can be interpreted as ideal supposi-
tions about what is necessary from the perspective of social
and economic activities concerning to the design, manufac-
turing, use and final disposal of products. Five main chal-
lenges concerning society and economy are identified and
described below:
• Education for CE: it is necessary and critical to include
sustainability and lifecycle thinking in the low, mid and
high school programs to ensure that the future world’s
citizens will be able to understand the importance of
reducing the adverse impacts on sustainability. The phi-
losophy of sustainable development needs to be imple-
mented from early ages at home to ensure a massive
implementation in the daily human tasks and all eco-
nomic activities of future generations.
• Consumer behaviour: this is closely linked to the first
challenge and is related to the change of mind about
the consumption habits and the generation of waste and
emissions from daily and industrial activities. A better
awareness is required to identify and prioritize the core
human needs and the actual consequences of the acquisi-
tion of products and their disposal once the useful life is
over.
• Sustainability as added value: sustainability needs to be
identified as a high added value by all actors involved
in the productive chain. Products, services, and goods
remarked as “sustainable” pushed towards a widely
spread of sustainability culture into organizations and
companies providing competitiveness and prestigious
based on indicators, enhanced processes and policies
addressed to generate more sustainable results. This topic
can also be addressed from the establishment of national
policies and laws to enforce the sustainable development
into companies and the society.
• Integrated Market System: the implementation of the
CE demands the connection among different companies
and industrial sectors to share non-desirable emissions
and to generate supply chains to establish newly added
value products or consumables for another process. For
instance, the waste or residual raw material of a particu-
International Journal of Precision Engineering and Manufacturing-Green Technology (2019) 6:377–391
lar manufacturing processing can be employed as raw
material for another company.
6 Conclusions
The main result of this study is the identification of trends
and perspectives of sustainable product design approaches
considering OAP and CE. Previous works available in the
literature were comprehensively analysed to identify the
advances in state of the art regarding sustainability respect to
the current manufacturing paradigm. A bibliometric analysis
was developed to reduce the whole number of papers with
some relevance concerning sustainability, OAP, and CE.
More than 100 works were revised and filtered to achieve a
selected group of articles. As a result of the literature review
an analysis, research opportunities were identified and cate-
gorized as well as a summary of fundamental strategies con-
sidered by authors to enhance sustainability was developed,
highlighting the lack of research considering the attributes
related to OAP and CE. In addition, several future trends
expected were identified from the perspective of review
papers analysed. In this work, several relevant gaps were
identified concerning the applicability of existing methods:
(a) The development of design methods focused on facili-
tate the reuse, remanufacturing and recycling of prod-
ucts and components. Existing methods are focused on
the decision-making for an optimum EOL scenario and
in the easy disassembly of products.
(b) The methodologies proposed in the existing literature
are based on single or isolated products; however, it
is necessary to analyse product families developed
through modular product platforms. The concept of
reconfiguration is not associated with the upgrading
strategy proposed in the CE model.
(c) The concept of sustainability is not formally integrated
into the manufacturing paradigm and the CE strategies.
The methods must include and consider the influence of
the customer in the design and manufacturing process;
the modularization of product platforms is an important
attribute to reduce the materials and energy consump-
tion to develop product families.
The analysis of the literature reveals trends and opportu-
nities for future works. Accordingly, it is possible to remark
the following topics:
(a) Generate design methods involving OAP conception
and the CE model. The design must include the plan-
ning of useful life of all components and the possi-
bilities of reuse, remanufacture and recycling of them.
In this paper, several relevant relationships between
389
OAP and CE were identified and remarked, such rela-
tionships offer future research opportunities for the
improvement of the sustainability performance of prod-
ucts.
(b) Consolidate relationships among companies to create
supply chains based on the waste and emissions gener-
ated during the lifecycle of the product as opportunity
of adding value and close different lifecycles.
(c) Integrate social and economic strategies to guarantee a
successful implementation of design methods focused
on CE. The existing challenges regarding social and
economic fields are strongly related to cultural and edu-
cational aspects that depend on the national education
policy.
Acknowledgements This work was supported by COLCIENCIAS
through the Ph.D. National Scholarship Program No 617-2. Contract
UN-OJ-2014-24072.
Compliance with ethical standards
Conflict of interest On behalf of all authors, the corresponding author
states that there is not conflict of interest.
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54. Martinez, M., & Xue, D. (2017). A modular design approach for
modeling and optimiation of adaptable products considering the Heriberto Maury Professor of
whole product utilization spans. Journal of Mechanical Engineer- Mechanical Engineering at Uni-
ing Science, 232(7), 1146–1164. pp. 1–19. versidad del Norte, Barranquilla
55. Amaya, J., Lelah, A., & Zwolinski, P. (2014). Design for intensi- Colombia. Received his B.S in
fied use in product–service systems using lifecycle analysis. Jour- Mechanical Engineering from
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tiple loops life cycle design approach for the circular economy. from Universidad Politécnica de
The Design Journal, 20(sup1), S1620–S1635. Cataluña, Spain. Dr. Maury’s
research is focused on the areas
Publisher’s Note Springer Nature remains neutral with regard to of product design, concurrent
jurisdictional claims in published maps and institutional affiliations. engineering, material handling
systems, sustainability, recon-
figuration, and modular design.
Jaime A. Mesa Associate Profes-
sor at Universidad Tecnológica
de Bolivar, Cartagena, Colom-
bia. Received his B.S in Mechan-
ical Engineering from Universi-
dad Pontificia Bolivariana,
Montería, Colombia and his
MSc. and Ph.D. in Mechanical
Engineering from Universidad
del Norte, Barranquilla, Colom-
bia. His research interests
include sustainable design,
design methods, circular econ-
omy, modular design and

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