Session: ASME Undergraduate Student Design Expo

Paper Number: 163724

Sustainable Manufacturing Through Data-Driven Innovation and Human-Centric Design 

The modern manufacturing landscape is undergoing a rapid transformation fueled by the convergence of data-driven technologies and a growing emphasis on human-centric and sustainable practices. This research explores the synergistic potential of these elements, investigating how data-driven innovation can empower smart product design and manufacturing while prioritizing human well-being and environmental responsibility. The motivation behind this work stems from the increasing complexity of products, the growing demand for personalized experiences, and the urgent need to minimize the environmental footprint of manufacturing processes. This research contributes to the advancement of sustainable manufacturing by developing a framework that integrates data analytics, human factors, and sustainability principles into the product lifecycle, from design and development to production and end-of-life management.  

This work employs a multi-faceted methodology combining data analytics, machine learning, human-computer interaction principles, and life cycle assessment (LCA). First, we leverage industrial internet of things (IIoT) devices and sensor networks to collect real-time data from various stages of the manufacturing process, including material flow, energy consumption, and product quality. This data is then processed and analyzed using machine learning algorithms to identify patterns, predict potential issues, and optimize process parameters for improved efficiency and reduced waste. Second, we incorporate human-centric design principles by employing user studies and ergonomic assessments to understand the needs and preferences of both manufacturing workers and end-users. This information is used to design human-machine interfaces (HMIs) that enhance operator comfort, safety, and productivity, while also ensuring that products are intuitive and user-friendly. Third, we integrate LCA methodologies to evaluate the environmental impact of different design and manufacturing choices. This allows us to identify opportunities for minimizing resource consumption, reducing emissions, and promoting circular economy principles.

Preliminary results demonstrate the potential of this integrated approach to achieve significant improvements in manufacturing sustainability. For example, data-driven optimization of process parameters has led to a 15% reduction in energy consumption in a case study involving a metal forming process. Furthermore, the implementation of human-centric design principles has resulted in a 10% increase in operator productivity and a 5% reduction in workplace accidents. LCA results have highlighted the importance of material selection and end-of-life strategies in minimizing the environmental impact of products, guiding the development of more sustainable material choices and recycling processes. We are currently expanding this research to include more complex manufacturing systems and exploring the use of digital twin technology to simulate and optimize entire production lines.  

This research provides a foundation for developing a comprehensive framework for sustainable manufacturing through data-driven innovation and human-centric design. By integrating these elements, manufacturers can achieve significant improvements in efficiency, productivity, and environmental performance, while also ensuring the well-being of their workforce and creating products that are both user-friendly and sustainable. Future work will focus on developing more robust and scalable data analytics tools, exploring the use of artificial intelligence for autonomous manufacturing, and expanding the application of LCA methodologies to encompass the entire product lifecycle. Ultimately, this research aims to contribute to the development of a more sustainable and resilient manufacturing ecosystem.

Presenting Author: Abdul Quadir Motihari College Of Engineering, Motihari

Presenting Author Biography: Abdul Quadir is a dedicated and passionate Mechanical Engineering student at Motihari College of Engineering, Motihari, expected to graduate in 2025. With a strong academic foundation and hands-on experience in the field, Abdul has demonstrated a keen interest in thermodynamics, fluid mechanics, and heat transfer, which are critical areas in mechanical engineering. His academic journey has been marked by consistent performance and a drive to apply theoretical knowledge to practical, real-world problems.

Abdul has gained valuable industry experience through internships at prestigious organizations such as the Oil and Natural Gas Corporation Limited (ONGC) and the National Thermal Power Corporation Limited (NTPC). During his time at ONGC, he worked on performance analysis of turbochargers in diesel engines and efficiency optimization of gas compression systems, ensuring adherence to safety protocols and operational efficiency. At NTPC, he gained insights into power generation systems, turbines, and mechanical maintenance procedures, further solidifying his understanding of industrial operations.

In addition to his academic and professional pursuits, Abdul has actively participated in technical competitions and extracurricular activities. He secured the 3rd position in the Prastuti science model competition at TechFest23, MIT Muzaffarpur, showcasing his innovative thinking and problem-solving skills. He has also been recognized for his oratory and critical thinking skills in debates and has received awards in volleyball, reflecting his well-rounded personality.

Abdul is an active member of the American Society of Mechanical Engineers (ASME) and the Institute for Educational Research and Publication (IERP), where he has contributed to technical workshops, conferences, and research activities. As a campus ambassador for TRYST, IIT Delhi, he has honed his leadership and organizational skills by promoting events and managing social media campaigns.

With a strong foundation in mechanical engineering principles, practical industry experience, and a passion for innovation, Abdul Quadir is poised to make significant contributions to the field of mechanical engineering. His commitment to sustainability and energy efficiency is evident in his project on designing a solar water heater using the thermosyphon principle, which underscores his dedication to creating eco-friendly solutions. Abdul aspires to continue his journey of learning and innovation, contributing to the advancement of mechanical engineering and sustainable technologies.

Authors:

Abdul Quadir Motihari College Of Engineering, Motihari