This study presents the result of a part count number reduction in the existing product design by using Design for Manufacturing Assembly (DFMA) method and conduct Life Cycle Analysis (LCA) into the process of product design to achieve the sustainability using Solid Work Sustainability. Thus, the use of finite element analysis is conducted to support the sustainability consideration towards product resilience. By applying DFMA, the production cost of manufacturing and assembly is reduced from 196.86s to 69.84s as well as improving the efficiency of the product by 5.2%. The result of LCA analysis shows that average of the overall effect of weight reduction by 20%, carbon footprint reduce 39.3%, water eutrophication decrease 39.5%, air acidification minimise by 39.9% and 29.3% of total energy consumed respectively. DFMA method provides a systematic procedure to analyse a product to improve product reliability and cost of assembly and manufacturing. The sustainability approach in the product design process helps to improve the sustainability aspects of a product.
