Adaptive model to increase resilience for emerging supply chains within the circular economy : "Zirkelmesser" an innovative case study

Variations in quantity, quality and time availability of input materials pose a major risk to circular supply chains (CSC) and require new models for creating and evaluating adaptive and resilient CSC in the circular economy (CE). This can be achieved through consistent modelling of the overarching relationship between resource input- and output streams, without neglecting the associated risks. The model proposed below consists of five components based on five resilience requirements for supply-chains (SCs). It provides a data-based recommended course of action for managers with a low entry-barrier. It consists of a CSC visualization, safety stock calculation, risk monitoring for each SC node, reporting logic, and a measurement catalogue. The inspiration for this model came from an innovative case study ("Zirkelmesser") in the metal processing industry, where secondary products and materials are used to produce new products. Here, the problem of maintaining the resource supply arose and led to resilience issues. The mentioned case study serves as an application example for the model application and contributes to making emerging circular supply chains predictable and more controllable, thus increasing their resilience

Digital twin of end-of-life process-chains for a circular economy adapted product design - A case study on PET bottles

The concept of Circular Economy (CE) is gaining increasing attention as an indispensable renewal of linear economy without neglecting sustainable development goals. Closing resource loops and keeping resources in the system at the highest level of use for as long as possible are cited as the main goals of CE. However, due to missing information exchange, the lack of consistency between the existing end-of-life (EOL) infrastructure and the respective product designs hinders a successful circularity of resources. This research presents a method to collect, process, and apply EOL process data to provide the beginning-of-life (BOL) with important EOL-knowledge through a CE-adapted product design assessment. EOL-data is collected using a Circular Value Stream Mapping (C-VSM), EOL-information is processed using a digital state flow representation, and EOL-knowledge is applied by providing a decision-support tool for product designers in the context of a PET bottle case study in Luxembourg. The goal is to anticipate a circular flow of resources by reflectively aligning product design with the relevant EOL infrastructure. In contrast to the linear economy, the developed method makes it possible to consider not only the requirements of users but also the actual end users, the EOL process chains, when designing products

Adaptive model to increase resilience for emerging supply chains within the circular economs - 'Zirkelmesser' an innovative case study

Variations in quantities, qualities and time availability of input materials pose a major risk to circular supply chains (CSC) and require new models for creating and evaluating adaptive and resilient CSC in the circular economy (CE). This can be achieved by consistently modelling the overarching relationship between resource input- and output streams, without neglecting the associated risks. The model proposed below consists of five components which are based on five resilience requirements for SCs and provides a data-based recommended course of action for managers at a low entry-barrier. It consists of a CSC visualization, a safety stock calculation, a risk monitoring for each SC node, a reporting logic, and a measurement catalogue. The inspiration for this model came from an innovative case study (“Zirkelmesser”) in the metal processing industry in which secondary products and materials are used to produce new products. Here, the problem of maintaining the resource supply arose and led to resilience issues. The mentioned case study is used as an application example for the model application and helps to make emerging circular supply chains predictable and better manageable, thus increasing their resilience

Sustainability and Circular Economy in Learning Factories – Case Studies

Since the mitigation of climate change is one of the biggest challenges to face on a global scale, the topic has become more relevant also in industrial context. Learning factories have proven to be suitable environments to address and convey competencies to tackle industrial challenges in an interactive way. Hence, several learning factories are already dealing with sustainability topics in various use cases. This paper strives to present a state of the art of sustainability and circular economy in learning factories. Therefore, a classification framework is developed based on the state of the art of several learning factories and existing literature regarding the topic. This framework is then used to systematically describe the different activities regarding sustainability and circular economy that are currently ongoing in learning factories worldwide. This can be used to get an idea about the different aspects of the topic and how to address them, but furthermore also offers assistance to identify “blind spots” which could and should be addressed in learning factories in the future

"Quality audit" process: assessment of its maturity level

“Quality Audit” Process beschreibt das Verfahren von Prozessaudits, anders ausgedrückt, die einzelnen Schritte welche notwendig sind, um übereinstimmende Prozessaudits durchzuführen. Ein Prozessaudit ist eine Methode zur unabhängigen Analyse und Beurteilung von Produktentstehungsprozessen und deren Wirksamkeit für festgelegte Produkte. Ziel ist es, die Übereinstimmung betrachteter Prozesse mit den Anforderungen und Vorgaben zu überprüfen. Daraus folgend steigt die Qualität innerhalb eines Unternehmens, da Schwachstellen ausfindig gemacht werden um dann später verbessern zu werden. Ein Reifegradmodell beschreibt die Reife eines Betrachtungsfeldes hinsichtlich einer bestimmten Methode und besteht aus aufeinander aufbauenden Stufen. Die kontinuierliche Darstellung ermöglicht es, die einzelnen Schritte eines Prozessaudits innerhalb der Prozessbereiche darzustellen, und somit einzeln zu bewerten. Ziel dieser Arbeit ist es, ein neues Bewertungsmodell zu erstellen, welches es ermöglicht die einzelnen Schritte von internen Prozessaudits zu bewerten. Das neue Reifegradmodell ist so aufgebaut, dass die einzelnen Dimensionen in einer entsprechenden Reihenfolge aufgebaut sind, damit jede Dimension einen bestimmten Vorgehensschritt eines Prozessaudits darstellt. Dies ermöglicht es übereinstimmende Prozessaudits durchzuführen, zu bewerten und somit Schwachstellen ausfindig zu machen. Zudem geben die einzelnen Stufen vor, was notwendig ist, um sich zu verbessern, jedoch nicht, wie man dies umsetzt. Da Qualität einen unmessbaren Parameter darstellt, wurde bei der Erstellung des neuen Reifegradmodells auf das Predictive Validity Framework (PVF) zurückgegriffen. Dieses ermöglicht es, konzeptionelle Definitionen mit operativen Definitionen zu verbinden und somit, unmessbare Parameter zu messen. Ein bekanntes Beispiel hierfür sind Abiturnoten, welche von Universitäten oft als Aufnahmekriterium genutzt werden um die Zuversicht auf ein erfolgreiches Studium widerzuspiegeln. Einen strukturierten Aufbau bei der Entwicklung des neuen Reifegradmodells wird durch die sechs Tätigkeiten der Design Science Research Methodology (DSRM) sichergestellt. Da die Problemstellung sowie die Vorführung des neuen Bewertungsmodells in Verbindung mit einem Unternehmen durchgeführt wurden, handelt es sich hierbei um eine Action Research Methodology. In Bezug auf die Wissenschaft wurde ein neues Bewertungsmodell für Prozessaudits erstellt, was in jedem Produktionsunternehmen anwendbar ist. Dieses wurde in einem Unternehmen getestet, was eine genaue Bewertung deren Prozessaudits, mit anschließender Auflistung von Verbesserungsmöglichkeiten, ermöglichte.“Quality Audit” Process describes the process-audits procedure, in other words, the necessary steps to conclude conform and uniform process-audits. Process-audits verify if processes are working within established limits by checking their conformity against given requirements and specifications and are a type of internal audits. They help an organization to accomplish its objectives by bringing a systematic approach to evaluate and improve the effectiveness of different processes. Consequential, the quality within an organization will improve by identifying and rectifying weak spots. Maturity models are used to measure the ability of an organization in a particular discipline. The different levels of a maturity model are stages building on each other, which mature continuously with increasing levels. The continuous representation, which is used in this work, allows to divide a process-audit into different individual steps, the process-audit procedure, which are represented by the different process areas of the new maturity model. The aim of this thesis is to create a new assessment model, which can be used to assess the individual process-audits steps. The structure of the process areas is constructed in a way that it can be used as a specified procedure to conduct conform and uniform process-audits. Every process area represents in a sequencing way, the individual steps to conduct process-audits, from the planning to the following-up. Since quality is an immeasurable parameter, a new maturity model was developed to assess the quality of the different process-audits steps. By using the Predictive Validity Framework (PVF), it is possible to connect conceptual definitions with operational definitions. In other words the PVF is used to measure immeasurable parameters. One example is the high-school grades which are used to predict the preparedness of a student for later success at university (admission procedure). The development of the new maturity model is based on the six activities of the Design Science Research Methodology (DSRM). The problem statement and the later demonstration of the new maturity model are realized in cooperation with the PS-Organization. That is why this thesis consists of an Action Research Methodology, which is a combination of a solution for a given problem to the concerning organization (Action) and a contribution to the world of science (Research). Scientifically, the result is a new assessment model, which can be used within any production plant. The outcome for the PS-Organization is an accurate assessment of their currently used process-audit procedure with suggestions for improvement.12

Analysis of End-of-Life Process Data to enable Design Knowledge for Circularity

The concept of Circular Economy (CE) is gaining increasing attention as an indispensable renewal of linear economy without neglecting sustainable development goals. Closing resource loops and keeping resources in the system at the highest level of use for as long as possible are cited as the main goals of CE. However, due to missing information exchange, the lack of consistency between the existing End-of-Life (EOL) infrastructure and the respective product designs hinders a successful circularity of resources. This research provides a modular method to collect, process, and apply EOL process data to provide the Beginning-of-Life (BOL) with important EOL-knowledge through a CE adapted product design assessment. EOL-data is collected using a Circular Value Stream Mapping (CVSM), EOL-information is processed using a digital state flow representation, and EOL-knowledge is applied by providing a graphical user interface for designers. The method is verified by a simulation model that serves as a decision-support tool for product designers in the context of a PET bottle case study in Luxembourg. The goal is to anticipate a circular flow of resources by reflectively aligning product design with the relevant EOL infrastructure. Within the linear economy, the focus has been on improving production processes while neglecting what happens to a product after its use. The developed method makes it possible to consider not only the requirements of users but also the actual end users, the EOL process chains, when designing products

Value Stream Mapping (VSM) to Evaluate and Visualize Interrelated Process-Chains Regarding Circular Economy

The concept of circular economy (CE) aims to close and slow resource loops without neglecting the goals of sustainable development. Recently, the concept received encouraging attention among researchers and business experts to be a convenient solution to move away from the finite linear economy concept to a more sustainable solution. However, this change of paradigm is only possible if we consider systems in a holistic manner and can localize the preventing hurdles. Value stream mapping (VSM) is a commonly known lean method, used to develop current state visualization of product and information flows within organization, helping to seek weaknesses and improve process flows. The motivation of this paper is a new C-VSM model, which enables its users to evaluate and visualize connected process-chains regarding CE on different levels in a holistic manner. For this purpose, the traditional VSM model was adapted towards the needs and requirements of CE through the application of a new representation method, additional indicators, and an appropriated evaluation system. C-VSM is in line with the current political and industrial objectives to apply CE principles by enabling a holistic reflection and consideration of supply-chains (SCs) on different levels. The model itself is validated through an extensive cross-company case study

MULTI-LEVEL INFORMATION VALUE STREAM MAPPING

Digitalization and automation of the production according to Industry 4.0 opens new opportunities for companies to develop more efficient value chains. In the context of mass customization, it is promising to examine more closely the complete internal value chain of companies, from the first customer contact to the delivery of the finished product, prior to provide digital configurations for customized products. A critical aspect for internal inefficiencies and complication of an aspired automation are the interfaces of departments due to inconsistent and non-uniform information transfer. This article presents a versatile approach to visualize the internal information flow at inter-departmental level as well as at intra-departmental level. The described multilevel information value stream mapping method perfectly suits as prerequisite for a digitalization or automation of internal information flows. As framework for the time capturing and visualization, ISO 22468 is used, and an industrial use case exemplifies the research findings

An Innovative Strategy Allowing a Holistic System Change towards Circular Economy within Supply-Chains

The concept of the circular economy (CE) is receiving encouraging attention among scholars and practitioners, as a convenient solution to move away from the linear economy concept without neglecting the goals of sustainable development. The main goals of the CE are the closing of resource loops and the keeping of resources in the system for as long as possible at the highest utility level. However, as a result of the lack of internationally accepted definitions of the CE and several unsolved barriers, an excessive and inconsistent number of different CE applications exist. Most fields are mainly focusing on making a linear system circular instead of applying the CE principles in a holistic way. This paper presents a strategy to close the mentioned inconsistency gap, by contrasting currently discussed CE barriers and goals and thereof deriving two areas with a need for action (1. identifying the needed collection, sorting, and recovery infrastructure, and 2. developing circular product design guidelines). The strategy itself consists of connecting these two areas through an improved information exchange between the end-of-life (EOL) and beginning-of-life (BOL) of products. The result is CE design guidelines which are in accordance with the available or needed collection, sorting, and recovery infrastructure. The proposed strategy presents an innovative solution to apply CE principles in a holistic manner, based on EOL-driven product design

An Innovative Strategy Allowing a Holisitic System Change towards Circular Economy within Supply-Chains

: The concept of the circular economy (CE) is receiving encouraging attention among scholars and practitioners, as a convenient solution to move away from the linear economy concept without neglecting the goals of sustainable development. The main goals of the CE are the closing of resource loops and the keeping of resources in the system for as long as possible at the highest utility level. However, as a result of the lack of internationally accepted definitions of the CE and several unsolved barriers, an excessive and inconsistent number of different CE applications exist. Most fields are mainly focusing on making a linear system circular instead of applying the CE principles in a holistic way. This paper presents a strategy to close the mentioned inconsistency gap, by contrasting currently discussed CE barriers and goals and thereof deriving two areas with a need for action (1. identifying the needed collection, sorting, and recovery infrastructure, and 2. developing circular product design guidelines). The strategy itself consists of connecting these two areas through an improved information exchange between the end-of-life (EOL) and beginning-of-life (BOL) of products. The result is CE design guidelines which are in accordance with the available or needed collection, sorting, and recovery infrastructure. The proposed strategy presents an innovative solution to apply CE principles in a holistic manner, based on EOL-driven product design