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.     

Decision rules for recycling returned products

Most retail and on-line outlets allow customers to easily return defective or even non-defective products. Due to increasing environmental and sustainable concerns, disposal of returned products is often costly and undesirable. Furthermore, these products contain parts and materials of value that can contribute to the companies' profit. One way to take advantage of these returns is by utilising good returned parts in production of after-market products. Recycling of parts from products at the end of their useful lives has been studied for a long time. Many of these studies, however, are focused on repairs and refurbishing of such products for reuse.

This paper addresses recycling of rather new parts recovered from returned products. In this process parts are assembled with other parts recovered from other products to make a complete unit. The main objective of this study is to provide quantitative decision rules for justification of recycling of returned parts. The proposed method consists of a computer-based simulation decision model that, given a set of production system parameters, determines the breakeven point for the primary production rate at which recycling is justified. The application of the system to several scenarios is demonstrated through a numerical example.     

Dynamic life cycle costing based on lifetime prediction

Reliable prediction of total product life cycle costs is crucial for the life cycle management of products. These costs are predominantly dictated by the actual operational behaviour of the product's lifetime, and cannot be sufficiently determined through deterministic calculations due to the stochastic and the dynamic nature of the problem. This is specifically true when considering running systems with unknown lifetime and operation parameters. Against this background, the paper presents a dynamic methodology for predicting life cycle costs based on product failure mechanisms, their associated critical lifetime prediction parameters and optional maintenance strategies to enable decision support for product design and use phase strategies.     

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.     

An integrated methodology for the used product selection problem faced by third-party reverse logistics providers

The rise of electronic commerce and the stricter government regulations on the recovery of end-of-life products increased the number of products returned by customers. A company may deal with increasing product returns by developing its own reverse logistic system. However, high fixed costs associated with dedicated reverse logistics equipment and infrastructure force many companies to outsource their reverse logistics operations to third-party reverse logistics providers. One of the important problems faced by third-party reverse logistics providers is the selection of the types of used products to be collected. In this study, a four-phase used product selection methodology is proposed. First, the quantitative and qualitative selection criteria are determined. Then the weights of the criteria are calculated using fuzzy analytic hierarchy process. Next, simulation models are employed to determine the values of quantitative criteria. Finally, technique for order preference by similarity to ideal solution ranks alternative used product types. A numerical example is also provided in order to present the applicability of the proposed methodology.     

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.     

Optimal acquisition price management in a remanufacturing system

Return items received from end customers for remanufacturing is uncertain in nature. In this paper, we considered that return demand function is uncertain and sensitive to the acquisition price and the availability of used products in the market. A mathematical model was developed to investigate the impact of the availability of return items in the market on acquisition price management. Here, three different methods of collection of return items from the market are considered: direct method, indirect method and coordinated method. A numerical study was conducted to illustrate the mathematical model, and an extensive sensitivity analysis was carried out for the three different methods of collection to examine the impact of market size and the available dependency factor on acquisition price and the channel profit. The results show that the total channel profit increases when the acquisition price increases for the direct method of collection. Furthermore, the results reveal that the total channel profit increases when the market size increases for the coordinated method of collection compared with the other two methods of collection.     

Design of automobile engines for remanufacture with quality function deployment

Parallel with the increase in environmental problems, the importance of design of environmentally friendly products has become more important together with the design for remanufacture. This paper presents the application of quality function deployment (QFD) methodology in the design of products for remanufacture. The main goal of this paper is to determine the engineering characteristics of automobile engines that firms have to focus on, in order to design automobile engines for remanufacture. In this paper, how a product can be designed for remanufacture using QFD and house of quality (HOQ) has been highlighted. A questionnaire survey was conducted on automobile engine refurbishing & remanufacturing facilities in order to find out what is required of the products which are remanufactured. With the establishment of the HOQ, the engineering characteristics that firms should focus on for designing automobile engines for remanufacture have been found as ‘position of the parts’ and ‘ types of parts used’.     

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.     

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.     

Impact of product heterogeneity and soft budget constraint on excess capacity in Chinese energy industry based on the duopoly model

Chinese energy industries are facing serious problems such as excess capacity, homogeneous product, and soft budget constraint. This paper provides a duopoly model to investigate the influence of heterogeneity and soft budget constraint on production capacity decision and internal action mechanism, respectively, under Cournot and Bertrand competitions, which reveals the formation mechanism of excess capacity. We conclude that excess capacity would exist when the products are not wholly heterogeneous under Cournot competition, and the higher level of the soft budget constraint or the more homogeneous the products are, the worse the excess capacity will be. The insufficient capacity would exist provided that products are not wholly heterogeneous under Bertrand competition, and the higher level of soft budget constraint or the more homogeneous the products are, the more insufficient capacity will be. Both soft budget constraint and product heterogeneity mutually affect to decision-making of capacity and output.     

Relative Assessment of Indicators in Sustainability Enhancement (RAISE): a first approach in the manufacturing stage of products

The estimation of the sustainability performance of products requires tools to provide systematic approaches to the definition of impacts, indicators and comparative scenarios from early design stages. This paper illustrates the Relative Assessment of Indicators in Sustainability Enhancement (RAISE) methodology that is based on the measure of negative impacts generated during any product life cycle stage. This approach includes a systematic process for the definition and evaluation of indicators to compare the sustainability performance of products considering each indicator individually and using a holistic index of sustainability to entail an overall comparison between products from manufacturing scenarios. The RAISE method is developed with the aim of assessing sustainability performance of product life cycle stages and incorporating this assessment into the decision-making process when comparing different manufacturing scenarios. A guitar capo manufactured in polymeric material is used as case study to demonstrate the use of the method. In this paper, only the manufacturing stage is considered; however, the method can also be employed in other stages of the life cycle.     

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.     

Computational energy estimation tools for machining operations during preliminary design

The aim of this paper is to develop computational machining energy estimation tools during the early design stage of product development. In the preliminary or embodiment design, a product's shape and materials are determined. At this stage, it is crucial for a designer to be able to compare alternative designs and materials based on many different criteria, such as cost, functionality, energy, etc. Automated tools for estimating energy consumption that could later be used to integrate with CAD/CAM systems are in demand. This study presents computational tools for estimating the energy consumption of machining operations during the early design phase. The computational tools utilize a preliminary computer representation of a product (CAD model), its material and candidate machining operations to automatically analyse and estimate a range of energy consumption during machining operations. Detailed steps for computing turning and milling energy consumption are presented. Case studies of both parts and assemblies were conducted to test the validity of the tools and to evaluate the performance of the tools. Environmental impacts such as carbon weight will also be estimated. The computation tools will assist users with little knowledge about energy computations to estimate energy consumption during the design stage. Such energy estimation can be used to redesign parts and assemblies, leading to the development of products with reduced machining energy. The computation tools are part of a larger research on estimating energy consumption throughout a product's life cycle.     

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。     

A sustainable method for optimizing product design with trade-off between life cycle cost and environmental impact

In today’s competitive market, corporations have learned that taking sustainability issues into account can significantly improve their public image. Modern producers therefore must simultaneously reduce the environmental impact of their products and make economic gains. Therefore, making trade-offs between economic and environmental issues is required to ensure a company’s continuity. In doing so, companies have attached a great deal of importance to the new product design phase. However, optimization at the design stage becomes very complex for a product with a large number of parts, which can have several design alternatives with similar forms and functionality, but different costs and environmental impacts. In the automobile, shipbuilding and aircraft industries, if the conventional complete enumeration method is applied, the time required for selecting the optimal combination of design alternatives with respect to life cycle cost and environmental impact may exceed a human’s natural life span. To overcome this limitation, this paper introduces an optimization method for use as a design aid tool that enables a designer to assess the life cycle cost and environmental impact of his/her design very early in the product development process. To support the developed method, an illustration is provided using a case study on a locally manufactured automobile.     

Review of nanomaterial aging and transformations through the life cycle of nano-enhanced products

In the context of assessing potential risks of engineered nanoparticles (ENPs), life cycle thinking can represent a holistic view on the impacts of ENPs through the entire value chain of nano-enhanced products from production, through use, and finally to disposal. Exposure to ENPs in consumer or environmental settings may either be to the original, pristine ENPs, or more likely, to ENPs that have been incorporated into products, released, aged and transformed. Here, key product-use related aging and transformation processes affecting ENPs are reviewed. The focus is on processes resulting in ENP release and on the transformation(s) the released particles undergo in the use and disposal phases of its product life cycle for several nanomaterials (Ag, ZnO, TiO₂, carbon nanotubes, CeO₂, SiO₂ etc.). These include photochemical transformations, oxidation and reduction, dissolution, precipitation, adsorption and desorption, combustion, abrasion and biotransformation, among other biogeochemical processes. To date, few studies have tried to establish what changes the ENPs undergo when they are incorporated into, and released from, products. As a result there is major uncertainty as to the state of many ENPs following their release because much of current testing on pristine ENPs may not be fully relevant for risk assessment purposes. The goal of this present review is therefore to use knowledge on the life cycle of nano-products to derive possible transformations common ENPs in nano-products may undergo based on how these products will be used by the consumer and eventually discarded. By determining specific gaps in knowledge of the ENP transformation process, this approach should prove useful in narrowing the number of physical experiments that need to be conducted and illuminate where more focused effort can be placed.     

An integrated approach for the benchmarking of production facilities’ environmental performance: data envelopment analysis and life cycle assessment

Environmental impacts have become an important consideration in the manufacturing industry due to increasing public pressure for environment protection and the requirements of recently launched legislations. Data envelopment analysis (DEA) is a widely adopted methodological approach for the benchmarking of the relative efficiency of different production units. Changes in production efficiency may affect environmental impacts. DEA can be used for identifying the most efficient production facility and hence, the environmental impacts generated from the different production lines can then be benchmarked. Life cycle assessment (LCA) is carried out to quantify the full environmental impacts of a product from ‘cradle to grave’. The integration of LCA with DEA, efficiency and environmental impact of different production processes for a certain family of products can be evaluated and benchmarked. The proposed two-stage approach can help to reduce the aggregate environmental impacts of the manufacturing phase and is used to benchmark the environmental performance of several production lines in a manufacturing company.     

排污权交易条件下古诺市场动态系统的均衡及复杂性研究

目前国内外关于排污权交易方面的研究很多,但是大多数学者在排污权交易的理论研究和实践讨论中忽略了排污权交易对产品市场结构的影响问题.实际上,在中国市场体制并不完善的条件下实施排污权交易制度,有可能导致排污权交易市场以及产品市场的扭曲,必须对此加以研究.文章建立了排污权交易条件下的古诺离散动态系统模型,分析了排污权交易条件下古诺市场动态均衡及其稳定性问题.理论研究和数值模拟的结果表明:当排污权交易价格、厂商调整产量的相对速度、边际污染治理成本以及边际生产成本等参数发生变化时,纳什均衡点失去稳定性,经倍周期分叉后出现混沌状态.厂商调整产量的相对速度越慢,厂商的利润越稳定;厂商的边际生产成本、边际污染治理成本、污染排放系数以及排污权交易价格等参数越大,厂商要承受的风险也就越大,厂商对产量的调整余地也越小,厂商的利润相对稳定.     

Eco-efficiency in logistics: a case study on distribution network design

Sustainability demands that managers deliberate effects on stakeholders and the environment alongside traditional profitability measures. This paper presents a case study suggested by the managers of a distribution firm that seeks to balance environmental impact with cost in an industrial distribution network configuration decision incorporating product returns, which is currently taking place. While this can be modelled using mathematical programming, nonlinear terms in the objective functions as well as the likeliness that a large number of combinations of binary decision variables result suggest that this will not be able to be relied upon for a solution. For this reason, we propose a heuristic that aims at finding the Pareto-efficient frontier, which managers can use to deliberate the best solution balancing cost and environmental impact, according to the relative trade-offs of various possible configurations. We illustrate this heuristic on the Italian region of Liguria, and further explore trade-offs juxtaposing the regions of Lombardi and Sicily. Lastly, various extensions for enhanced product recovery opportunities for returns are suggested.