Field Study and Multimethod Analysis of an EV Battery System Disassembly

In the coming decades, the number of end-of-life (EoL) traction battery systems will increase sharply. The disassembly of the system to the battery module is necessary to recycle the battery modules or to be able to use them for further second-life applications. These different recovery paths are important pathways to archive a circular battery supply chain. So far, little knowledge about the disassembling of EoL batteries exists. Based on a disassembly experiment of a plug-in hybrid battery system, we present results regarding the battery set-up, including their fasteners, the necessary disassembly steps, and the sequence. Upon the experimental data, we assess the disassembly duration of the battery system under uncertainty with a fuzzy logic approach. The results indicate that a disassembling time of about 22 min is expected for the battery system in the field study if one worker conducts the process. An estimation for disassembling costs per battery system is performed for a plant in Germany. Depending on the plant capacity, the disassembling to battery module level is associated with costs between EUR 80 and 100 per battery system

Integrating Closed-loop Supply Chains and Spare Parts Management at IBM

Ever more companies are recognizing the benefits of closed-loop supplychains that integrate product returns into business operations. IBMhas been among the pioneers seeking to unlock the value dormant inthese resources. We report on a project exploiting product returns asa source of spare parts. Key decisions include the choice of recoveryopportunities to use, the channel design, and the coordination ofalternative supply sources. We developed an analytic inventory controlmodel and a simulation model to address these issues. Our results showthat procurement cost savings largely outweigh reverse logistics costsand that information management is key to an efficient solution. Ourrecommendations provide a basis for significantly expanding the usageof the novel parts supply source, which allows for cutting procurementcosts.supply chain management;reverse logistics;product recovery;inventory management;service management

Disassembly line scheduling with genetic algorithms.

International audienceDisassembly is part of the demanufacturing and it is meant to obtain components and materials from end-of-line products. An essential performance objective of a disassembly process is the benefits it brings, that is the revenue brought by the retrieved parts and material, diminished by the cost of their retrieval operations. A decision must be taken to balance an automatic disassembly line. A well balanced line will decrease the cost of disassembly operations. An evolutionary (genetic) algorithm is used to deal with the multi-criteria optimization problem of the disassembly scheduling

Proactive-reactive, robust scheduling and capacity planning of deconstruction projects under uncertainty

A project planning and decision support model is developed and applied to identify and reduce risk and uncertainty in deconstruction project planning. It allows calculating building inventories based on sensor information and construction standards and it computes robust project plans for different scenarios with multiple modes, constrained renewable resources and locations. A reactive and flexible planning element is proposed in the case of schedule infeasibility during project execution

Decision makings in key remanufacturing activities to optimise remanufacturing outcomes : a review

The importance of remanufacturing has been increasing since stricter regulations on protecting the environment were enforced. Remanufacturing is considered as the main means of retaining value from used products and components in order to drive a circular economy. However, it is more complex than traditional manufacturing due to the uncertainties associated with the quality, quantities and return timing of used products and components. Over the past few years, various methods of optimising remanufacturing outcomes have been developed to make decisions such as identifying the best End-Of-Life (EOL) options, acquiring the right amounts of cores, deciding the most suitable disassembly level, applying suitable cleaning techniques, and considering product commonality across different product families. A decision being made at one remanufacturing activity will greatly affect the decisions at subsequent activities, which will affect remanufacturing outcomes, i.e. productivity, economic performance effectiveness, and the proportion of core that can be salvaged. Therefore, a holistic way of integrating different decisions over multiple remanufacturing activities is needed to improve remanufacturing outcomes, which is a major knowledge gap. This paper reviews current remanufacturing practice in order to highlight both the challenges and opportunities, and more importantly, offers useful insights on how such a knowledge gap can be bridged

Modelling and condition-based control of a flexible and hybrid disassembly system with manual and autonomous workstations using reinforcement learning

Remanufacturing includes disassembly and reassembly of used products to save natural resources and reduce emissions. While assembly is widely understood in the field of operations management, disassembly is a rather new problem in production planning and control. The latter faces the challenge of high uncertainty of type, quantity and quality conditions of returned products, leading to high volatility in remanufacturing production systems. Traditionally, disassembly is a manual labor-intensive production step that, thanks to advances in robotics and artificial intelligence, starts to be automated with autonomous workstations. Due to the diverging material flow, the application of production systems with loosely linked stations is particularly suitable and, owing to the risk of condition induced operational failures, the rise of hybrid disassembly systems that combine manual and autonomous workstations can be expected. In contrast to traditional workstations, autonomous workstations can expand their capabilities but suffer from unknown failure rates. For such adverse conditions a condition-based control for hybrid disassembly systems, based on reinforcement learning, alongside a comprehensive modeling approach is presented in this work. The method is applied to a real-world production system. By comparison with a heuristic control approach, the potential of the RL approach can be proven simulatively using two different test cases

Integrating Closed-loop Supply Chains and Spare Parts Management at IBM

Ever more companies are recognizing the benefits of closed-loop supply chains that integrate product returns into business operations. IBM has been among the pioneers seeking to unlock the value dormant in these resources. We report on a project exploiting product returns as a source of spare parts. Key decisions include the choice of recovery opportunities to use, the channel design, and the coordination of alternative supply sources. We developed an analytic inventory control model and a simulation model to address these issues. Our results show that procurement cost savings largely outweigh reverse logistics costs and that information management is key to an efficient solution. Our recommendations provide a basis for significantly expanding the usage of the novel parts supply source, which allows for cutting procurement costs

An integrated approach to value chain analysis of end of life aircraft treatment

Dans cette thèse, on propose une approche holistique pour l’analyse, la modélisation et l’optimisation des performances de la chaîne de valeur pour le traitement des avions en fin de vie (FdV). Les recherches réalisées ont débouché sur onze importantes contributions. Dans la première contribution, on traite du contexte, de la complexité, de la diversité et des défis du recyclage d’avions en FdV. La seconde contribution traite du problème de la prédiction du nombre de retraits d’avions et propose une approche intégrée pour l’estimation de ce nombre de retraits. Le troisième et le quatrième articles visent à identifier les parties prenantes, les valeurs perçues par chaque partenaire et indiquent comment cette valeur peut affecter les décisions au stade de la conception. Les considérations relatives à la conception et à la fabrication ont donné lieu à quatre contributions importantes. La cinquième contribution traite des défis et opportunités pouvant résulter de l’application des concepts de la chaîne logistique verte, pour les manufacturiers d’avions. Dans la sixième contribution, un outil d’aide à la décision a été développé pour choisir la stratégie verte qui optimise les performances globales de de toute la chaîne de valeur en tenant compte des priorités et contraintes de chaque partenaire. Dans la septième contribution, un modèle mathématique est proposé pour analyser le choix stratégique des manufacturiers en réponse aux directives en matière de FdV de produits comme le résultat des interactions des compétiteurs dans le marché. La huitième contribution porte sur les travaux réalisés dans le cadre d’un stage chez le constructeur d’avions, Bombardier. Cette dernière traite de l’apport de « l’analyse du cycle de vie » au stade de la conception d’avions. La neuvième contribution introduit une méthodologie d’analyse de la chaîne de valeur dans un contexte de développement durable. Finalement, les dixième et onzième contributions proposent une approche holistique pour le traitement des avions en FdV en intégrant les concepts du « lean », du développement durable et des contraintes et opportunités inhérentes à la mondialisation des affaires. Un modèle d’optimisation intégrant les modèles d’affaires, les stratégies de désassemblage et les structures du réseau qui influencent l’efficacité, la stabilité et l’agilité du réseau de récupération est proposé. Les données requises pour exploiter le modèle sont indiquées dans l’article. Mots-clés: Fin de vie des avions, analyse de la chaîne de valeurs, développement durable, intervenants.The number of aircrafts at the end of life (EOL) is continuously increasing. Dealing with retired aircrafts considering the environmental, social and economic impacts is becoming an emerging problem in the aviation industry in near future. This thesis seeks to develop a holistic approach in order to analyze the value chain of EOL aircraft treatment in the context of sustainable development. The performed researches have led to eleven main contributions. In the first contribution, the complexity and diversity of the EOL aircraft recycling including the challenges and problem context are discussed. The second contribution addresses the challenges for estimation of retired aircrafts and proposes an integrated approach for prediction of EOL aircrafts. The third and fourth contributions aim to identify the players involved in EOL recycling context, values perceived by different shareholders and formulate that how such value can affect design decisions. Design stage consideration and manufacture’s issues are discussed and have led to four main contributions. The fifth contribution addresses the opportunities and challenges of applying green supply chain for aircraft manufacturers. In the sixth contribution, a decision tool is developed to aid manufactures in early stage of design for their green strategy choices. In the seventh contribution, a mathematical model is developed in order to analyze the strategic choice of manufacturers in response to EOL directives as the result of the interaction of competitors in the market. An internship project has been also performed in Bombardier and led to the eighth contribution, which addresses life cycle approach and incorporating the sustainability in early stage of design of aircraft. The ninth contribution introduces a methodology for analyzing the value chain in the context of sustainable development. Finally, the tenth and eleventh contributions propose a holistic approach to EOL aircraft treatment considering lean principals, sustainable development, and global business environment. An optimization model is developed to support decision making in both strategic and managerial level. The analytical approaches, decision tools and step by step guidelines proposed in this thesis will aid decision makers to identify appropriate strategies for the EOL aircraft treatment in the sustainable development context. Keywords: End of life aircraft, value chain analysis, sustainable development, stakeholders

A Linear Programming Model for Renewable Energy Aware Discrete Production Planning and Control

Industrial production in the EU, like other sectors of the economy, is obliged to stop producing greenhouse gas emissions by 2050. With its Green Deal, the European Union has already set the corresponding framework in 2019. To achieve Net Zero in the remaining time, while not endangering one's own competitiveness on a globalized market, a transformation of industrial value creation has to be started already today. In terms of energy supply, this means a comprehensive electrification of processes and a switch to fully renewable power generation. However, due to a growing share of renewable energy sources, increasing volatility can be observed in the European electricity market already. For companies, there are mainly two ways to deal with the accompanying increase in average electricity prices. The first is to reduce consumption by increasing efficiency, which naturally has its physical limits. Secondly, an increasing volatile electricity price makes it possible to take advantage of periods of relatively low prices. To do this, companies must identify their energy-intensive processes and design them in such a way as to enable these activities to be shifted in time. This article explains the necessary differentiation between labor-intensive and energy intensive processes. A general mathematical model for the holistic optimization of discrete industrial production is presented. With the help of this MILP model, it is simulated that a flexibilization of energy intensive processes with volatile energy prices can help to reduce costs and thus secure competitiveness while getting it in line with European climate goals. On the basis of real electricity market data, different production scenarios are compared, and it is investigated under which conditions the flexibilization of specific processes is worthwhile