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In the past decades, the German paper industry has been increasing the sustainability of paper production by continuously using more recovered paper. Today, recovered paper is an essential secondary raw material to produce new paper. Nevertheless, around 20 % of the paper produced in Germany is still not returned to the recovered paper stream and instead is mostly thermally used. To further increase the use of fibers from recovered paper as secondary raw material and thus, to reduce primary energy consumption and greenhouse gas emissions, new approaches to recycle recovered paper from mixed waste streams are needed. In the research project "Energy savings in paper production by opening up the value chains of recovered paper from lightweight packaging, residual waste and commercial waste" (EnEWA), a treatment process is developed to recover and recycle recovered paper from the mentioned waste streams. The advanced mechanical process to be newly developed consists of dry-mechanical sorting, the manufacturing of economically usable secondary raw materials (defibration), their wet-mechanical dissolution, separation and hygienization and finally their reuse in paper production. This enables the exploitation of new waste streams in material recycling and thus contributes to reduced energy consumption as well as CO2 emissions within the circular economy. Initial material characterization analyses show that on the one hand the quality of the paper discarded in mixed waste streams is sufficient to be used as secondary raw material and that on the other hand up to 50 % of the paper discarded could have been disposed of within the separate paper collection. The results are incorporated in the development of a sorting process for pre-concentrates, which serves as input material for the treatment process to recover paper fibers. In further steps, the results generated will be integrated, for instance, into the future development of the minimum standard for packaging recycling. [ABSTRACT FROM AUTHOR]

The dissemination of emerging electronic devices increases considerably alongside with the Internet of Things (IoT) paradigm. Some key elements considered in these devices (e.g. rare-earth) are becoming critical materials and are associated with serious environmental concerns. Therefore, there is a major requirement for designing differently our electronic technologies at the early stages of the research process. Many reports present the promising properties of paper-based electronics as meant to address this challenge. Through technical and life cycle assessments, this article discusses the main design levers in terms of material and fabrication process choices for the eco-design of paper-electronics water quality sensors. Our results suggest conscientious choices of conductive nanomaterials and additive fabrication techniques. [ABSTRACT FROM AUTHOR]

In Paper and Pulp (P&P) industry resource management scenarios, such as processing cell(s) efficiency reduction, equipment break-down or failures, alternative energy source (biomass and solar energy) utilization/ synchronization with regular energy sources and management decided change in production rate or product quality often occur in industrial processes causing material flow disruption, energy and production losses. In such scenarios, immediate and appropriate actions are required to be taken to minimize energy and production losses. Emerging resource management options tackle these issues through four different ways i.e., by mixing of readymade pulp at various processing stages, by varying the percentage of input raw material, by adopting a parallel utilization of alternative energy sources and by switching on/off some processing units or parallel working segments. These ways are implementable with immediate effect, accurately monitorable and their degree of application can be regulated within a wide range, thus denoted as adaptive solutions. This research work proposes a discrete-event simulation based real-time resource management technique for paper and pulp industry, wherein some resource management challenges are addressed and solved strategically with adaptive solutions. The presented examples validate that using the developed approach, the effective adaptive strategy can be timely planned to resolve occasionally or permanently happening resource management challenges ensuring an un-interrupted material flow throughout the plant along with the minimization of productivity and energy losses. [ABSTRACT FROM AUTHOR]

It is critical for manufacturers to identify quality issues in production and prevent defective products being delivered to customers. We investigate the use of deep neural networks to perform automatic quality inspections based on image processing to eliminate the current manual inspection. A deep neural network was implemented in a real-world industrial case study, and its ability to detect quality problems was evaluated and analyzed. The results show that the network has an accuracy of 94.5%, which is considered good in comparison to the 70–80% accuracy of a trained human inspector. [ABSTRACT FROM AUTHOR]

Small companies encounter difficulties to adapt to new markets with a sustainable perspective. The subject of this article is a paper transformation company which has been eager to develop the organic farming market by developing a new plant support. Alternatives made from plant fibres or plastics exist, such as jute and polypropylene. The main difficulty of this project was to ecodesign a paper product with a multicriteria approach. The factors considered have been divided into two categories. Firstly, the environmental impacts calculated according to the Life Cycle Assessment methodology (on raw material extraction, manufacturing and end-of-life) are summarised. Secondly, the characteristics of the product are discussed in regards to these results and sustainability questions as part of the interpretation phase. Finally, ways of improvement of the LCA methodology to improve the study in terms of geographical representativeness and societal considerations are discussed. [ABSTRACT FROM AUTHOR]

Life Cycle Assessment (LCA) has been used to evaluate the life-cycle Greenhouse Gas (GHG) emissions of pulp and paper production, and most previous studies rely on process-based models for specific product types (e.g., printing paper), industry-average data, or information from a few mills. In this work, a data-mining approach is used to quantify GHG emissions intensities of different paper products manufactured by the U.S. mills. Facility-level emission data collected from publically available governmental databases and mill-level production data collected from the private sector were integrated to track the GHG emissions for different product lines and paper products in mills (in total, 165 mills were matched and analyzed). The results highlight the ranges of GHG emissions intensities by different product groups and categories, and can be used as a transparent data source for LCA practitioners, policymakers, and the pulp and paper industry to perform further analysis on carbon accounting and strategic planning for GHG mitigation. [ABSTRACT FROM AUTHOR]

Abstract To improve energy efficiency of a Paper & Pulp industry, full capacity utilization of the processing equipment and diverse energy source utilities are promoted, while same time processing of diverse raw materials, meeting of strict processing time requirements, seamless material flow and obtaining required product quality are important concerns to be fulfilled. This is similar to a resources management problem while energy is considered as one of the measurable resources, wherein estimation of energy consumptions is crucial/complicated aspect. Discretized form of energy consumption (approximate energy consumed by unit amount of intermediate products at different intermediate processing stages) concept is utilized here with discrete event simulation for consumed energy estimation/analysis. The research deals with a real time working Paper & Pulp industry resource management problem, wherein overall energy consumption rate and production rate were analyzed for some commonly occurring situation of efficiency reduction of the processing station(s). Energy efficient solutions are evaluated with varying production flow (varying the percentage of raw material) and resources management options (turning on/off paper machines). Energy efficient solution which ensures minimum loss in production rate and minimizes disturbances in material flow is suggested for implementation. [ABSTRACT FROM AUTHOR]

Reducing “energy waste” has helped manufacturing companies to systematically improve their productivity. However, optimization goals related to the resource energy (energy efficiency, demand side management, integration of renewables) are still addressed in an isolated manner. Here we present a stepwise methodology on how to unite the different facets of energy usage in a factory planning process. Our results indicate that addressing the energy related planning goals in an integrated manner helps to reduce both life cycle costs and the environmental impact of factories. Future research will refine the presented planning framework and quantify the correlation between conventional and energy related planning targets. [ABSTRACT FROM AUTHOR]

The power of the rotating transverse paper cutting machine is huge because of unreasonable motion. The paper researched the motion mechanism of the structure, transformed the 3D trajectory of rotating blade and paper cutting marks into the same plane space. Ultimately the motion mechanism of the parameters of cutter and paper cutting are established and the reasonable cutting conditions are founded. At last the parameters are optimized according to the relationship of the planning and useless power consumption, achieve the goal of the roller rotate smoothly and the useless power consumption is zero in theory. [ABSTRACT FROM AUTHOR]

The functional performance of mechanical components depends on their surface characteristics, surface integrity and geometric accuracy. It is critical to understand the influence of these surface properties on product performance, so the manufacturing processes can be designed to deliver the required performance. This paper presents the influence of surface characteristics on functional performance including surface topography, surface 2D/3D parameters, tribological parameters and residual stresses. It then discusses the surface properties created by various finishing methods such as hard turning, grinding, superfinishing, mass finishing, etc. Finally, it provides guidelines for the design and selection of finishing processes in order to yield the critical product performance characteristics. [ABSTRACT FROM AUTHOR]

In this paper a new process to manufacture unidirectional reinforcements for eco-composite materials, made of natural fibers, is presented. Starting with flax rovings of different sizes, an apparatus was developed to feed and align the rovings over the wet-end section of a paper machine. The short kraft paper fibers are therefore mixed with the long flax roving as the machine is running, and at the end of the process, a sheet of the hybrid dry reinforcement is obtained and cut to size for impregnation with various resins, using different processes. This novel manufacturing process allows for high volume production of reinforcement. It is very flexible, and many different combinations of long and short fibers can be exploited for the production of a vast variety of dry reinforcements. In this paper, composite samples are obtained out of these reinforcements, using the resin infusion (RI) molding process with a commercial epoxy resin. The results are compared with those of usual glass fiber reinforcement. An interesting aspect is that the large variability, typical for natural fibers, is largely reduced when the short kraft fibers are present in the composite. In terms of permeability to resin, reasonably comparable values can be obtained compared to that of glass fabrics, if a low surface density of reinforcement is chosen. [ABSTRACT FROM AUTHOR]

This paper investigates a Life Cycle Assessment (LCA) based methodology to determine baseline emissions for an aerospace manufacturer. Aerospace manufacturing entails high complexity and low throughput of a vast array of components. Rather than establishing the environmental footprint through waste, electric, and gas data alone; an LCA cradle-to-gate approach extends to a product's raw material acquisition and shipment to provide a comprehensive set of environmental performance indicators. The approach combines several products that follow a similar manufacturing process and can be denoted as a product family. This paper discusses the ability that LCA product families must develop baseline emissions for products validated with a case study of an aerospace component. The methodology can be extended to other product families manufactured within the facility which when combined will accumulate to a site-wide environmental footprint. The paper further evaluates how this methodology can identify environmental hotspots at a process and product level. The aerospace component case study incorporates several manual and automated stages. This work aims to demonstrate the ease of determining baseline emissions using an LCA product family and enable aerospace manufacturing companies to adopt a similar approach to establishing environmental hotspots. This can drive strategic internal change for sustainable manufacturing aligning with company environmental, social, and financial frameworks. [ABSTRACT FROM AUTHOR]

In the recent decades, sustainability has emerged as a crucial concern for governments and industries worldwide. While the political sphere appears to take the lead in the pursuit of a greener world from a societal standpoint, industries play a pivotal role in implementing innovative technologies. Certain industries, however, still heavily rely on natural gas consumption for their operations. Metal manufacturers, in particular, face significant energy demands due to their melting processes, which have historically necessitated the use of combustion. This paper focuses on examining the current workflow of secondary aluminum manufacturing, with a specific emphasis on rolled sheet production. By analyzing combustion intensive equipment involved in the process, the paper identifies inherent deficiencies and energy losses throughout the production process and propose strategies that can effectively reduce the industry's global carbon footprint. Results show that optimizing work flow to retain embodied energy and heat of intermediate products, as well as smart waste heat reuse can result in significant savings in secondary aluminum manufacturing. [ABSTRACT FROM AUTHOR]

Sustainable development should meet the needs of the present without compromising future generation needs. While political and standards approaches insist on regulatory directives, this paper proposes a quasi-satisficing methodology considering the sustainability topic within a larger encompassing framework. Starting from three reflections originated by the classical thermodynamics, the effect of knowledge accumulation on the Production Possibility Frontier (PPF), and a model for the human wellbeing in manufacturing ecosystem, this paper proposes a new production model and a heuristic approach to drive the decision process towards sustainable manufacturing. [ABSTRACT FROM AUTHOR]

To implement environmentally sustainable, resource-efficient manufacturing, the quantification of the environmental impacts is a central task. This task requires suitable methods. Various lifecycle phases, including remanufacturing concepts, and the associated increasing complexity demand a change from static to dynamic assessment methods. Flexible changes must be considered. Thereby, data quality has a major impact on the subsequent assessment results. Though the available data amount in a manufacturing environment is constantly increasing, the influence of data quality on the respective method – and thus, the reliability of the results – remains a key issue. To address this problem, this paper investigates the necessary developments regarding data quality for environmental assessment methods in dynamically changing manufacturing settings. First, relevant data quality dimensions are identified. Subsequently, a cross-comparison of data quality dimensions and different approaches of environmental evaluation in manufacturing is developed. The necessary changes to data quality requirements in operational environmental assessments are derived. Finally, a concept for the improvement of data quality in dynamic assessments is proposed and discussed based on the use case of battery modules' remanufacturing. This paper contributes to the development of environmental assessment methods that are evolving from static, historical data-based evaluations to dynamic assessment tools of flexible productions. [ABSTRACT FROM AUTHOR]

Over the last years two factors have deeply affected research in Manufacturing: the growing interest around Additive Manufacturing (AM) processes and the need to reduce the anthropogenic environmental impact. As result, a large papers concerning the environmental impact performance of AM compared to conventional processes have been published. Specifically, very complex models accounting for the impact of each life cycle stage of AMed components have been released. Results revealed that AM, at present, guarantees energy savings only within some domains, and the potential saving depends on several factors: product complexity, eco-properties of the material, energy intensity of the material deposition, light-weighting enabled by AM approaches and extent of the use phase. Above all, the result of the comparative analysis depends both on the considered factors and on the selected system boundaries. The already proposed models are very complex and many inventory data are needed, this could make them unapplicable at industrial level. In the presented paper, simplified models are proposed and the performances of these are quantified with varying the analyzed scenario (considered factors and selected system boundary). Results revealed that, for given scenarios, simplified models characterized by low computational effort, can provide reliable results. Guidelines for the implementation of different models with varying the system boundary are provided for the cumulative energy comparison of Electron Beam Melting and conventional turning for the production of titanium alloys components. [ABSTRACT FROM AUTHOR]

The global discourse surrounding plastics has been marked by a profound perceptual schism, also for plastic packaging in the fresh food industry. The public opinion expresses mounting concerns in terms of such plastic packaging solutions. However, in many cases the unique material properties and the well-established methodology of Life Cycle Assessment (LCA) actually demonstrate the environmental advantage of plastics for food packaging. This paper delves into the chasm between the two perspectives, leveraging empirical evidence to resolve the divide. While performing both a consumer analysis and LCA, this paper underscores the potential for innovative, yet practical design solutions to harmonise the public opinion with counterintuitive positive environmental impacts. A transformative design solution that centres around the concept of shape and material renewal is proposed. It demonstrates how a simple, yet effective redesign can enhance both the environmental impact and consumer acceptance in the industry for mass-produced fresh food packaging. It emphasises the role of LCE in design, with a focus on the pre-consumer phase. The findings provide a practical approach, emphasising the need to reconcile theory with consumer desires, to forge a sustainable path forward in packaging design. [ABSTRACT FROM AUTHOR]

This paper discusses the first development of the industrial PhD project research project sponsored by Simonelli Group at Politecnico di Milano, aimed to develop and patent a heating system technology that enhances the energy efficiency of professional coffee machines. This paper crosses the issue of the sustainable design of products through a qualitative life cycle assessment on three professional coffee machines of Simonelli Group. The LCA analysis considers the manufacturing, use, and disposal phases. The analysis was performed using the Simapro software that integrates the Ecoinvent3 database. The life cycle impact assessment is carried out in accordance with other case studies in the literature, relying on the parameter "GWP" in accordance with the IPCC method. Laboratory tests are used to assess the kWh of energy consumed during the use phase of professional coffee machines. Following that," use phase scenarios" were created for the life cycle impact assessment, based on existing scenarios in the literature, and elaborated with the company's marketing support. The findings indicate that the most critical environmental phase is the use phase and that the heating elements are the most energy-consuming items in professional coffee machines. Click here and insert your abstract text. [ABSTRACT FROM AUTHOR]

Industrial technologies have evolved towards circular-oriented manufacturing. New approaches in the management of production systems are needed to guarantee the success of such a circular approach. This paper identifies three research questions related to the complexities of decision-making within CEs and defines the concept of Green Gateways in the circular economy. A Green Gateway is a type of decision that supports to realizing the full potential of products and materials. Indeed, the potential value of products and materials must be assessed and leveraged and the concept of Green Gateway will be useful to identify common decisions and to define a common framework in the future. The integration of digital information and digital twins of products, processes, and circular value and supply chains emerges as a key factor in guiding decision-makers effectively, especially for Green Gateways where adequate information, tools and methods must be used to manage value retention options, product flows, production and pricing decisions jointly with the multiple objectives of profitability and sustainability. Additionally, this paper explores specific examples of circular economy use cases, drawing attention to their similarities and highlighting key insights. [ABSTRACT FROM AUTHOR]

Current challenges such as climate change, the limits of natural resources, and increasing customer-specific sustainability demands require a transformation of value creation. The aim is to move from global sourcing to more local value creation by creating synergistic energy and circular material flows and making better use of capacities while taking urban structures into account. This paper discusses an approach of Smart Glocal Production that combines spatially networked production in global enterprise networks. Based on a literature review, examples of Smart Glocal Production in Germany and Austria are presented. The core of the paper is a novel assessment approach for manufacturing companies to determine their readiness level for glocal production. On this basis, smart measures can be derived with special consideration of digitization initiatives to support manufacturing companies on their way to a more sustainable value creation in industrial areas. [ABSTRACT FROM AUTHOR]

The upscaling of technology encompasses many facets a designer concerned with reducing environmental impacts must manage. Therefore, previous research proposed an environmental assessment for upscaling (EAU) methodology. This method hinges on Life Cycle Assessment (LCA) approaches (e.g., prospective, absolute) and coordinates the environmental modelling from an ecodesign perspective. The originality of this paper is to present an illustrative application on photovoltaic systems. The focus is on the modelling practices (step 3 of the method) using upscaling design levers and generating parametrized scenarios meant to be interpretable for a design team. Examples of data collection and upscaling modelling are provided for the upscaling of silicon-based photovoltaic technology in France from 2021 to 2050. This case study shows that integrating upscaling parameters, such as industrial process evolutions, the technology deployment strategy, and the socio-technical context associated with the technology upscaling phenomenon influence LCA results significantly. The paper, therefore, discusses recommendations for design teams to support them in assessing the environmental implications of their technology choices. [ABSTRACT FROM AUTHOR]

With Industry 5.0 on the horizon, research and innovation is prioritising the transition to sustainable, human-centred and resilient manufacturing. In this context, Zero Defect Manufacturing (ZDM) strategies combine tools, resources and rules with the aim of avoiding defects and increasing the sustainable performance of complex manufacturing systems. Five distinct strategies for ZDM have been identified in the literature: (I) detection, (II) prediction, (III) prevention, (IV) repair, and (V) mitigation or compensation. The main motivation of this paper is to discuss an extension of these five existing dimensions by three more, which will enable the transformation of classical ZDM towards a more sustainable production. The main objective of this paper is to conduct a systematic literature review that covers the state of the art of ZDM and highlights the need to add the three (Zero3) dimensions: i) Zero Resource Loss (resource and emission improvement) ii) Zero Human Potential Loss (productivity and stability improvement) iii) Zero Data Gap (increase in efficiency of data use). [ABSTRACT FROM AUTHOR]

The problem of effectively managing Configuration Lifecycle Management (CLM) processes for customizable products in the manufacturing industry presents challenges in striking the right balance between product customization and standardization, particularly for complex products like wind turbines. This paper addresses this issue through a comprehensive analysis and enhancement of CLM processes in a case company that manufactures, install, and service energy solutions focusing on wind turbines. This paper addresses the challenges in CLM processes through a comprehensive analysis and enhancement within a case company specializing in the manufacturing, installation, and servicing of energy solutions, with a specific emphasis on wind turbines. Specifically, within the CLM framework, the study delves into the Input Signal Management (ISM) process, addressing challenges associated with handling specific requirements, features, or functionalities that customers or stakeholders want in the product. The study maps the current state of the processes, identifies weaknesses, and proposes two suggestions to enhance the so-called Input Signal Management (ISM) process. The ISMs are the specific requirements, features, or functionalities that customers or stakeholders want to be included in the product. The challenge in the ISM process lies in handling a large number of requests, ensuring consistency, avoiding conflicts, and making timely decisions. Hence, the paper proposes two key enhancements to the process: the development of guidelines for data creation and categorization of ISM requests, and the prototyping of a Natural Language Processing (NLP)-based system for expedited request assessment. The paper emphasizes the significance of optimizing CLM processes for effective configuration management. Incorporating data-driven methods, the ISM process can become agile, efficient, and customer-centric, leading to better management of customization, reduced response times, and increased customer satisfaction. [ABSTRACT FROM AUTHOR]

The push to decarbonize has spurred the demand for clean energy technologies such as electric vehicles (EVs) and wind turbines (WTs). These technologies rely on rare earth permanent magnets (REPMs), namely Neodymium-Iron-Boron (NdFeB) magnets that in turn rely on rare earth elements (REEs), including Neodymium (Nd), and Dysprosium (Dy). As the demand for clean energy technologies increases, so will the demand for Nd and Dy-containing REPMs. Both Nd and Dy are critical elements that are prone to supply chain risks. As our reliance on them increases, it becomes essential to anticipate future market dynamics for these elements. This paper aims to address the current gap in the literature in the context of forecasting future Nd and Dy demand quantities. The Bass Diffusion Model is a widely used approach to forecast the adoption of new products or technologies and, to predict demand trends. Over the years, the model has found applicability in a wide variety of sectors including consumer durables, medical services, and agricultural innovations. This paper demonstrates the use of the Bass Diffusion Model to estimate future global Nd and Dy demands, enabling a better understanding of swiftly evolving clean energy technology and REPM-related market dynamics. [ABSTRACT FROM AUTHOR]

The increasing market share of electric vehicles leads to a growing demand for raw materials such as lithium and cobalt, where the supply situation is fraught with risk. Product-specific challenges regarding high voltage, product state/variance, and labor shortage require flexible automated non-/ semi-/ destructive disassembly. However, there is a need to implement industrial, scalable automation approaches to deal with this problem. This paper addresses the development of a flexible robotic cell for the fully automated disassembly of battery modules from battery systems. The paper presents all required tools and processes for battery diagnoses, machine learning-based object recognition, loosening and removing fasteners, opening sealings, gripping components, separating cables and plugs, and removing the battery modules. Based on this, a sorted disposal/recycling of the material can be realized. Finally, the holistic robot cell, including a safety concept, is described using the example of an actual disassembly process. [ABSTRACT FROM AUTHOR]

Since the machining of complex aerospace components, like integral compressor-rotors (blade integrated disks), is very cost-intensive, optimizing the process by means of process simulations is an active field of research. With the rise of Quantum Computing, a new instrument with high optimization potential is moving into focus. In this paper, a possible application of Quantum Computing for the machining simulation of multiaxis milling of thin-walled aerospace components is discussed. For this reason, a simulation framework used for the milling simulation is analyzed and each component is evaluated separately in relation to Quantum Computing. Parts of the Harrow, Hassidim, and Lloyd algorithm are proposed to enhance the Finite-Element simulation-based component, like the modal analysis for dynamics simulation. This algorithm can solve linear system problems with exponential speed-up over the classical method. The paper presents a roadmap on how the classical steps of a modal analysis for dynamics simulation could be replaced by quantum algorithms based on quantum phase estimation. The implementation of the first working steps is presented to validate this approach. The linear system problem, arising from the dynamics simulation, is analyzed in detail and a minimal value problem of linear coupled oscillators is derived. [ABSTRACT FROM AUTHOR]

By integrating data-driven analysis methods into existing procedures, quality and failure management performance can be increased systematically. Linking product and process data with existing failure and quality knowledge offers significant potential for enhancing the continuous improvement of processes and products. Nevertheless, the potential of data-driven analysis still needs to be fully exploited. Despite the apparent advantages of analysis-oriented approaches, many companies are hesitant to implement such transformation projects because quantifying possible benefits is challenging. Thus, there is an economic risk due to the limited availability of resources, which must be utilized purposefully. An approach that allows the systematic identification and prioritization of promising use cases and reduces the risk of introducing data-based approaches is missing. This paper conceptualizes a model to evaluate the potential for introducing data-based analysis in production processes. A maturity assessment, consisting of four dimensions and seventeen sub-dimensions, is presented, which enables the identification of promising use cases for implementing data-based approaches. The conceptualized model is validated using an expert survey. [ABSTRACT FROM AUTHOR]

Strategic planning of industrial systems has become increasingly challenging for decision makers at different production levels, due to everal aspects, such as global competition, market uncertainty and volatility, and changing regulations. These evolving aspects often lead to unplanned and high-effort reconfigurations of systems. Additionally, high-paced innovation in industrial technologies and the diffusion of software, data analytics, and big data technologies in industrial systems, while potentially supporting ever smarter, safer, and greener decisions, also challenge decision makers, as often multi-disciplinary knowledge is required to successfully plan and operate increasingly complex systems. Existing literature provides little guidance on how strategic planning of industrial systems is expected to evolve in order to fully exploit advanced industrial technologies to responsively and cost effectively respond to global challenges. To fill this gap, this paper reviews existing literature on industrial systems' planning and reconfigurability and derivesmulti-sectorial requirements. Based on the findings, a life cycle conceptualmodel for strategic planning of reconfigurable industrial systems and value chains is provided. Moreover, the concepts of hierarchical interfaces, functional interfaces, and reconfigurability bottleneck are introduced and directions for future research are accordingly outlined. [ABSTRACT FROM AUTHOR]

The increase in global material demands while having finite natural reserves has made the transition from a linear to a Circular Economy (CE) more crucial. Various approaches have been proposed for such a transition, which closed-loop system is an approach aiming to maximize resource efficiency ensuring that materials are continually reused and recycled, thereby reducing waste and conserving resources. However, there are some obstacles/gaps in the implementation of CE practices, one of them is the lack of a proper Circularity assessment unit, as called Circularity Indicators (CIs). The CIs play a crucial role by enabling to quantify the success of circularity strategies. This paper critically reviews the existing CIs and introduces a novel scoring system that evaluates them against five main circularity categories. This scoring system allows for assessing CI's alignment with core CE principles. Our findings reveal that some CIs demonstrate broad applicability and robustness, while others have more narrowed focuses. This dementated the need for a unified CI that is versatile, comprehensive and integrates various 'R' strategies with the triple bottom line model of sustainability. This scoring system can be used in policy making and business strategy decisions to embed CE in new developments such that support sustainable development. [ABSTRACT FROM AUTHOR]

Several factors are influencing the spread of Electric Vehicles (EVs) in the automotive market. However, while battery-electric vehicles emit no tailpipe emissions, the manufacturing phase, particularly the manufacturing of the battery packs, can have significant environmental impacts. In addition, as the EV market expands, there will be a significant increase in demand for critical materials used in lithium-ion batteries, such as lithium, cobalt, and nickel. These materials are essential for producing high-performance batteries, and their global demand is expected to rise rapidly to meet the demands of the expanding market. This paper investigates the main challenges that need to be tackled to reach a sustainable path in the battery industry. A cradle-to-gate boundary is set to focus on raw material extraction, production of precursors, cell and module production, and battery pack assembly. In addition, because 7.8 million tons of EV batteries per year are expected to reach the end-of-life phase by 2040, a brief overview of the recycling issue is provided to investigate the potential usage of recycled material in the early stages of battery production. [ABSTRACT FROM AUTHOR]

The industrial transition towards sustainable production systems is a fundamental step for companies to achieve environmental, social and economic goals. This transition includes implementing sustainable practices across the entire value chain, by which sustainability management can quickly become data intensive and increasingly complex. The integration of digital solutions into sustainability management can massively increase the efficiency of data collection and aggregation, prevent errors and data inconsistencies, besides further supporting industrial decision-making based on sustainability data evaluation. This paper presents a case study with a manufacturing company in the German state of Baden-Württemberg, in which its sustainability management system is evaluated and screened for digital optimization opportunities. The development and creation of a digital solution concept is comprised of the initial assessment through a detailed requirement analysis, then a systematically determination of an information system architecture that fulfills all requirements and can be implemented to improve the sustainability performance of the company. This developed approach assists the company to reach environmental reporting obligations through the continuous evaluation of internal sustainability KPIs. The insights gained and the developed concept can further support other companies in making their sustainability management more efficient and transparent through digitalization. [ABSTRACT FROM AUTHOR]

A sustainable supplier selection problem can be concisely defined as a classical supplier selection problem that incorporates environmental and social criteria to select and monitor suppliers' performances, creating the sustainable supplier selection and order allocation (SSS&OA) problem. Finding the optimal order allocation to suppliers in the automotive industry is crucial as it can significantly improve the social, environmental, and economic performance of the whole supply chain. Therefore, this research aims to find an optimal order allocation plan for suppliers using an augmented ε-constraint optimization method in the automotive industry while considering all three dimensions of sustainability. Using a previously established comprehensive framework, this paper has adapted the solution approach of an existing bi-objective order allocation model that was used to make sourcing decisions. The results showed a higher total value of sustainable purchasing is achieved by the augmented ε-constraint optimization method compared to the traditional max-min method. [ABSTRACT FROM AUTHOR]

From both economic as well as environmental perspective energy demand is of strong and even more increasing relevance for manufacturing nowadays. But typically energy demand and manufacturing system performance (e.g. output, time demands, quality) are considered separately while actually being inherently connected in technical systems. Against this background, the paper presents a data-based approach to analyze and model those important aspects and interdependencies in an integrated manner. The developed theoretical framework and defined methodology enable deeper understanding of energy related impacts of operative influencing factors and eventually to derive fields of action for improvement. The approach was exemplary applied in an industrial case study. Results underline the feasibility, applicability, and potential benefits of the approach. [ABSTRACT FROM AUTHOR]

Broaching is a machining technique that plays a crucial role in the quality and integrity of manufactured products as it demands superior surface quality and precision compared to other machining methods. Monitoring tool condition is essential, as a damaged tool can significantly affect the quality of the surface finish and integrity of the final part causing irreparable damage to both the part and the work tool. This paper presents the development of a virtual sensor designed for the real-time detection of tool fractures during the broaching process, allowing timely decision-making without generating greater damage to the part or tool. The virtual sensor is created using signals collected from the broaching machine's data, without the need for external sensors; having the potential to improve product quality, increase process efficiency, and reduce material waste as well as production costs by detecting tool fractures early and, therefore, increasing the overall sustainability of the process. [ABSTRACT FROM AUTHOR]

The pursuit of environmental sustainability and resource conservation has underscored the growing significance of the circular economy paradigm across industries. This transformation is particularly pertinent within the automotive industry, necessitating a profound restructuring of the value chain, with a specific focus on end-of-life considerations. Significant potential for circular economy arises from the thorough examination of end-of-life vehicles and processes, involving strategies such as component reuse, material recycling and primary resource reduction. Providing process-, product-, component-, and material-specific information at the end-of-life of automotive vehicles can improve decision-making regarding circular strategies. It also demands for new digital solutions. This paper addresses an integrated approach of data flow analysis and Life Cycle Assessment (LCA) to enable a comprehensive monitoring of the environmental impact of these processes. First, the use case of end-of-life dismantling processes is presented - including pyrotechnics neutralization, vehicle dehydration, disassembly of reuse components as well as vehicle compaction. Secondly, the data demand respective information and material flows is depicted. As a main result, the LCA data flow model specifically tailored to the end-of-life vehicle dismantling processes is described. This model serves as a fundamental basis for analyzing the environmental impact of end-of-life processes combined with the underlying data flow. [ABSTRACT FROM AUTHOR]

The reduction of environmental impacts from the early stages of product and system design is a major challenge. Thus, traditional ecodesign methods are not appropriate because they reason by fixing the functional definition of products/systems and address the complexity of these new systems in a simplistic way, which leads to a marginal reduction of impacts. Moreover, these methods do not consider the attractiveness for users, leading to an optimization oriented towards functional reduction. In this paper, a comprehensive ecodesign approach is presented suggesting a paradigm shift, which involves a hybrid ecodesign approach based on constraint modeling of systems based on the constraint satisfaction problem formalism (CSP) with more traditional environmental assessment methods to decide which design choices to make. This approach was applied to generate and characterize product and life cycle architectures of a serial hybrid vehicle powertrain focusing on the use and end-of-life phase. [ABSTRACT FROM AUTHOR]

Life cycle assessment (LCA) is a well-established approach and benchmark for design for sustainability efforts, in which detailed reports are produced that can serve as decision-making guides for developing new products. However, LCA reports are typically dense and technically complex, making it difficult for many engineering design project stakeholders to appropriately leverage the information found within them. Our work seeks to understand and improve the transfer of knowledge from LCA reports during the early stages of the design process, specifically leveraging the natural language capabilities of large language models (LLMs). In this paper, we investigate how four LCA-and sustainability-centric prompting frameworks can extract relevant design knowledge from LCA reports, demonstrated through a case study where an LLM (ChatGPT) is prompted on a provided electric toothbrush LCA report. Key findings illustrate the prompting frameworks can establish high-level summaries and identify life-cycle specific information, but the development of specific and design-focused sub-prompts will allow for richer understanding. We envision designers can use these proposed frameworks to query an LLM to gain context and insights from relevant LCA reports. The proposed techniques serve as a basis for automatic knowledge extraction from life cycle documents, creating accessible information in a user-friendly manner for designers who look to develop life-cycle-informed products. [ABSTRACT FROM AUTHOR]

The Circular Economy Action Plan is the main building block of the European Green Deal, Europe's new agenda for sustainable growth. Businesses need new technologies, new methods and new industrial organization either to create new businesses or to transform their products, processes and business models. They also need new talents to innovate, create businesses and new jobs, and transform society into a more sustainable one. Circular economy has grown significantly in recent years as a topic taught in engineering curricula. The purpose of this paper is to present the design, implementation and evaluation of a summer school program dedicated to the development, transformation and implementation of circular economy systems and new business models in manufacturing. The program was designed in collaboration with three university partners during a European project and relied on contributions from industrial companies, including start-ups and innovative companies. At the end, some lessons are drawn in order to show the main added value based on the evaluation of this summer school and to identify recommendations for the design and implementation of similar summer schools. [ABSTRACT FROM AUTHOR]

The relevance of digital solutions to enable sustainable value creation, the monitoring and ultimately the reduction of the environmental footprint has increased. New information technologies and increased data availability along a product's lifecycle offer more tools to assess product sustainability than ever before. This paper presents how a Digital Twin needs to be designed to help monitor product-level energy efficiency and how such a Digital Twin can be implemented. State-of-the-art research on Digital Twins and their development, lifecycle assessment, and energy efficiency are introduced. There is a lack of evaluated implementations of methodical DT development in different scenarios, especially for the evaluation of product-level energy efficiency during production. Results of a research project with the focus on the development and implementation of Digital Twins are presented. The use case is set within the scenario of the sequential development of a product simultaneously with the development of the Digital Twin. The focus is put on the implementation of an energy consumption prediction and product carbon footprint analytics module as part of the Digital Twin. The development approach is presented and recommendations for the development of future Digital Twins are derived. [ABSTRACT FROM AUTHOR]

The application of simulation technologies (STs) in the industry 4.0 paradigm can accelerate the implementation of the circular economy (CE) in companies by faster modeling and optimization of value retention processes (VRPs), such as remanufacturing or refurbishment. In business practices, the efficiency of the collection of used products and their recovery for a new or extended lifecycle is influenced by a high level of uncertainty. The product-as-a-service (PaaS) model might change the boundary conditions, which will decisively influence the operational factors such as time for a disassembly, and material recovery rate. The state-of-the-art in commercial simulation software (e.g., FlexSim, Simio, Arena) is based on the object-oriented approach, which requires that users must build the model themselves from a set of objects (object libraries), which is effective for a traditional linear process but is less suitable for multiple flow of a product between PaaS contracts. Remanufacturing in PaaS for consumer markets is currently a niche practice, due to the difficulties of providing its economic viability. Lean management practices are promising in lowering the cost of remanufacturing. The aim of this paper is to develop a new method for simulation modeling using a high-level script language, similar to those used by industry experts, according to lean remanufacturing principles under PaaS conditions. This novel method is built on the user-centric principle. Thus, it enables to build the simulation models and to use them by decision-makers in business practice who are not specialists in simulation modeling and do not have programming competences. The library of reference processes for remanufacturing in PaaS is defined with the industrial partners. [ABSTRACT FROM AUTHOR]

Ensuring precise measurement is critical for manufacturing industries; and a coordinate measuring machine (CMM) is widely used for automated inspection of critical and complex components. But there is a lack of clarity regarding optimal timepoint for CMM probe re-calibration. Too frequent calibrations increase the cost and an uncalibrated CMM probe affects the inspection quality. When to get a CMM probe calibrated is still an open question. It is important to accurately determine the optimal probe re-calibration intervals to mitigate the adverse effects on the quality and the time. This paper presents a novel data-driven approach to predict the optimal timepoint to re-calibrate a CMM probe. The data is collected at various levels to develop, train, and validate the predictive model, which includes numerical and categorical data-frame such as probe usage metrics, probe calibration environmental condition, probe specifications, workpiece data, probe calibrated dimension data and calibration requirement. The research potentially aims to reduce the CMM downtime without compromising the product quality variations that arise from the anomalies/errors related to the probe re-calibration thereby enhancing the inspection efficiency as well as sustainability. [ABSTRACT FROM AUTHOR]

Originating from product life cycle management, more and more Digital Twins (DTs) are implemented in research contexts and industrial use cases. DTs allow for continuous information provision, a mandatory requirement, e.g., for the circular economy. Implementing a DT faces integration challenges and requires precise planning for selecting specific components of a DT and its functionalities. A process model supports making informed decisions, structuring the application and its demand for certain DT elements, and streamlining implementation processes. Albeit specific implementations come with individual requirements, a generic process model allows for the transfer of general instructions and rules to particular cases. Our ongoing research focuses on developing a process model for implementing DTs. The process model builds upon the VDI norm 2206 for implementing cyber-physical systems and enhances the VDI norm by providing more granular sub-modules. This paper reports on the first development steps and preliminary artifacts, e.g., a visual inquiry tool in a DT implementation canvas. Our research builds upon a thorough analysis of theoretical and practical requirements and existing frameworks and architectures for DTs. [ABSTRACT FROM AUTHOR]

Sustainability has emerged as a primary concern across a wide range of industries, particularly in manufacturing due to its energy-intensive nature. To understand the environmental impact of manufacturing processes and make them less detrimental to the environment users monitor and track energy consumption data. Although this approach is valuable in assessing the overall impact, energy consumption mapping needs to be conducted per product to compare and assess different process strategies. Available research in literature, provides unit process energy consumption models in isolation from manufacturing operations, neglect of machine and operational variations, and limited consideration of detailed data acquisition for indirect energy consumption. This paper presents a comprehensive framework designed to address the existing gaps in the literature on energy consumption mapping within the manufacturing industry. The proposed framework provides a solution by offering a structured approach to data collection, analysis, and utilization within manufacturing processes, aiming to achieve two main outcomes: the calculation of embodied energy per unit product and the provision of systematically analysed data for operation management to enhance energy efficiency. Four key steps constitute the framework: data acquisition, simulation and modelling, impact assessment, and operation management. The data acquisition step involves the identification of manufacturing process flows, equipment specifics, and process parameters, emphasizing machine operation requirements and power readings. These elements are systematically logged into a database providing essential information for both embodied energy calculation and simulation purposes. Results obtained from simulations are subjected to analysis in the impact assessment step to assess embodied carbon and overall environmental impacts. The collective findings from the first three steps are then utilized for operation management. [ABSTRACT FROM AUTHOR]

A critical shift is required to meet the challenges reflected in the sustainable development goals. Policymakers in the EU are betting on a transition from a linear to a circular economy to make this happen. Public procurement is vital in this context, e.g., accounting for 20% of Swedish GDP, with circular public procurement being critical to the transition. Until now, the research focus in this area has been narrower, concentrating on, e.g., IT equipment or furniture. However, plastic medical products have not been addressed despite generating substantial environmental impact and offering a tremendous upside. To enable the application of circular economy strategies in this context, changes are required on two ends: the design of the products and the criteria under which the products are procured. Indicators are the central basis of decision-making in any purchasing decision and are considered powerful enablers and drivers of the transition to a circular economy. This paper reviews circular indicators as a starting point toward guidelines for the circular design and procurement of plastic products in the healthcare sector. Based on this, critical factors for developing a comprehensive indicator for the design and procurement of circular plastic medical products are identified. [ABSTRACT FROM AUTHOR]

In the face of substantial environmental impact, energy-intensive industries are compelled to deal with a spectrum of future energy scenarios, including the adoption of electrification and hydrogen use. In addition, these sectors are under pressure to enhance energy efficiency and adaptability to reduce costs. The integrated planning and control of production and energy system components is challenging due to the complexity and lack of available methods, though. This paper addresses this gap, by introducing a simulation-based method that optimizes production and energy system components. The planning method is based on a multicriteria meta-heuristic with an integrated simulation of production and energy system behavior. It evauates different future energy scenarios with electrification and hydrogen use including variable energy markets and storage systems. The method is applied and validated in a case study in an energy-intensive steel production. The results show the significant benefits of the dynamic planning and optimization for various variables in two different heat-treatment process technologies. [ABSTRACT FROM AUTHOR]

To facilitate the shift from a Linear to a Circular Economy, it is essential to alter the manner in which we manufacture, use, and dispose of products. Interoperable information exchange among various stakeholders throughout the product lifecycle is crucial if we wish to encourage reuse, repair, remanufacturing, refurbishing, or recycling. The Digital Product Passport (DPP) is a concept for capturing product information. This paper presents an end-to-end process for sharing product-related information along the product lifecycle explicitly designed to cater to the needs of all stakeholders, including end-of-life actors. This process is based on a DPP concept and implementation called the Digital Lifecycle Passport and a multi-stakeholder platform. Technically, it relies on the Asset Administration Shell (AAS), which enables information to be shared in a structured way. We demonstrate how this process can improve waste sorting and how it can be used for life cycle assessment (LCA). LCA results are captured in an interoperable way based on DIN SPEC 91474, which will facilitate automatic documentation for regulatory purposes in the future. Our approach is a forerunner in the sense that it uses the DPP and the AAS for end-of-life management. [ABSTRACT FROM AUTHOR]

Environmental consciousness is growing amongst companies in the construction industry. Often these companies are performing Life Cycle Assessments (LCA) for their Environmental Product Declarations (EPD) to convey impact data of their products to their customers. The LCA studies also reveal insights regarding the distribution of the impacts within the companies, offering a prime opportunity for sustainable product development. Despite the acquired LCA expertise it appears difficult to capitalize this potential. Therefore, this paper will explore the integration of LCA and EPD data and company expertise into company specific guidelines for sustainable product development. The aim of the case study at Aalberts Integrated Piping Systems, a supplier of valve, connection and fastening technology, was to support decision-making by outlining considerations and simplified LCAs for comparing options during product development. Additionally, a more general framework was developed to assist sustainability managers in other companies in tailoring design guidelines to their contexts. By adopting this framework, LCA data and expertise seamlessly integrate into product development, aligning with the existing product development process for easy adoption within the company. The framework's systematic approach ensures no vital aspects are overlooked. Its adaptability to businesses with varied sustainability knowledge ensures a broad range of potential users. [ABSTRACT FROM AUTHOR]

Laser cleaning technology is a promising technology for selective removal of coatings from substrates to facilitate re-use and recoating. A leading coating of interest for reduced friction and operating forces is Diamond like Carbon (DLC) coating. This paper reports on the energy requirements and associated unit process scope 2 emissions for the DLC laser removal process to facilitate re-use of tooling in a circular economy. This work can assist in providing a greater understanding of the energy requirements and of energy consumption and emissions reduction strategies for the DLC removal process. This is important for the transition to net-zero emissions in manufacturing. [ABSTRACT FROM AUTHOR]

The electrification of transportation has accelerated greatly in recent years with the support of policymakers. However, this transformation raises the crucial question of the sustainability of such a change. In parallel, the concept of Planetary Boundaries has recently emerged as a framework for quantifying the human pressure on the Earth System. A real interest in applying the Life Cycle Assessment methodology in relation with the Planetary Boundary framework is growing to evaluate the absolute sustainability of products or services. In fact, this could be an opportunity to establish sustainable thresholds for each technology that should not be exceeded. This paper aims to develop a methodology for evaluating the absolute sustainability of the deployment of batteries in the context of the electrification of the French private car fleet. Several sharing principles are used for assigning a Share of the Safe Operating Space, and a prospective LCA is conducted based on different de-carbonization pathways. As a result, this work will provide insights into the development of a go/no-go strategy for the ecodesign and the upscaling of the electric batteries in a prospective perspective. [ABSTRACT FROM AUTHOR]

Owing to the unique technological merits of additive manufacturing (AM), design for AM, particularly eco-design for AM, has been gaining attention in improving the sustainable performance of AM-fabricated (AMed) parts. The main challenge in harvesting potential sustainability benefits is how to capture the impact of design on sustainable performance. Though several existing studies adopted quantitative evaluation on AM sustainability and investigated the relationships between design information and sustainability information of AMed part, the sustainability information is still unavailable in the design phase. This hardly guides eco-design for AM in practice. To support the increasing industrial applications of AM, this paper illustrates related knowledge, that is, material-process-structure-ecoProperty (MPSeP) relationships to connect design and sustainability information in eco-design for AM. An ontology-based method is proposed to model the MPSeP relationships of the AMed part in a structured way. An example of an AMed hydraulic valve body was used to demonstrate the MPSeP modeling process. It is discussed that how the constructed model effectively assists AM designers through providing eco-design recommendation, and enables design software tools to perform sustainability analysis towards eco-design for AM. [ABSTRACT FROM AUTHOR]