The carbon footprint of manufacturing digitalization: Critical literature review and future research agenda

As the world of manufacturing is accelerating to its digital paradigm, it could become a significant generator of energy-consuming data. The storage of such data is facilitated by the proliferation of easily accessible cloud services, whilst the cost of transmission and storage has significantly dropped. Within a sustainability context, the carbon-footprint characteristics of these masses of data-capture, transmission, storage and management have not been given adequate due-diligence. A cause of this omission may be the assumption that renewable forms of energy generation and storage, may eventually render the big cloud data-centers carbon neutral. However, such assumptions may be pre-mature and not synchronized with unfolding realities, as the carbon footprint implications of the industry 4.0 discourse have not been assessed. This paper ascertains the absence of any structured assessment framework of CO2 emissions of the various components of industrial digitalization, as an evaluation tool of the accelerating digital transformation of manufacturing within a sustainable growth context

Improving the curing cycle time through the numerical modeling of air flow in industrial continuous convection ovens

Drying, curing, baking are few of the manufacturing processes that require the use of impingement ovens. For the manufacturing of large batches typically continuous flow ovens are used that are part of an automated conveyor processing line. The retention time for a product to be treated in the oven usually drives the production efficiencies (i.e. energy usage or lead times). In many processing lines though, the ovens are not designed and run in the most efficient way, and as a result become the “bottleneck” process phase. In such ovens, usually the hot air is ejected from rows of nozzles perpendicularly to the moving product. In the most advanced designs the ovens are divided in zones, with each zone having different targeted operating temperature. The optimization of the manufacturing process is difficult to be experimentally determined due to several reasons: the length of the ovens and the complexity of the movement of the product in and out of the oven are the most challenging ones. The main objective of this paper thus is the development of a Computer Fluid Dynamics model for simulating the thermal - transfer efficiency of an existing hot-air convection oven used to produce continuous products. The model is used for the estimation of the maximum speed that the conveyor belt can be run, and further investigate possible improvements on the design of the oven for the reduction of the cycle time. The results can be useful during the overview of the actual production and manufacturing rules

Management tool design for eco-efficiency improvements in manufacturing - a case study

As the worldwide GDP is forecasted to double by 2035, the energy demand globally is expected to increase by 34%. The industrial sector is also expected to account for more than 30% of the primary energy demand by 2040. These projections make manufacturing operations even more complicated when combined with predicted long-term inflation of raw material prices and increasingly stringent environmental regulations. Therefore, it has become increasingly more challenging for practitioners in manufacturing to improve their eco-efficiency or to “do more with less”. Traditional manufacturing management tools based on lean principles such as Value Stream Mapping have not been designed to facilitate eco-efficiency improvements. On the other hand, environmental management tools such as Life-Cycle Analysis focus more on improving environmental impacts rather than financial sustainability. This paper addresses the design gap between these tools and proposes an integrated toolkit for eco-efficiency improvements. The toolkit development process and design principles are described through a case study in the flooring industry. Results from each module are validated and the overall output is used to propose a range of applicable solutions to the manufacturer. Paper presented at: Complex Systems Engineering and Development Proceedings of the 27th CIRP Design Conference Cranfield University, UK 10th – 12th May 2017

Modelling the operations of a circular economy fashion start-up

Presented at: 56th CIRP International Conference on Manufacturing Systems 2023, 24-26 October 2023, Cape Town, South AfricaThis paper presents a case study of Pantala, a fashion start-up, intending to operationalise a circular supply of luxury womenswear through a monthly subscription-fee model. To optimize the company's cashflow and ensure success, the operational flows were modelled and analysed through discrete-event simulation techniques, with a focus on inventory management and minimizing operational costs. Simulation results demonstrated a high level of accuracy in predicting system performance, with an average relative error of less than 5% for most performance indicators. Insights are provided into the benefits of using simulation modelling for operational planning and optimization of complex systems, especially in the case of start-ups

Critical success factors for improving learning management systems diffusion in KSA HEIs: an ISM approach

Higher educational institutes (HEIs) are managing their resources by using learning management systems (LMS) which facilitate the learning processes. This paper aims to develop the relationships among success factors typically found in the technology, as well as the human and organisational aspects using an interpretive structural modelling (ISM) approach for LMS diffusion in HEIs in the Kingdom of Saudi Arabia (KSA). The success factors possessing a higher driving power in the ISM approach need to be prioritised as many other dependent variables are affected by them. Success factors emerging with high dependence contribute to facilitating the implementation of LMS. A key finding of the modelling is that clearly defined information technology (IT) policies along with appropriate technology infrastructure are significant factors for facilitating the technology aspect of LMS implementation. Additionally, the strengthening and standardisation of IT education resources, level of computer skills, proper training programmes for staff to deliver knowledge to users as well as a high level of human competencies are significant factors for facilitating the human aspect of LMS implementation. Moreover, the support of top management is a very significant factor for improving the organisational aspect of LMS. To ensure successful LMS implementation, KSA HEIs should focus on effective learning environments, facilitate education activities, top management involvement and increased interaction between pedagogy and technology. Understanding user characteristics and online needs is essential to ensure that barriers are overcome, ensuring successful and continued LMS implementation. Further, in this research, the relationship models among the identified success factors in terms of technology, human and organisational have not been statistically validated. However, it has been suggested that future research may be targeted to develop the initial model through ISM for success factors for improving LMS implementation and then testing it using Structural equation modeling (SEM)

Supply chain control towers: Technology push or market pull—An assessment tool

As digital technology and connectivity advance rapidly, the premise of bringing supply chain (SC) visibility across multiple tiers of supply, whilst facilitating the velocity to achieve strategic business objectives, is gaining interest. The feasibility and timing for successful adoption and implementation of such technology depend primarily on the readiness level and specific needs of each organisation, making it imperative to exercise insightful judgement as it can be expensive to acquire, develop and master. This research study examines the market pull versus technology push components of the functionalities enabled by digital SC control towers and buildings on the outcome of an extensive survey and expert interviews and proposes an assessment tool to aid decision making for the consideration of their adoption

Modelling sources of operational noise in production systems

This paper aims to identify and model the sources of operational noise that contribute to unstable and poor flow of materials in production systems. 80 interviews with managers and decision-makers were conducted and analyzed and have revealed that internal technical instabilities, employee variability, and customer and supplier uncertainty are the major sources of operational noise. They have also identified the relationships between the different variables of a production system that contribute to the amplification of operational noise and hence should be managed effectively to ensure a smooth flow in manufacturing operations

The concept of carbon accounting in manufacturing systems and supply chains

Carbon accounting is primarily a process for measuring, reporting, and allocating greenhouse gas emissions from human activities, thus enabling informed decision-making to mitigate climate change and foster responsible resource management. There is a noticeable upsurge in the academia regarding carbon accounting, which engenders complexity due to the heterogeneity of practices that fall under the purview of carbon accounting. Such plurality has given rise to a situation where diverse interpretations of carbon accounting coexist, often bereft of uniformity in definition and application. Consequently, organisations need a standardised, comprehensive, and sequentially delineated carbon accounting framework amenable to seamless integration into end-to-end manufacturing systems. This research commences with the progressive evolution of the conceptual definition of carbon accounting. Then, it delves into the current state of carbon accounting in manufacturing systems and supply chains, revealing gaps and implementation issues warranting future scholarly exploration

Carbon accounting management in complex manufacturing supply chains: a structured framework approach

Improving the management of carbon emissions in the drive to Net-Zero can involve both complex measurements and the development of cleaner technologies, which is a demanding challenge for both the private and public sectors. Specifically, within complex and often sensitive supply chains such as aerospace manufacturing, accounting for carbon management requires quantification of the extended enterprise’s direct and indirect emissions as a system. Currently however, there is a lack of standardised methods for carbon accounting suitable for use in the measurement and auditing of carbon performance both in the production process as well as in the supply chain. This research presents a structured framework-based approach, that could facilitate accurate, consistent and simplified management of carbon scoping, measurement and reporting, across complex extended supply chains. The proposed five step approach sets a thematic orientation for future customisation of carbon accounting tools at every step of the framework

Multi-objective reconfigurable manufacturing system scheduling optimisation: a deep reinforcement learning approach

Rapid product design updates, unstable supply chains, and erratic demand phenomena are challenging current production modes. Reconfigurable manufacturing systems (RMS) aim to provide a cost-effective solution for responding to these challenges. However, given their complex adjustable nature, RMSs cannot fully unlock their potential by applying old-fashion fixed dispatching rules. Reinforcement learning (RL) algorithms offer a useful approach for finding optimal solutions in such complex systems. This paper presents a framework to train a scheduling agent based on a proximal policy optimisation (PPO) algorithm. The results of a numerical case study that implemented the framework on a simplified RMS model, suggest a good level of robustness and reveal areas of unpredictable behaviour that could be the focus of further research