Simplifying Modular Life Cycle Assessment (LCA) for Metalworking Assembly Lines: A Framework for Efficiency

Abstract

This thesis presents a framework to simplify Life Cycle Assessment (LCA) for modular metalworking assembly lines by integrating parameterization techniques within a customized Excel-based tool. Traditional LCA approaches often face challenges when applied to modular production environments due to the dynamic nature of configurations, component variability, and the complexity of input data management. In response, this study proposes a streamlined, transparent methodology that enables rapid environmental impact evaluations by leveraging weight-based, time-based, and distance-based parameters. The research begins by reviewing key developments in LCA, with particular attention to simplification methods, European Union climate policies, and the evolving role of modularization in manufacturing. The framework design is supported by existing literature and guided by recognized standards and regulations, including ISO 14040 and 14044, Environmental Product Declarations (EPD), and the Product Environmental Footprint (PEF) methodology. A case application is conducted using a hypothetical modular machinery example, allowing the developed Excel tool to be tested for consistency, adaptability, and usability. The tool will provide the users inputs in a drop-down-based structure, demonstrate automated calculations, and visualization sheets will be shared so that emission outputs can be interpreted. Results from two distinct customer orders demonstrate how the framework can capture and compare environmental impacts based on individual module configurations. Additionally, emission insights across modules are explored to identify optimization opportunities, including the use of alternative materials, transport strategies, and energy-saving techniques. The findings support the feasibility of applying modular LCA frameworks in industry, offering flexibility, transparency, and integration potential with ERP or PLM systems. The study concludes by acknowledging current limitations and recommending future development, such as expanding the tool to include full life cycle phases and broader impact categories. This work contributes to a practical, scalable solution for advancing environmental assessments in modern modular manufacturing.