Search results for: remanufacturing.

Authors: Michael R. Johnson, Ian P. McCarthy

Abstract:

There is a growing body of evidence to support the proposition of product take back for remanufacturing particularly within the context of Extended Producer Responsibility (EPR). Remanufacturing however presents challenges unlike that of traditional manufacturing environments due to its high levels of uncertainty which may further distract organizations from considering its potential benefits. This paper presents a novel modeling approach for evaluating the uncertainty of part failures within the remanufacturing process and its impact on economic and environmental performance measures. This paper presents both the theoretical modeling approach and an example of its use in application.

Keywords: Remanufacturing, Demanufacturing, Extended Producer Responsibility, Sustainability, Uncertainty.

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Authors: Tariq Aljuneidi, Akif Asil Bulgak

Abstract:

An efficient remanufacturing network lead to an efficient design of sustainable manufacturing enterprise. In remanufacturing network, products are collected from the customer zone, disassembled and remanufactured at a suitable remanufacturing facility. In this respect, another issue to consider is how the returned product to be remanufactured, in other words, what is the best layout for such facility. In order to achieve a sustainable manufacturing system, Cellular Manufacturing System (CMS) designs are highly recommended, CMSs combine high throughput rates of line layouts with the flexibility offered by functional layouts (job shop). Introducing the CMS while designing a remanufacturing network will benefit the utilization of such a network. This paper presents and analyzes a comprehensive mathematical model for the design of Dynamic Cellular Remanufacturing Systems (DCRSs). In this paper, the proposed model is the first one to date that considers CMS and remanufacturing system simultaneously. The proposed DCRS model considers several manufacturing attributes such as multi period production planning, dynamic system reconfiguration, duplicate machines, machine capacity, available time for workers, worker assignments, and machine procurement, where the demand is totally satisfied from a returned product. A numerical example is presented to illustrate the proposed model.

Keywords: Cellular Manufacturing System, Remanufacturing, Mathematical Programming, Sustainability.

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Authors: Siva Prasad Darla, C. D. Naiju, K. Annamalai, Y. Upendra Sravan

Abstract:

In recent years, environment regulation forcing manufactures to consider recovery activity of end-of- life products and/or return products for refurbishing, recycling, remanufacturing/repair and disposal in supply chain management. In this paper, a mathematical model is formulated for single product production-inventory system considering remanufacturing/reuse of return products and rate of return products follows a demand like function, dependent on purchasing price and acceptance quality level. It is useful in decision making to determine whether to go for remanufacturing or disposal of returned products along with newly produced products to satisfy a stationary demand. In addition, a modified genetic algorithm approach is proposed, inspired by particle swarm optimization method. Numerical analysis of the case study is carried out to validate the model.

Keywords: Genetic Algorithm, Particle Swarm Optimization, Production, Remanufacturing.

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Authors: Achim Kampker, Heiner H. Heimes, Mathias Ordung, Christoph Lienemann, Ansgar Hollah, Nemanja Sarovic

Abstract:

Electric cars with their fast innovation cycles and their disruptive character offer a high degree of freedom regarding innovative design for remanufacturing. Remanufacturing increases not only the resource but also the economic efficiency by a prolonged product life time. The reduced power train wear of electric cars combined with high manufacturing costs for batteries allow new business models and even second life applications. Modular and intermountable designed battery packs enable the replacement of defective or outdated battery cells, allow additional cost savings and a prolongation of life time. This paper discusses opportunities for future remanufacturing value chains of electric cars and their battery components and how to address their potentials with elaborate designs. Based on a brief overview of implemented remanufacturing structures in different industries, opportunities of transferability are evaluated. In addition to an analysis of current and upcoming challenges, promising perspectives for a sustainable electric car circular economy enabled by design for remanufacturing are deduced. Two mathematical models describe the feasibility of pursuing a circular economy of lithium ion batteries and evaluate remanufacturing in terms of sustainability and economic efficiency. Taking into consideration not only labor and material cost but also capital costs for equipment and factory facilities to support the remanufacturing process, cost benefit analysis prognosticate that a remanufacturing battery can be produced more cost-efficiently. The ecological benefits were calculated on a broad database from different research projects which focus on the recycling, the second use and the assembly of lithium ion batteries. The results of this calculations show a significant improvement by remanufacturing in all relevant factors especially in the consumption of resources and greenhouse warming potential. Exemplarily suitable design guidelines for future remanufacturing lithium ion batteries, which consider modularity, interfaces and disassembly, are used to illustrate the findings. For one guideline, potential cost improvements were calculated and upcoming challenges are pointed out.

Keywords: Circular economy, electric mobility, lithium ion batteries, remanufacturing.

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Authors: Yu-Jen Chang, Shih-Chieh Chen, Yu-Wei Kuo

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In this study, we are interested in the economic lot scheduling problem (ELSP) that considers manufacturing of the serviceable products and remanufacturing of the reworked products. In this paper, we formulate a mathematical model for the ELSP with reworks using the basic period approach. In order to solve this problem, we propose a search algorithm to find the cyclic multiplier ki of each product that can be cyclically produced for every ki basic periods. This research also uses two heuristics to search for the optimal production sequence of all lots and the optimal time length of the basic period so as to minimize the average total cost. This research uses a numerical example to show the effectiveness of our approach.

Keywords: Economic lot, reworks, inventory, basic period.

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Authors: A. Buruzs, A. Torma

Abstract:

The relationship of the automotive industry with raw material supply is a major challenge and presents obstacles. Automobiles are ones of the most complex products using a large variety of materials. Safety, eco-friendliness and comfort requirements, physical, chemical and economic limitations set the framework in which this industry continuously optimizes the efficient and responsible use of resources. The concept of circular economy covers the issues of waste generation, resource scarcity and economic advantages. However, circularity is already known for the automobile industry – several efforts are done to foster material reuse, product remanufacturing and recycling. The aim of this study is to give an overview on how the producers comply with the growing demands on one hand, and gain efficiency and increase profitability on the other hand from circular economy.

Keywords: Automotive industry, circular economy, international requirements, natural resources.

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Authors: Zhi Sheng Lin, K. C. G. Ong, Lado Riannevo Chandra, Bee Hong Angeline Tan, Chat Tim Tam, Sze Dai Pang

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Design for Disassembly (DfD) aims to reuse the structural components instead of demolition followed by recycling of the demolition debris. This concept preserves the invested embodied energy of materials, thus reducing inputs of new embodied energy during materials reprocessing or remanufacturing. Both analytical and experimental research on a proposed DfD beam-column connection for use in residential apartments is currently investigated at the National University of Singapore in collaboration with the Housing and Development Board of Singapore. The present study reports on the results of a numerical analysis of the proposed connection utilizing finite element analysis. The numerical model was calibrated and validated by comparison against experimental results. Results of a parametric study will also be presented and discussed.

Keywords: Design for Disassembly (DfD), finite element analysis, parametric study.

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Authors: Siva Prasad Darla, C. D. Naiju, K. Annamalai, S. S. Rajiv Sushanth

Abstract:

Supply chain consists of all stages involved, directly or indirectly, includes all functions involved in fulfilling a customer demand. In two stage transportation supply chain problem, transportation costs are of a significant proportion of final product costs. It is often crucial for successful decisions making approaches in two stage supply chain to explicit account for non-linear transportation costs. In this paper, deterministic demand and finite supply of products was considered. The optimized distribution level and the routing structure from the manufacturing plants to the distribution centres and to the end customers is determined using developed mathematical model and solved by proposed particle swarm optimization based genetic algorithm. Numerical analysis of the case study is carried out to validate the model.

Keywords: Genetic Algorithm, Particle Swarm Optimization, Production, Remanufacturing

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Authors: Tao Yin, Zeqiang Zhang, Wei Liang, Yanqing Zeng, Yu Zhang

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To accelerate the remanufacturing process of electronic waste products, this study designs a partial disassembly line with the multi-robotic station to effectively dispose of excessive wastes. The multi-robotic partial disassembly line is a technical upgrade to the existing manual disassembly line. Balancing optimization can make the disassembly line smoother and more efficient. For partial disassembly line balancing with the multi-robotic station (PDLBMRS), a mixed-integer programming model (MIPM) considering the robotic efficiency differences is established to minimize cycle time, energy consumption and hazard index and to calculate their optimal global values. Besides, an enhanced NSGA-II algorithm (HNSGA-II) is proposed to optimize PDLBMRS efficiently. Finally, MIPM and HNSGA-II are applied to an actual mixed disassembly case of two types of computers, the comparison of the results solved by GUROBI and HNSGA-II verifies the correctness of the model and excellent performance of the algorithm, and the obtained Pareto solution set provides multiple options for decision-makers.

Keywords: Waste disposal, disassembly line balancing, multi-robot station, robotic efficiency difference, HNSGA-II.

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Authors: Yuan-Jye Tseng, Yi-Shiuan Chen

Abstract:

The paper presented a sustainable design model for integrated evaluation of the design and supply chain of a product for the sustainable objectives. To design a product, there can be alternative ways to assign the detailed specifications to fulfill the same design objectives. In the design alternative cases, different material and manufacturing processes with various supply chain activities may be required for the production. Therefore, it is required to evaluate the different design cases based on the sustainable objectives. In this research, a closed-loop design model is developed by integrating the forward design model and reverse design model. From the supply chain point of view, the decisions in the forward design model are connected with the forward supply chain. The decisions in the reverse design model are connected with the reverse supply chain considering the sustainable objectives. The purpose of this research is to develop a mathematical model for analyzing the design cases by integrated evaluating the criteria in the closed-loop design and the closed-loop supply chain. The decision variables are built to represent the design cases of the forward design and reverse design. The cost parameters in a forward design include the costs of material and manufacturing processes. The cost parameters in a reverse design include the costs of recycling, disassembly, reusing, remanufacturing, and disposing. The mathematical model is formulated to minimize the total cost under the design constraints. In practical applications, the decisions of the mathematical model can be used for selecting a design case for the purpose of sustainable design of a product. An example product is demonstrated in the paper. The test result shows that the sustainable design model is useful for integrated evaluation of the design and the supply chain to achieve the sustainable objectives.

Keywords: Closed-loop design, closed-loop supply chain, design evaluation, mathematical model, supply chain management, sustainable design model.

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Authors: Han-Mei Chen, Rongxin Zhou, Taige Wang

Abstract:

Glass is widely used in everyday life, from glass bottles for beverages, to architectural glass for various forms of glazing. Although the mainstream of used glass is recycled in the UK, the single-use and then recycling procedure results in a lot of waste as it incorporates intact glass with smashing, re-melting and remanufacturing. These processes bring massive energy consumption with a huge loss of high embodied energy and economic value, compared to re-use which’s towards a ‘zero carbon’ target. As a tourism city, Liverpool has more glass bottle consumption than most less leisure focused cities. It is therefore vital for Liverpool to find an upgrading approach for the single-use glass bottles with a low carbon output. This project aims to assess the feasibility of an industrial symbiosis and upgrading framework of glass and to investigate the ways of achieving them. It is significant to Liverpool’s future industry strategy since it provides an opportunity to target on economy recovery for post-COVID by industry symbiosis and an up-grading waste management in Liverpool to respond to the climate emergency. In addition, it will influence the local government policy for glass bottle reuse and recycling in North West England, and as a good practice to be further recommended to other areas of the UK. First, critical literature review of glass waste strategies has been conducted in the UK, and world-wide industrial symbiosis practices. Second, mapping, data collection and analysis have shown the current life cycle chain and the strong links of glass reuse and upgrading potentials via site visits to 16 local waste recycling centres. The results of this research have demonstrated the understanding the influence of key factors on the development of a circular industrial symbiosis business model for beverage glass bottles. The current waste management procedures of glass bottle industry, its business model, supply chain and the material flow have been reviewed. The various potential opportunities for glass bottle up-valuing have been investigated towards an industrial symbiosis in Liverpool. Finally, an up-valuing business model has been developed for an industrial symbiosis framework of glass in Liverpool. For glass bottles, there are two possibilities: 1) focus on upgrading processes towards re-use rather than single-use and recycling, 2) focus on ‘smart’ re-use and recycling leading to optimised values in other sectors to create a wider industry symbiosis for a multi-level and circular economy.

Keywords: Glass bottles, industry symbiosis, smart reuse, waste upgrading.

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