Design-integrated obsolescence diagnostics for sustainable manufacturing: a multi-dimensional evaluation framework

Proactive obsolescence management from early design stages is critical to extending product lifecycles, reducing waste, and enhancing manufacturing system performance. This study introduces the Multi-Obsolescence Diagnostic Tool (MODT), a structured and scalable methodology for evaluating a product’s susceptibility to six types of obsolescence: technological, functional, psychological, economic, planned, and diminishing manufacturing sources and material shortages. MODT operates at both the product and component levels, using design attributes scoring and impact weighting to quantify obsolescence potential. A case study using an electromechanical drill demonstrates the tool’s feasibility and reveals key design aspects such as reparability and material availability that drive several types of obsolescence. Beyond supporting sustainable product development, the tool contributes to manufacturing system design and decision-making by enabling early interventions in material selection, modularity, and supply chain strategies. MODT also supports after-sales service planning, cost management, and spare part provisioning. Its structured format allows for integration with Computer-Aided Design and Product Lifecycle Management environments, enabling broader industrial applications. Results validate the tool’s relevance in minimizing product lifecycle disruptions, improving component-level robustness, and informing redesign efforts. MODT offers a practical and adaptable approach for manufacturers, designers, and engineers aiming to enhance durability and align product development with circular economy principles and strategic obsolescence management.