Reverse logistics network design: a conceptual framework for decision making

Reverse logistics play a significantly increased role in supply chains. Producers are incorporating reverse logistics into their supply chain design because of governmental legislation, economic benefits from product recovery, and customers' demands for better environmental practices. Motivated producers face two main challenges in reverse logistics network design: (1) how do you build product recovery activities into traditional forward logistics networks? and (2) how do you manage the impact of uncertainty in the reverse logistics supply chain? Moreover, producers need to consider many tradeoffs leading to efficient network design. Published case studies have discussed these tradeoffs, and we describe a framework to evaluate these tradeoff considerations. We then apply the framework to three new case studies: medical device refurbishing, municipal e‐waste recycling, and carpet fibre recycling.     

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.     

Sustainability risk identification in product development

Sustainability-related issues present significant financial, strategic, compliance and operational risks to manufacturers. Many of these risks directly or indirectly result from the way a product is designed and managed across its life cycle. Assessing sustainability risk (S _R) at the product design stage is crucial for the development of products that both minimise sustainability risk exposure and are environmentally sustainable. Managing the costs associated with these risks requires risk management intervention at the design stage before these costs are committed throughout the life cycle (production, use, end-of-life). The goal of the sustainability risk assessment (SRA) methodology is to provide an approach to comparing the financial cost of a ‘sustainable product’ vs. an ‘unsustainable product’, by factoring in the effects of S _R on life-cycle cost. The SRA methodology demonstrates that, in some cases, sustainable products cost less than unsustainable products when sustainability risk is considered in the costing analysis. This paper outlines the first step of the SRA methodology, which is a process for identifying S _R inherent in the product life cycle. Once key risks are identified, the subsequent steps of the SRA assess and prioritise these risks for treatment through changes to product design and materials composition.     

A design for EoL approach and metrics to favour closed-loop scenarios for products

Recently, environmentally conscious design and extended producer responsibility have become key aspects for companies that need to develop products that are sustainable along their whole life cycle. Design for End of Life (EoL) is a strategy that aims to reduce landfill waste through the implementation of closed-loop product life cycles. It is important to consider disassembly and EoL scenario management as early as the design phase. For these reasons, this paper presents an approach to help designers in the evaluation and subsequent improvement in product EoL performance. The method is based on four innovative EoL indices that compare different EoL scenarios for each product component. In this way, the designer can modify the product structure or the liaisons to maximise the reuse and remanufacture of components as well as material recycling. The presented case studies confirm the validity of the approach in helping designers during the redesign phase of goods and products to reduce the quantity of materials and industrial wastes sent to landfill.     

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.     

Application of QFD for enabling environmentally conscious design in an Indian rotary switch manufacturing organisation

Many businesses are recognising that environmental consciousness is an important concept for survival in today's highly competitive market. This paper presents a project in which quality function deployment (QFD) for environment (QFDE) has been applied to an Indian rotary switch manufacturing organisation to enable environmentally conscious design at the early stage of product development. QFDE consists of four phases. QFDE phases I and II are concerned with the identification of the rotary switch parts that are important in enhancing environmental consciousness. QFDE phases III and IV are concerned with the evaluation of the effect of design improvement on environmental quality requirements. The results obtained from the case study revealed that QFDE could be applied in the early stage of rotary switch product development as it identified the vital components from an environmental perspective and enabled the options for design improvement to be effectively evaluated. The managerial implications of the case study have also been presented.     

Towards an integrated framework for sustainable innovation

Sustainable innovation represents a current challenge for companies, as firms need to change the way they design, develop, produce and distribute products and services. Therefore, this paper proposes a new framework to be used as a reference guideline for organisations to define a roadmap, specific actions and projects to achieve sustainable innovation, integrating four key enablers. The first enabler is mass customisation (MC), which targets the identification and compliance with customers' specific needs and requirements in order to achieve customer‐driven design. At the same time, the sustainable development (SD) paradigm is taken into consideration, where for any new product or service, companies analyse the benefits, risks and impacts of not only economic factors, but also social and environmental implications. The third enabler is linked to the value network (VN), where innovations happen owing to the active collaboration and distributed knowledge of partners inside and outside the company. Finally, the fourth and last considers the complete product and service life cycle (PSLC), where the three sustainable elements are identified and analysed in each single business process. Two case studies, (footwear sector and water treatment plants) are described to show the validity and successful deployment of the proposed framework in real industrial scenarios.     

Multiobjective optimisation method for life-cycle design of mechanical products

Manufacturing that minimises the exhaustion of natural resources, energy used and deleterious environmental impact is increasingly demanded by societies that seek to protect global environments as much as possible. To achieve this, life-cycle design (LCD) is an essential component of product design scenarios; however, LCD approaches have not been well integrated in optimal design methods that support quantitative decision-making. This study presents a method that yields quantitative solutions through optimisation analysis of a basic product design incorporating life-cycle considerations. We consider two types of optimisation approaches that have different aims, namely, (1) to reduce the use of raw materials and energy consumption and (2) to facilitate the reuse of the product or its parts when it reaches the end of its useful life. We also focus on how the optimisation results differ according to the approach used, from the viewpoint of the 3R concept (Reduce, Reuse and Recycling). Our method obtains optimum solutions by evaluating objectives fitted to each of these two optimisation approaches with respect to the product's life-cycle stages, which are manufacturing, use, maintenance, disposal, reuse and recycling. As an applied example, a simple linear robot model is presented, and Pareto optimum solutions are obtained for the multiobjective optimisation problem whose evaluated objectives are the operating accuracy of the robot and the different life-cycle costs for the two approaches. The characteristics of the evaluated objectives and design variables, as well as the effects of using material characteristics as design parameters, are also examined.     

Limits of ecodesign: the case for open source product development

Abstract

In pursuit of coping mechanisms for the challenges of sustainable manufacturing, systematic methods have been developed to allow engineers to improve the ratio between products’ utility and environmental impact. These necessary efforts remain however limited if the surrounding production and consumption practices are not called into question at the same time. This article introduces open source product development as a potential approach for unlocking the limits of existing sustainable product design practices and to lead towards alternative and eco-efficient production and consumption practices termed as participative production. First, it discusses the potential advantages of this emerging practice in terms of environmental sustainability. Second, it provides a screened qualitative environmental analysis of 18 exemplary open source hardware products. Specific sustainable design principles implemented by these products are highlighted and discussed in order to identify challenges for further common research in the field of open source and sustainable product development.     

Making the user more efficient: design for sustainable behaviour

User behaviour is a significant determinant of a product's environmental impact; while engineering advances permit increased efficiency of product operation, the user's decisions and habits ultimately have a major effect on the energy or other resources used by the product. There is thus a need to change users' behaviour. A range of design techniques developed in diverse contexts suggest opportunities for engineers, designers and other stakeholders working in the field of sustainable innovation to affect users' behaviour at the point of interaction with the product or system, in effect ‘making the user more efficient’. Approaches to changing users' behaviour from a number of fields are reviewed and discussed, including: strategic design of affordances and behaviour‐shaping constraints to control or affect energy‐ or other resource‐using interactions; the use of different kinds of feedback and persuasive technology techniques to encourage or guide users to reduce their environmental impact; and context‐based systems which use feedback to adjust their behaviour to run at optimum efficiency and reduce the opportunity for user‐affected inefficiency. Example implementations in the sustainable engineering and ecodesign field are suggested and discussed.     

The elaboration process – an approach for sustainable product development: a case study

Environmentally conscious product development, eco-design or design for environment is the methodology trying to introduce environmental requirements into product design. The first step of this process is the gathering of customer requirements for a structured product development procedure, such as quality function deployment (QFD). The problem is that environmental requirements are usually unspoken by the customers. This paper describes a methodology for uncovering such requirements by using environmental default questions in an elaboration process. This leads to an increased customer environmental awareness, and it generates a comprehensive list of requirements suitable for use in a subsequent QFD process. The effects of the elaboration process are demonstrated in one case study.     

Value of information in product recovery decisions: a Bayesian approach

There is a widespread recognition of the need for better information sharing and provision to improve the viability of end-of-life (EOL) product recovery operations. The emergence of automated data capture and sharing technologies such as RFID, sensors and networked databases has enhanced the ability to make product information; available to recoverers, which will help them make better decisions regarding the choice of recovery option for EOL products. However, these technologies come with a cost attached to it, and hence the question ‘what is its value?’ is critical. This paper presents a probabilistic approach to model product recovery decisions and extends the concept of Bayes' factor for quantifying the impact of product information on the effectiveness of these decisions. Further, we provide a quantitative examination of the factors that influence the value of product information, this value depends on three factors: (i) penalties for Type I and Type II errors of judgement regarding product quality; (ii) prevalent uncertainty regarding product quality and (iii) the strength of the information to support/contradict the belief. Furthermore, we show that information is not valuable under all circumstances and derive conditions for achieving a positive value of information.     

Selection of green product design scheme based on multi-attribute decision-making method

The function, cost and environmental performance are the primary decision-making factors for scheme selection in green design. For the comprehensive and accurate decision-making in selecting green product design scheme, a quantitative analysis method of multi-attribute decision-making (MADM) is presented. With analysing the multi-attribute of scheme selection, the MADM model is established, which takes environmental impact of materials, disassembly performance, recycling performance, energy efficiency, noise, pollutants to environmental and functional values. Fuzzy technique for order performance by similarity to ideal solution method is applied to solve this model for the feasible solutions. Finally, a case study is given to validate the application of this methodology as a useful design guideline for scheme selection in green design.     

Lean framework for planning redesign proposals to optimise EOL environmental behaviour in WEEE products

The aim of this research was to define a sequence of actions to guide redesign propositions for electrical and electronic equipment products, which minimise negative consequences to the environment after the end of their useful life. Current practices mainly encourage the examination of individual problems as disassembly process and identification of suitable product end-of-life (EOL) treatment strategies. There also exist previous studies that try to incorporate EOL concerns in product design phase. In most cases, the main problem is the limited available EOL information because of its delayed retrieval. The proposed method focuses primarily on minimising this problem. The steps of the analysis performed include the selection of the optimal EOL treatment strategy and, afterwards, the evaluation of its results concerning the environment. In parallel, product design characteristics are grouped and examined concerning their expected significance for the environment in the EOL stage. The results from the previous stages are combined and product improvement actions are proposed for further examination in the redesign stage. The general framework used to conduct all these actions is lean thinking methodology. In the end, results concerning the application of the proposed method on a distribution transformer are presented.     

Metamodelling-based Product Family Design of Plug-in Hybrid Electric Vehicles

Development of plug-in hybrid electric vehicles (PHEVs) is stimulated by the need to replace non-renewable energies with sustainable and more environment-friendly new energy types. PHEVs benefit from a combination of an internal combustion engine and an electric motor with a rechargeable and larger battery pack than conventional hybrid vehicles. In order to maximise customer satisfaction and motivate replacement of the conventional vehicles with this new technology, the design of PHEVs requires sufficient differentiation in the product specifications for diverse market segments. The added set-up time, processes, costs and longer lead time for designing and manufacturing a diverse range of such vehicles is a hurdle towards increasing their diversity. This study proposes an efficient product family design (PFD) method for mass customisation of the PHEV powertrains. The methodology is less dependent on expensive simulations due to use of metamodelling and non-conventional sensitivity analysis. The PFD concept and its implications to a family of five PHEVs are investigated, and benefits as well as limitations of a sustainable development for this complex product are discussed.     

Design standards for product end-of-life processing

In 2006, the British Standards Institute (BSI) published BS 8887-1 ‘Design for Manufacture, Assembly, Disassembly and End-of-life processing’ (MADE) subtitled ‘General Concepts, Processes and Requirements’. This was the first British Standard to address design for efficient post-consumer product reprocessing. By designing and planning for remanufacture, much of the embodied energy and production investment can be retrieved after the consumer no longer requires the original item. Therefore, end-of-life products become an asset rather than a liability. Design for disassembly facilitates efficient deconstruction and thus enables materials to be recycled with minimal loss of purity, thus maximising their value. The analysis presented here is based on the Standard Industrial Classification codes of companies and organisations that have purchased BS 8887-1. These data are considered in relation to the influence of environmental legislation. Company age, size and location, as well as ISO 9001 and ISO 14001 certifications, are discussed. This paper concludes by suggesting suitable directions for the continued distribution and development of this environmentally, economically and socially beneficial standard.     

Review and future of active disassembly

Disassembly has been widely accepted as a disadvantageous end-of-life activity, but with increasing pressures from directives, such as waste on electrical and electronic equipment, and with increasing pressures to become sustainable disassembly is becoming necessary. Current disassembly methods, including both manual and automated disassembly, need improvements to meet this necessity. This paper will introduce the improvements needed and suggest through literature the validity of active disassembly (AD) to provide these improvements. Past and current research will also be considered to provide a future path for AD. This future path for AD will consider a collaborative effort to solve problems with materials, environmental triggers and costs seen with AD.     

Design for environment as a tool for the development of a sustainable supply chain

In this work, design for environment (DfE) methodologies have been used as a tool for the development of a more sustainable supply chain. In particular by combining life‐cycle assessment (LCA) techniques and by using the quality function deployment (QFD) multi‐criteria matrices, an ‘environmental compromise’ can be reached. In this work, the QFD matrices have been developed in a new way using an iterative process that involves the whole supply chain starting from the product life‐cycle, taking into consideration the machines that make the product and their components. This methodology is compatible with the requirements of the various stakeholders, suppliers, manufacturers and clients, involved in the supply chain. To assess the validity of the proposed approach a specific supply chain was studied concerning packaging systems for liquid food substances (beverage cartons). Firstly all the stages which are most critical from the environmental point of view in the supply chain of packaging systems were identified and assessed. The starting point for the analysis of environmental aspects and impacts which characterise the supply chain was LCA, which proved to be useful for the identification and the environmental assessment of the various stages in a packaging system. Through the use of ‘iterative QFD’ it is possible to arrive at a definition of the engineering characteristics of all the machinery which is involved in the supply chain. In particular in this work the authors have tried to identify the critical points in the design of those machines which either make the beverage cartons or are involved in the filling process.     

Comparing environmental product footprint for electronic and electric equipment: a multi-criteria approach

Electronic and electric devices are now applied in most human activities: their diffusion is increasing worldwide; furthermore, most of them are characterized by a high replacement rate due to technological obsolescence. Consequently, environmental problems due to their diffusion are increasing; several aspects are involved from the energy consumption derived from their manufacturing processes and their use phases to their end-of-life (EOL) management. Such legislative (e.g. the European Energy Efficiency directive for household appliances) or voluntary interventions (e.g. based on the ISO standards) have been introduced for such devices: the aim is to incorporate environmental considerations in product design and manufacturing in order to benefit the environment. Some attempts are focusing on defining standardized models for the overall lifecycle including waste management. The aim of this paper is to introduce a reference model for comparing environmental product footprint of electrical and electronic equipment (EEE). All life cycles of EEE will be evaluated: a specific focus is on the EOL management process as their waste management represents a complex problem for developed and developing countries. A multi-criteria decision-making model will be developed based on the well-known analytical hierarchy process (AHP) method: differently from traditional AHP applications, an absolute model has been proposed in order to compare EEE effectively from an environmental point of view. A case study validation regarding large household appliances is proposed.