Exploring the Application of Lean Best Practices in Remanufacturing: Empirical Insights into the Benefits and Barriers

Remanufacturing processes have been widely identified as being important elements of a sustainable economy. However, the commercial viability of this product recovery route is significantly influenced by several operational challenges that are different from those that occur in conventional manufacturing. One of the most widely used systematic process improvement methods in conventional manufacturing is lean production, which seeks to minimize all forms of waste throughout an operation. As the academic study of lean best practices in remanufacturing processes is relatively new, there is a lack of knowledge regarding implementation and impact. As such, this paper presents multiple case studies investigating the application of lean methods in industrial remanufacturing operations. These studies focus on the automotive industry, where both conventional and remanufacturing operations have been the leading adopters of lean thinking and practice. The results of the investigation identify specific lean methods that help manage the inherent complexity of the remanufacturing processes, and consequently improve the overall productivity of the process. Similarly, factors that limit the application of lean practices within remanufacturing are also identified and discussed. Matrices for opportunities and threats are developed to enable the simple adoption of these findings. Overall, the research provides a more holistic understanding of the application of lean within a remanufacturing environment, with benefits for both academia and industry

Lean remanufacturing

"How do I apply lean methods in my remanufacturing organization?" is a question many executives and managers ask themselves. Since the literature on using lean tools in production environments is usually focused on original equipment manufacturers (OEMs), its application in commercial remanufacturing is often unreported. This chapter fills a gap in the literature with a brief overview of how remanufacturers can translate manufacturing-oriented lean tools and principles into their processes. The authors also discuss the challenges and opportunities that are peculiar to lean remanufacturing operations

Lean and the circular economy: A systematic literature review

Lean is a well-renowned strategy for increasing the value of products by minimizing waste. The circular economy is a new paradigm designed to mitigate environmental problems in production activities. Considering both perspectives, this article aims to understand how the application of lean can support the achievement of the circular economy. In order to attain this goal, the research presents a systematic literature review using the Scopus and Web of Science databases. Notably, the literature on the theme is still at an exploratory stage, the vast majority of research consisting of case studies. The main lean tools identified in the research are 5S and value stream mapping. The main circular practices, with lean support, are the Rs and ecodesign. The research proposes Circular Lean as a novel concept, one which merges some of the existing lean and circular economy principles. The main idea of this concept is the reutilization of material and energy, adding value and reducing waste within production processes and product life cycles

Lean Remanufacturing Of Electric Motors: Process Steps, Challenges And Solutions

The circular economy is an approach that aims to increase resource efficiency and hence sustainability. Remanufacturing as an element of the circular economy enables sustainability by multiple product utilization cycles. However, remanufacturing companies are seeking for optimization solutions for specific challenges in order to increase their competitiveness. Based on a case study with a remanufacturing SME (small and medium-sized enterprise), this paper focuses on process-oriented challenges when it comes to lean remanufacturing of electric motors. First, the process of remanufacturing is pointed out with its single steps. Then challenges are collected based on the process of remanufacturing electric motors. Lastly, potential solutions from the lean production point of view are evaluated regarding their effectiveness to overcome the collected challenges. The results can be applied by companies which consider to establish processes to remanufacture electric motors and at companies which have already established remanufacturing of electric motors but aim to improve their remanufacturing activities

Sustainable supply chain management trends in world regions: A data-driven analysis

This study proposes a data-driven analysis that describes the overall situation and reveals the factors hindering improvement in the sustainable supply chain management field. The literature has presented a summary of the evolution of sustainable supply chain management across attributes. Prior studies have evaluated different parts of the supply chain as independent entities. An integrated systematic assessment is absent in the extant literature and makes it necessary to identify potential opportunities for research direction. A hybrid of data-driven analysis, the fuzzy Delphi method, the entropy weight method and fuzzy decision-making trial and evaluation laboratory is adopted to address uncertainty and complexity. This study contributes to locating the boundary of fundamental knowledge to advance future research and support practical execution. Valuable direction is provided by reviewing the existing literature to identify the critical indicators that need further examination. The results show that big data, closed-loop supply chains, industry 4.0, policy, remanufacturing, and supply chain network design are the most important indicators of future trends and disputes. The challenges and gaps among different geographical regions is offered that provides both a local viewpoint and a state-of-the-art advanced sustainable supply chain management assessment

Circular Procurement: The First Step in a Series.

The Dutch Ministry of Infrastructure & Environment proudly hosted the first International Congress on Circular Procurement in Amsterdam on 20-22 April 2016. Attended by 120 experts from over 23 countries around the world, the Congress aims were to profile examples of Circular Procurement, to share experiences and to discuss how Procurement could be used as a powerful tool to deliver more circular economies.The Congress did not seek to define Circular Procurement but described it as the use of procurement as a mechanism to stimulate the circular economy by fulfilling the need for goods and services in a more circular, resource efficient way, by closing the loops of products, their components and the resources used as far as possible. Circular procurement therefore acts as a driver to help develop the circular economy by creating a demand for circular products. Collaboration, especially with the market, is an essential element in finding the best possible circular option available at the current time

Interrelationships between Circular Economy and Industry 4.0: A Research Agenda for Sustainable Supply Chains

The purpose of this article is to propose a novel classification of the interrelationships between I4.0 technologies and CE principles that highlights the most conclusive findings and extant gaps in the relevant research. A Systematic Literature Review has been developed to locate, select and evaluate relevant contributions made to CE interrelationships with I4.0 technologies. Studies have been analysed and classified according to the specific I4.0 technology and CE principle addressed (10Rs). The articles have been clustered into three main groups: (i) useful application of materials; (ii) extending the lifespan of products and their parts, and (iii) smarter product use and manufacture. A mind map of the investigated articles has been used to establish the interrelationships between individual technologies and each CE principle at the supply chain level. Based on this classification, a focus group interview (FGI) was held with experts to dig deeper into the interrelationships between I4.0 technologies and CE principles. The FGI results have identified how each as yet unexplored I4.0 technology could be linked to each CE principle. A Fuzzy Delphi (FD) study was also applied to identify the most relevant I4.0 technologies for improving CE principles and closing gaps in the literature regarding the 10R CE principles. In addition, guidelines have been established to assist with practical applications and generate a research agenda on the interrelationships between I4.0 technologies and CE principles at the supply chain level. Implications for theory include the extension of view from the research gaps between I4.0 technologies and the 10Rs identified in the literature; also, an FGI and FD were performed based on the detected research gaps to identify future lines of research for academics and offer useful guidance to directors and managers on I4.0 technology interrelationships for improving at least one of the 10R CE principles. The contribution to practice aims to enable managers to easily identify which technology from the I4.0 domain should be used to advance any given CE principle. Lastly, we provide useful guidance on the application of as yet-unused technologies to improve CE principles

Production planning and control of closed-loop supply chains

More and more supply chains emerge that include a return flow of materials. Many original equipment manufacturers are nowadays engaged in the remanufacturing business. In many process industries, production defectives and by-products are reworked. These closed-loop supply chains deserve special attention. Production planning and control in such hybrid systems is a real challenge, especially due to increased uncertainties. Even companies that are engaged in remanufacturing operations only, face more complicated planning situations than traditional manufacturing companies.We point out the main complicating characteristics in closed-loop systems with both remanufacturing and rework, and indicated the need for new or modified/extended production planning and control approaches. An overview of the existing scientific contributions is given. It appears that we only stand at the beginning of this line of research, and that many more contributions are needed and expected in the future.closed-loop supply chains;Production planning and control