INTEGRATED LIFE CYCLE-BASED OPTIMIZATION OF PRODUCT DESIGN AND MANUFACTURING FOR ENHANCED SUSTAINABILITY

This study examines the role of life cycle costing (LCC) and sustainability factors in enhancing the sustainable product life cycle of manufacturing firms, with a particular focus on Tata Motors Ltd. LCC is recognized as a comprehensive economic assessment method that considers the total cost of a product from conceptualization to disposal, integrating environmental, social, and economic perspectives. Using a mixed-method approach, the study employed thematic analysis of over 900 pages of Tata Motors' sustainability reports and surveyed 140 employees across various departments and managerial levels. NVIVO software was used for text mining and word cloud development to identify high-frequency sustainability-related keywords and themes. Results reveal that environmental factors such as energy efficiency, material optimization, waste reduction, water conservation, and emissions control were dominant themes, alongside social and economic dimensions. The findings highlight that sustainable manufacturing practices, resource efficiency, and stakeholder engagement significantly contribute to extending product life cycles and reducing overall life cycle costs. The research provides valuable insights into integrating sustainability into the manufacturing process, thereby supporting strategic decision-making for sustainable industrial growth.