Design for optimal quality by recycling returned products

For many manufacturers, the cost of replacing returned products may more than offset the cost of producing parts with a higher quality. This is especially true if good parts from returned products are used to remanufacture aftermarket products. Furthermore, such policy allows for satisfying a customer population with a variable expectation for acceptable quality. In this study, the total cost of supplying a given demand is derived as an analytical function of the targeted primary production rate and product quality when the demand is satisfied with a combination of primary and remanufactured products. The decision variables of this function consist of the primary production rate and the designed product and production quality. This cost is then minimised to determine the production rate and the optimum quality to target. A numerical example is provided and used to demonstrate the application of this function. This example also demonstrates the use of the proposed solution for optimising quality when there is a limit on primary production size. The example also demonstrates the use of the function for optimising service levels. The results show a close match between the theoretical functions developed in this study and those obtained from a Monte Carlo simulation model.     

Impact of incorporating customer preference in sustainable remanufacturing of commercial returns

This paper investigates optimum production parameters for a reverse supply chain for manufacturing of primary products and remanufacturing of commercial returns (products returned by customers for refund or exchange). The market for the product consists of two categories, the primary and remanufactured products. The demands for these markets are independent and considered to be random variables following a normal distribution function. The approach presented in this work differs from many previously published works because the acceptability of products varies among customers. The interaction between the designed quality and variable customers’ preferences determines the likelihood of a product being returned. Two major decision variables targeted in this study are the production cycle time and the targeted quality for production of parts used in the product. Through an analytical formulation and numerical examples, a relationship between the total profit of the system and the two decision variables is developed and optimised. The analysis demonstrates that the total profit of the hybrid system could be increased significantly by targeting the optimum targeted (not necessarily the highest) values for quality of parts and the optimum cycle length. And this objective could be accomplished with significant gain with respect to sustainability and waste reduction.     

Recycling – the importance of understanding the complexity of the issue

Natural resources and raw materials such as metals and minerals are often taken for granted in today’s society. Without them, the offerings of an enormous variety of modern conveniences, including computers and mobile phones, would not be possible. The production of these everyday items depends on a secure, sustainable, and reliable supply of critical raw materials. In addition, product development also requires new hybrid materials when targeting lightweight structures, etc. However, the mandatory recyclability of new products or materials is not obligatory or even prevailing practice in present manufacturing business. Therefore, the main research question in this article is: “how to solve the challenge of recycling in industrial system?” In this article, a comprehensive approach to recycling based on the findings of research projects is presented. Simplified, this involves moving the challenge from the end of the product’s life cycle to the beginning, to the design or even to material development phases. Life cycle and system thinking and material know-how in the design phase are found to be essential elements of a new approach to recycling. This approach stems from the material development and market economy perspectives. Furthermore, the vulnerability of the industrial system to create uncertainty to recycling is also demonstrated.     

Application of active disassembly to extend profitable remanufacturing in small electrical and electronic products

Alternative production approaches are required because of conventional manufacturing's adverse environmental impacts. Remanufacturing returns used products to at least original performance specification from customers' perspectives and gives the resultant products warranties at least equal to that of new equivalents. Remanufacturing is relatively novel in research terms compared to conventional manufacture and recycling but often is more profitable than both. It would help manufacturers address competitive, environmental and legislative pressures by enabling them to meet pressing waste legislation while producing high-quality, lower cost products with less environmentally damaging end-of-life (EoL) and manufacturing modes. Remanufacturing is highly profitable in large, complex mechanical and electromechanical products but with conventional manufacturing and design modes not so in smaller products; particularly fast moving ones. However, effective waste management is urgently required for such products because waste electrical and electronic equipment constitutes the fastest growing EU waste stream and a large percentage of products being produced by major developing economies such as China are of this type. Active disassembly (AD) enables product non-destructive, self-disassembly at EoL and was invented to facilitate a step-change improvement in recycling. This research investigated the use of AD to extend profitable remanufacturing into small EoL electrical and electronic products.     

Issues in reverse supply chains,part I: end‐of‐life product recovery and inventory management – an overview

Recovery of used products has become a field of rapidly growing importance in reverse supply chain management. Product recovery includes collection, inspection/separation, disassembly, reconditioning/reuse, remanufacturing, and recycling. In real time situations, the collection of end‐of‐life (EoL) products from the customer and their return to the manufacturer is tedious and time consuming. Reduced product life cycles have increased the rate of product returns and disposals. Owing to shortened product economic life cycles, the recovery of value from EoL products is becoming a necessity. Companies have realised the value that they could recover by remanufacturing or recycling EoL products. Researchers have developed various models for product recovery network design, optimal inventory, production planning and control, remanufacturing, recycling, disposal, etc. The main purpose of this paper is to review the literature on EoL product recovery and inventory management issues in reverse supply chains and to outline some future directions for research on these issues.     

Potential release scenarios for carbon nanotubes used in composites

The expected widespread use of carbon nanotube (CNT)-composites in consumer products calls for an assessment of the possible release and exposure to workers, consumers and the environment. Release of CNTs may occur at all steps in the life cycle of products, but to date only limited information is available about release of CNTs from actual products and articles. As a starting point for exposure assessment, exploring sources and pathways of release helps to identify relevant applications and situations where the environment and especially humans may encounter releases of CNTs. It is the aim of this review to identify various potential release scenarios for CNTs used in polymers and identify the greatest likelihood of release at the various stages throughout the life-cycle of the product. The available information on release of CNTs from products and articles is reviewed in a first part. In a second part nine relevant release scenarios are described in detail: injection molding, manufacturing, sports equipment, electronics, windmill blades, fuel system components, tires, textiles, incineration, and landfills. Release from products can potentially occur by two pathways; (a) where free CNTs are released directly, or more frequently (b) where the initial release is a particle with CNTs embedded in the matrix, potentially followed by the subsequent release of CNTs from the matrix.The potential for release during manufacturing exists for all scenarios, however, this is also the situation when exposure can be best controlled. For most of the other life cycle stages and their corresponding release scenarios, potential release of CNTs can be considered to be low, but it cannot be excluded totally. Direct release to the environment is also considered to be very low for most scenarios except for the use of CNTs in tires where significant abrasion during use and release into the environment would occur. Also the possible future use of CNTs in textiles could result in consumer exposure. A possibility for significant release also exists during recycling operations when the polymers containing CNTs are handled together with other polymers and mainly occupational users would be exposed.It can be concluded that in general, significant release of CNTs from products and articles is unlikely except in manufacturing and subsequent processing, tires, recycling, and potentially in textiles. However except for high energy machining processes, most likely the resulting exposure for these scenarios will be low and to a non-pristine form of CNTs. Actual exposure studies, which quantify the amount of material released should be conducted to provide further evidence for this conclusion.     

Two-echelon closed-loop supply chain deterministic inventory models in a batch production environment

This paper considers a two-echelon closed-loop supply chain consisting of a manufacturer and a remanufacturer at the upper echelon and a retailer at the lower echelon. The retailer faces a constant demand from customers, which is satisfied through recovered and new products received from the remanufacturer and the manufacturer, respectively. The manufacturer produces the product with finite rate, whereas the recovery of returned product is instantaneous at the remanufacturer. We develop three models to determine the optimal production-inventory policy of the players for minimizing the joint total cost of the system. In the first model, the retailer receives the product in batches from the manufacturer and the remanufacture simultaneously, whereas in the second and third models, the batches are received alternatively. In the third model, however, the procurement of raw material at the manufacturer is also considered. Numerical illustration is presented to examine the impact of certain key parameters.     

Developing a fuzzy linear programming model for locating recovery facility in a closed loop supply chain

In this research a closed loop supply chain is designed which incorporates reverse logistics and forward logistic system simultaneously. In the design of reverse logistic system, recovery options are embedded in traditional supply chain for treating returned products. The recovery system includes collection centres, remanufacturing plants and disposal centres. Since the product return is supply driven, there is an uncertainty about it. In the proposed configuration for closed loop supply chain, the optimised configuration for supply chain in terms of locating recovery plants is developed. Accordingly, a fuzzy mixed integer linear programming model develops to deal with the uncertainty of returning products by customers. A general-purpose solver (LINGO 8.0) and a Meta heuristic approach (genetics algorithm) are implemented to solve the proposed model. The answers are compared by defining indexes and then the optimal answer, configuration and variables are identified. This solution will suggest a new design of supply chain network in which waste of materials is minimised and the new raw materials are necessary only when the used products may not be recovered by recovery options.     

A meta‐heuristic approach for supporting adaptive disassembly sequencing using a multi‐objective concept

One of the key features of environmentally conscious manufacturing has been the efforts to promote product recycling and remanufacturing. Efficient material re‐utilisation through product disassembly to retrieve the desired parts and/or subassemblies is one rational approach. This is because it can promote the conservation of both material and energy resources whilst concurrently reducing environmental impact. However, because manufactured products may be made from many components, disassembly load becomes a critical factor that may obstruct the recovery of materials. Accordingly, it is essential to develop a practical method for deriving a disassembly plan to decrease such load, and to endow a certain value to the product at the end of its life cycle. With this understanding, the authors have developed a practical procedure to produce an adaptive disassembly strategy. The authors have applied a meta‐heuristic method known as genetic programming (GP) as a search engine to derive the adaptive disassembly sequence together with a multi‐objective optimisation method termed MOON^2R. The authors have also proposed a hierarchical sequencing method to cope with large/complex products and added several ideas to increase the applicability associated with the interests in disassembly of hazardous and/or valuable parts, and alternative disassembly actions. Through numerical experiments, the authors examined the effectiveness of the proposed approach by showing its support for relevant planning and design decisions for product recycling and remanufacturing from various viewpoints.     

Measuring the environmental impact of waste flow management in Brazilian apartment buildings

As biodegradable material represents approximately 70% of household waste in Brazil, any strategy to divert appreciable waste quantities from landfills of necessity has to include valorization and recycling of this material. A societal change of attitude is required to perceive this challenge. Experiments in an urban apartment building are described that produced this change of attitude with a success factor of 80%. Divided waste collection was implemented that separated at the source biodegradable from inert material. Correct collection, handling and display procedures were established. Composting of biodegradable material was carried out under the rooftop of the building as an alternative to using it as animal feed. Half of the inert material entered the reverse logistics chain and was also diverted from the landfill. Waste related material flow through the building is completely quantified, food intake and waste production are related, diversion of both biodegradable and inert waste components from the landfill is measured and the composting process is described. The landfill diversion stands at 61%, mass reduction through the composting process is 80% and matured compost is returned to residents for use in flower cages. The system has been operational for two years and stands out as a precedent in successful decentralized household waste management supported by material flow analysis. Readers should send their comments on this paper to: BhaskarNath@aol.com within 3 months of publication of this issue.     

Industrial complexes and their relevance for pulp and paper mills

Advantages and disadvantages of the concept of an industrial complex are discussed. From an environmental standpoint an ideal industrial complex is one containing a group of compatible industrial plants utilizing completely each other's wastes and products as raw materials and manufacturing products with no adverse environmental impact and at a minimum of cost. A typical complex centering about a pulp and papermill is pictured in this paper. This complex produces six products for external sale and four products for internal use. In addition, all major wastes of suspended solids, cooking liquor, fillers, heat and bark are reused within the complex in the manufacture of these products. A literature review evolved typical concentrations of recoverable suspended solids in various process effluents. A mass balance was prepared assuming that the total production of fine paper is 907.2 kg × 10³ (1000 tons) per day. Little or no air or water pollution results from this complex. In addition, it is anticipated that no expensive waste-water treatment plant would be required for this complex. Ten additional practices are described which, when used, will reduce operating costs even further. A continuing study with more precise data on the production requirements for the service plants in the complex will yield a more balanced and realistic system.     

可持续转型与延伸生产者责任制度

本文采用多层次转型理论的分析框架,回顾了国内外延伸生产者责任(EPR)制度的理论和实践进展,对比了EPR制度倡导者最初提出的创新导向的制度设计,与当前各国实践中基于成本—效益平衡所开展的政策评估研究,指出两者在是否应该将激进的可持续转型作为EPR基本政策目标上观点不同,其原因在于政策的技术创新激励效果难以通过可测量的政策评估方法进行有效考察,由此造成两者在EPR政策调整方向上的分歧:前者坚持EPR制度设计应该进一步完善个体责任原则,以激励生产者创新和采纳绿色技术,推进生产消费模式的系统转型;而后者则强调在现有管制框架下简化制度设计,重点完善循环处理基础设施及其管理效率。这种分歧不仅影响到发达国家EPR制度的演化,也深刻影响了发展中国家EPR制度的移植和建构。结论以中国电子废物管理实践为例,提出构建包含三个层次的演化经济学分析框架,考察EPR制度建构过程中,微观层次的企业技术选择,中观层次的供应链治理结构变动,和宏观层次的再生资源产业转型,以系统考察制度发展对技术创新的激励效果。     

A cross-border recycling system in Asia under the resource and environmental constraints: a challenging project by the city of Kitakyushu and the city of Tianjin

In this article, we present an overview of the current circumstances of the trade of recyclable resources, i.e. end-of-life products, parts and materials, and recycled resources in Asian countries, indicating that pollution potential is spreading there due to the improper handling of those resources. Conversely, Japan’s domestic recycling activities are shown to be adversely affected by the increasing outflow of those resources on one hand and the sudden stagnation of trade on the other. Considering that cross-border resource circulation in Asia is unavoidable and desirable in certain conditions, we propose a feasible and sustainable transaction scheme of recyclable and recycled resources, exemplified by a project which was carried out by the city of Kitakyushu and the city of Tianjin.     

A Framework for Assessing Carbon Flow in Indian Wood Products

This paper uses a lifecycle analysis to trace the fate of carbon bound in wood products until most of the carbon is released back into the atmosphere. A sensitivity analysis has been carried out to find the effect of change in terminal use (recycling, land filling and burning of discarded products), half-life of wood products and decay rate of carbon in landfills. Of the total carbon harvested from forests in India, about 90% is released into the atmosphere in the first year, due to burning of fuelwood; at the end of 100 years, about 0.8% still remains in the wood products. The sensitivity analysis shows that the length of the lifespan of wood products has only a marginal effect on the amount of carbon sequestered but has significant effect on the amount of carbon in products in use. Thus an important conclusion from this scenario is that by increasing the durability of the wood products, carbon can be locked over a period equal to the time needed to grow the timber for these products. Further, the carbon storage is affected more significantly by the decay rate of carbon in landfills than the proportion of products recycled. The study also shows that wood products can be important stores of carbon, but only if they can substitute for a unit of carbon emitted by burning fossil fuels. Such a lifecycle analysis has the potential to account completely for carbon stock changes in the wood products, where and when they are occurring, and explain how they are occurring.     

Ecological and economical assessment of end‐of‐life waste recycling in the electrical and electronic recovery sector

Technological innovation and shorter product life cycles of electrical and electronic equipment coupled with their rapidly growing applications have resulted in the generation of an enormous amount of waste from electrical and electronic equipment (WEEE). To address the potential environmental problems that could stem from improper end‐of‐life management of WEEE, many countries have drafted national legislation to improve the reuse, remanufacture and material recycling from WEEE, and to reduce the amount of such waste going to landfills. With the introduction of such legislation comes an increased need for the recovery operators to evaluate the recycling costs and environmental benefits of reclaimed products and materials in order to select the most appropriate end‐of‐life options for individual products in WEEE. This paper presents a systematic methodology for ecological and economical assessment to provide a holistic understanding of the impacts associated with different end‐of‐life options for such waste. This assessment, in addition to providing decision‐support for the selection of the best possible end‐of‐life option for a particular product in WEEE, could also generate vital information to support the design and material selection processes during the initial product development activities. The assertion made is that the detailed considerations of the ecological and economical impacts associated with different end‐of‐life options will significantly improve the recovery and recycling of WEEE.     

Water pollution footprints induced by industrial import and export in China

With the rapid development of foreign trade in China, industrial import and export has been an absolute subject in recent years. The huge trade surplus of import and export trade of industrial products brings not only high profits, but also pollution costs as well. Based on the concept of water pollution footprints (WPFs), this study applies the input-output method and calculates pollutant-producing coefficients of 20 major industrial sectors in China and investigates the WPFs caused by the import and export trades of these industrial sectors. The research results show that WPF resulting from exports exceeds that of imports from 2011 to 2015 in China. The net inflow of pollution footprint is mainly from paper mills, printing and stationery manufacturing, and textile industry; whereas a great number of WPFs are transferred to other countries by these sectors, such as metal mining and dressing industry and oil and natural gas exploitation industry.     

Performance evaluation of reverse logistics enterprise – an agent-based simulation approach

Reverse logistics (RL) has been applied in many industries and sectors since its conception. Unlike forward logistics, retracing consumer goods from the point of consumption to the point of inception is not a well-studied process. It involves many uncertainties such as time, quality and quantity of returns. The returned products can be remanufactured, have parts harvested, or be disposed safely. It is important to implement these activities in a cost-effective manner. The aim of this research is to measure the performance of the RL enterprise with the help of an agent-based simulation model. The major entities in the RL network are considered as Agents that can act independently. There are several different agents: collector agent, sorting-cum-reuse agent, remanufacturing agent, recycler agent, supplier agent and distributor agent. The individual performances of the agents are measured and recommendations are given to improve their performance, leading to the enhancement of the total performance of the RL enterprise. The approach is applied to a case study involving cell phone remanufacturing.     

基于整体开发管理的国际河流决策支持系统

基于国际河流开发管理的现状，分析国际河流整体开发管理理论的演进。得出整体开发管理决策实施的原则及思路：流域开发管理要以流域边界为界，将整个水系自然联系的区域作为不可分割的整体，进行统一权衡，突出共同利益，流域内开发与流域外开发相结合。以建立多层次的国际合作机构。对国际河流决策支持系统进行设计，即以国际河流流域为体系，各国国内流域测点为单元。国际流域综合协调委员会为决策支持中心、各国流域机构委员会为决策支持分中心。并研究系统的公用信息平台建设，信息开发、管理与维护。河流水资源、水环境实时监控等技术支持系统。实证分析澜沧江-湄公河流域决策支持系统的建设。并指出国际河流水资源的开发与管理，水权等问题有待进一步深入研究。     

OPTIONS FOR ENVIRONMENTAL SUSTAINABILITY OF THE CRUDE PALM OIL INDUSTRY IN THAILAND THROUGH ENHANCEMENT OF INDUSTRIAL ECOSYSTEMS

The crude palm oil industry plays an important role in the economic development of Thailand and in enhancing the economic welfare of the population. Despite obvious benefits of this industrial development, it also significantly contributes to environmental degradation, both at the input and the output sides of its activities. On the input side, crude palm oil mills use large quantities of water and energy in the production process. On the output side, manufacturing processes generate large quantities of wastewater, solid waste/by-products and air pollution. Current industrial wastes and recoverable materials are empty fruit bunches, fibers, shells and ash. It is estimated that in 2003, a total of 2.1 million ton of solid wastes/by-products and 2.5 million m³ of wastewater were generated. The concept of the industrial ecosystem points at the potential of industrial waste recycling resembling food chains, food webs and nutrient cycles of nature. Following the notion of industrial ecology crude palm oil mills can develop a number of waste recycling and reuse systems. This paper analyzes the nature of these industrial ecosystems, divided in in-plant ecosystems (clean technology options) and external waste exchange between crude palm oil industries and other economic activities in Thailand.     

长江三角洲城市群循环经济发展水平的空间格局分析

开展循环经济,走可持续发展道路是提升长江三角洲城市群全球竞争力的必由之路。在参考大量城市循环经济评价指标体系的基础上,从社会经济发展、减量化、再循环再利用、生态环境质量4个方面,选取18项代表性指标,建立了城市循环经济水平评价指标体系。采用中国城市统计年鉴2006年的统计数据,运用层次分析法（AHP）确定各指标的权重,计算得出长江三角洲城市群各城市循环经济综合指数,并对其空间格局和影响因素进行分析。研究结果表明：①各城市循环经济发展水平差异显著;②各城市循环经济发展水平由城市群外围向中心逐渐递增;③随着人均地区生产总值的上升,循环经济水平呈不规则“W”变化。循环经济发展政策、产业结构、经济发展水平和乡镇企业的规模和数量是影响长江三角洲城市群各城市循环经济发展水平的主要因素。最后,对长江三角洲城市群循环经济发展提出了几点对策建议.