Integrating DFMA and Sustainability Assessment for Mini-Fan Redesign: A Comparative Case Study

M. F. Rosli; M. S. M. Effendi; M. L. Abd Latif; M. K. Asmawi; Suhaimi Shahrin

doi:10.58915/aset.v5i2.3536

Authors

M. F. Rosli Universiti Malaysia Perlis
M. S. M. Effendi Universiti Malaysia Perlis
M. L. Abd Latif Universiti Malaysia Perlis
M. K. Asmawi Universiti Malaysia Perlis
Suhaimi Shahrin Universiti Malaysia Perlis

DOI:

https://doi.org/10.58915/aset.v5i2.3536

Keywords:

Computer-aided sustainability assessment, Design for manufacturing and assembly, Mini-fan, Product redesign, Sustainable product development

Abstract

The environmental performance of small consumer products can be improved when manufacturability and life-cycle considerations are incorporated before detailed design is fixed. This study integrates Design for Manufacturing and Assembly (DFMA) principles with a screening-level, CAD-based sustainability assessment to compare a baseline mini-fan with a redesigned alternative. The baseline assembly was modelled in SolidWorks 2020, and the main housing, battery casing, and base were modified through geometric simplification and material-volume reduction. Both alternatives were evaluated using identical manufacturing processes and regional settings. The redesign reduced product mass from 99.00 to 88.88 g (10.22%). The software outputs also indicated reductions of 67.16% in carbon footprint, 66.94% in water eutrophication, 67.37% in air acidification, and 67.16% in total energy consumption. The findings demonstrate the value of combining DFMA-informed geometry review with rapid environmental screening to compare alternatives before tooling and prototype production. However, the results are comparative rather than a complete life-cycle assessment because the archived dataset does not report the material database version, transport assumptions, use-phase profile, end-of-life scenario, or uncertainty analysis. The redesign supports resource-efficient product development and contributes to SDG 9 and SDG 12.

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