Advances in Green Manufacturing and Optimization

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 April 2024) | Viewed by 23707

Special Issue Editors


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Guest Editor
Department of Mechanics, Mathematics & Management, Polytechnical University of Bari, Piazza Umberto I, 1, 70121 Bari BA, Italy
Interests: manufacturing processes; product lifecycle management; sustainable manufacturing; eco-sustainability; industrial and manufacturing engineering; continuous improvement of manufacturing processes; distributed and delocalized production systems; quality management; renewable sources; manufacturing execution systems; cyber-physical systems; smart materials and their manufacturing and applications
Special Issues, Collections and Topics in MDPI journals
College of Information Science and Engineering, Northeastern University, Shenyang 110000, China
Interests: intelligent manufacturing; industrial big data; intelligent decision-making; production planning and scheduling

Special Issue Information

Dear Colleagues,

The rising carbon dioxide emissions and waste streams from industry sectors is a crucial factor for global warming. Therefore, the development of scientific and engineering solutions for green manufacturing is becoming an emerging topic to help reduce carbon intensity and other production waste, and to enhance the utilization of energy and natural resources. The recent advancement of intelligence technologies further expands the scope of typical environmentally conscious manufacturing, making modeling, analysis, real-time monitoring, control, and optimization of production and service automation more effective and efficient.

This Special Issue on “Advances in Green Manufacturing and Optimization” is to report the latest advancements in green manufacturing, with a focus on the development and deployment of new analytical models, frameworks, optimization algorithms, and management strategies aiming at improving the sustainability of manufacturing. The ultimate goal of this Special Issue is to foster the dissemination of high-quality research in terms of theory and practices related to green manufacturing automation. Topics include, but are not limited to:

  • Modeling and optimization of energy-aware manufacturing
  • Modeling and optimization of demanufacturing and remanufacturing;
  • Green process design and operation: production planning and scheduling
  • Green product design
  • Materials for green manufacturing
  • Artificial intelligence and machine learning in green manufacturing for product quality and process control
  • Life-cycle assessment: streamlined methods and case studies
  • Sustainable manufacturing practices
  • Smart paradigms for sustainability in manufacturing

Prof. Dr. Michele Dassisti
Dr. Shixin Liu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • green manufacturing
  • remanufacturing
  • demanufacturing
  • process industry
  • production planning and scheduling
  • modeling and optimization
  • intelligent manufacturing
  • smart paradigms
  • sustainable materials

Published Papers (8 papers)

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Research

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23 pages, 8105 KiB  
Article
Research on the Application of Structural Topology Optimisation in the High-Precision Design of a Press Machine Frame
by Zeqi Tong, Cheng Shen, Jie Fang, Mingming Ding and Huimin Tao
Processes 2024, 12(1), 226; https://doi.org/10.3390/pr12010226 - 20 Jan 2024
Viewed by 749
Abstract
This article aims to optimise the structure of a press machine to enhance its stability and accuracy, as well as reduce the frame deformation during processing. The outer supporting frame of the JH31-250 press machine (Zhejiang Weili Forging Machinery Co., Ltd, Shaoxing, China) [...] Read more.
This article aims to optimise the structure of a press machine to enhance its stability and accuracy, as well as reduce the frame deformation during processing. The outer supporting frame of the JH31-250 press machine (Zhejiang Weili Forging Machinery Co., Ltd, Shaoxing, China) is used as a typical sample for exploring optimisation. Commercial software is utilised to conduct a finite element analysis on the three-dimensional model of the press machine frame. A topological optimisation algorithm using the solid isotropic microstructures with penalisation (SIMP) method is then applied to improve the structure of the press frame. The size of the topological structure is further refined with the response surface method and particle swarm optimisation method to ensure it is more relevant to engineering application. The analysis results indicate that the initial frame’s deformation under the static conditions is 0.4229 mm, and after optimisation, the deformed structural displacement is 0.2548 mm, a decrease of 39.75%. Additionally, a simplified experimental method is designed to effectively validate the simulation and the proposed design. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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31 pages, 5133 KiB  
Article
The Low-Carbon Scheduling Optimization of Integrated Multispeed Flexible Manufacturing and Multi-AGV Transportation
by Zhengchao Liu, Qiang Luo, Lei Wang, Hongtao Tang and Yibing Li
Processes 2022, 10(10), 1944; https://doi.org/10.3390/pr10101944 - 27 Sep 2022
Viewed by 1530
Abstract
As low-carbon and sustainable manufacturing becomes the mainstream development direction of the current manufacturing industry, the traditional heavy industry manufacturing enterprises in China urgently need to transform. For the heavy cement equipment manufacturing enterprise investigated here, there is a large amount of energy [...] Read more.
As low-carbon and sustainable manufacturing becomes the mainstream development direction of the current manufacturing industry, the traditional heavy industry manufacturing enterprises in China urgently need to transform. For the heavy cement equipment manufacturing enterprise investigated here, there is a large amount of energy waste during the manufacturing operation due to scheduling confusion. In particular, the multispeed, multi-function machining and the transportation of multiple automated guided vehicles (multi-AGV) are the main influencing factors. Therefore, this paper addresses a novel low-carbon scheduling optimization problem that integrated multispeed flexible manufacturing and multi-AGV transportation (LCSP-MSFM & MAGVT). First, a mixed-integer programming (MIP) model is established to minimize the comprehensive energy consumption and makespan in this problem. In the MIP model, a time-node model is built to describe the completion time per workpiece, and a comprehensive energy consumption model based on the operation process of the machine and the AGV is established. Then, a distribution algorithm with a low-carbon scheduling heuristic strategy (EDA-LSHS) is estimated to solve the proposed MIP model. In EDA-LSHS, the EDA with a novel probability model is used as the main algorithm, and the LSHS is presented to guide the search direction of the EDA. Finally, the optimization effect and actual performance of the proposed method are verified in a case study. The experimental results show that the application of the proposed method in actual production can save an average of 43.52% comprehensive energy consumption and 64.43% makespan, which effectively expands the low-carbon manufacturing capacity of the investigated enterprise. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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25 pages, 1982 KiB  
Article
Analyzing Decision-Making Factors of Green Design for Kid’s Toys Based on the Concept of Product Lifecycle
by Jui-Che Tu, Ku-Hsi Chu, Ding-Ze Gao and Chun Yang
Processes 2022, 10(8), 1523; https://doi.org/10.3390/pr10081523 - 3 Aug 2022
Cited by 2 | Viewed by 4340
Abstract
In promoting the SDGs (Sustainable Development Goals), increasing attention has been given to environmental pollution and abnormal climate issues. In particular, a large number of products made of plastic materials have caused harm to the environment. Secondly, with the improvement of average spending [...] Read more.
In promoting the SDGs (Sustainable Development Goals), increasing attention has been given to environmental pollution and abnormal climate issues. In particular, a large number of products made of plastic materials have caused harm to the environment. Secondly, with the improvement of average spending power, many parents are more willing to buy toys for their children. However, the lifespan of kid’s toys is often short, and most materials are made of plastic, which also causes issues as they are not easy to break down and are difficult to recycle. This study investigates the concept of the product life cycle in kid’s toys and explores the decision-making factors of green design. First, analysis and induction were conducted through literature collection. Through semi-structured interviews with experts, the design dimensions related to the green design of kid’s toys and the elements that affect the willingness of consumption by consumption values and behavior were obtained. After the questionnaire survey and data analysis, the design factors and purchasing decision factors of green design for the product life cycle and consumption values and behavior of kid’s toys were obtained. Finally, combined with kid’s toy design, green design, product life cycle and consumers’ consumption values and behavior, the decision-making factors for the green design of kid’s toys were extracted, which included (1) using non-toxic materials; (2) designing for maintainability and disassembly of the toy; (3) refining the toys to be artistic and collectable; (4) upgrading the educational functions of toys; (5) improving the recycling of toys; (6) emphasizing green packing; (7) creating a green brand and increasing product visibility; and (8) advocating the value of green design for toys. In addition to supplying green design considerations for kid’s toys to designers and companies, the results can also be used as an important reference with regard to the research topics of product life cycle, toy design and development for the sustainable designs of products. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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16 pages, 1905 KiB  
Article
Sustainable Machining: Tool Life Criterion Based on Work Surface Quality
by Asif Iqbal, Guolong Zhao, Quentin Cheok, Ning He and Malik M. Nauman
Processes 2022, 10(6), 1087; https://doi.org/10.3390/pr10061087 - 30 May 2022
Cited by 6 | Viewed by 1851
Abstract
Extending the use of a component without compromising its intended functionality is the neatest approach to enhance sustainability. From this perspective, limiting the working life of a cutting tool based merely on the blunting of its cutting edge to a specific value is [...] Read more.
Extending the use of a component without compromising its intended functionality is the neatest approach to enhance sustainability. From this perspective, limiting the working life of a cutting tool based merely on the blunting of its cutting edge to a specific value is highly questionable. The very question that serves as the motivation for this work is, “why should tool life criterion be based on the shape of the tool when all that matters for business is the quality of the part being machined?”. This work puts forward a tool life criterion based on the surface quality of the machined part. The proof of the concept is provided by a series of face-turning experiments performed on a commonly used alloy steel using the following cutting inserts in dry conditions: (1) uncoated carbide; (2) coated carbide; and (3) cubic boron nitride (CBN). It is found that different combinations of tooling and cutting parameters lead to entirely different values of surface roughness at the same level of flank wear, thus raising the possibility of extending the working life of the tools. Overall, the CBN inserts yielded the longest tool life values, especially at high levels of cutting speed. Being more economical in respect of acquisition cost than the CBN inserts and more effective than the uncoated carbide inserts regarding tool life, the coated carbide inserts came out as the most sustainable tooling option. Finally, it is concluded that a tool life criterion based on work surface roughness can yield longer tool life values and make the machining process more sustainable. For the experimental work reported herein, the surface-quality based tool life criterion yielded on average 23% longer tool life. The presented work is novel as it presents a new approach to extend the working life of cutting tools without compromising the other sustainability measures. The outcomes are expected to find applicability in all sectors of the metal cutting industry, which are striving for elongations in tool life and improvements in work surface quality. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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18 pages, 2785 KiB  
Article
Channel Structure Choice for Remanufacturing under Green Consumerism
by Hong Tan, Guohua Cao, Yu He and Yujia Lu
Processes 2021, 9(11), 1985; https://doi.org/10.3390/pr9111985 - 7 Nov 2021
Cited by 6 | Viewed by 1832
Abstract
In recent decades, more and more consumers—referred to as “green consumers”—are willing to incorporate environmentally responsible decisions into their purchasing behaviors. This tendency is particularly notable in the European Union, the USA, and China. From a research perspective, while recent studies on remanufacturing [...] Read more.
In recent decades, more and more consumers—referred to as “green consumers”—are willing to incorporate environmentally responsible decisions into their purchasing behaviors. This tendency is particularly notable in the European Union, the USA, and China. From a research perspective, while recent studies on remanufacturing have investigated optimal practices in regard to green consumerism, they have failed to address the flexibility manufacturers are afforded to outsource remanufacturing operations to third parties. In practice, some brand-name manufacturers—such as IBM, Land Rover, and Sun—do indeed outsource their remanufacturing operations. To further our understanding of the implications of differentiated structures for remanufacturing operations under green consumerism, we developed two models: one for a manufacturer undertaking remanufacturing themselves (Model M), and one for a manufacturer outsourcing it to a third-party remanufacturer (Model O). Our results indicate that, for markets with significant green consumerism, Model M tends to result in more remanufactured units and creates higher profitability for the manufacturer. However, under certain conditions, this model may also result in greater harm to the environment due to the comparative excess of manufacturers in the remanufacturing process. This implies that environmental groups and agencies should not only aim to encourage green consumerism, but should also focus their attention on the channel structures for remanufacturing. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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17 pages, 512 KiB  
Article
Optimizing Painting Sequence Scheduling Based on Adaptive Partheno-Genetic Algorithm
by Jun Yang, Tong Sun, Xiuxiang Huang, Ke Peng, Zhongxiang Chen, Guoguang Qian and Zekai Qian
Processes 2021, 9(10), 1714; https://doi.org/10.3390/pr9101714 - 24 Sep 2021
Cited by 1 | Viewed by 1708
Abstract
In this paper, we formulate and solve a novel real-life large-scale automotive parts paint shop scheduling problem, which contains color arrangement restrictions, part arrangement restrictions, bracket restrictions, and multi-objectives. Based on these restrictions, we construct exact constraints and two objective functions to form [...] Read more.
In this paper, we formulate and solve a novel real-life large-scale automotive parts paint shop scheduling problem, which contains color arrangement restrictions, part arrangement restrictions, bracket restrictions, and multi-objectives. Based on these restrictions, we construct exact constraints and two objective functions to form a large-scale multi-objective mixed-integer linear programming problem. To reduce this scheduling problem’s complexity, we converted the multi-objective model into a multi-level objective programming problem by combining the rule-based scheduling algorithm and the adaptive Partheno-Genetic algorithm. The rule-based scheduling algorithm is adopted to optimize color changes horizontally and bracket replacements vertically. The adaptive Partheno-Genetic algorithm is designed to optimize production based on the rule-based scheduling algorithm. Finally, we apply the model to the actual optimization problem that contained 829,684 variables and 137,319 constraints, and solved this problem by Python. The proposed method solves the optimal solution, consuming 575 s. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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Review

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30 pages, 2977 KiB  
Review
A Qualitative and Quantitative Analysis of Remanufacturing Research
by Bashir Salah, Aiman Ziout, Mohammed Alkahtani, Moath Alatefi, Abdelatty Abdelgawad, Ahmed Badwelan and Umar Syarif
Processes 2021, 9(10), 1766; https://doi.org/10.3390/pr9101766 - 1 Oct 2021
Cited by 12 | Viewed by 3868
Abstract
The advancements in human lifestyle result in growth in daily demands of products, and accordingly, an increased rate of manufacturing. However, the resources on the planet Earth are limited, thus depleting day-by-day. More goods also contribute to more end-of-life (EOL) dumping or even [...] Read more.
The advancements in human lifestyle result in growth in daily demands of products, and accordingly, an increased rate of manufacturing. However, the resources on the planet Earth are limited, thus depleting day-by-day. More goods also contribute to more end-of-life (EOL) dumping or even before EOL in some cases. Therefore, an interest in remanufacturing has appeared, and it offers a solution that can solve or perhaps mitigate the risks of consuming more resources and increasing waste. Remanufacturing is a procedure of bringing used products to “like-new” functional status with a matching warranty. However, due to its relative novelty in terms of research field and industry, remanufacturing is poorly understood. People often mix it with other terms such as recycling, reconditioning, or repair. Therefore, in this research, the focus is on the remanufacturing systems’ definition, relevance, main phases, case studies, and solution methods proposed by various researchers. The word ‘remanufacturing’ is clearly described in this paper by differentiating it from alternative green manufacturing initiatives. Both qualitative and quantitative analysis of literature are performed. The quantitative analysis is conducted using a bibliometric method. For quantitative analysis, a systematic approach is utilized for research papers’ selection. The qualitative analysis has been carried out by discussing different aspects of remanufacturing and how the researchers are working on its different domains and phases. The review showed that researchers focused on some phases more as compared with others. Moreover, it is also revealed from the literature that the common solutions methods applied in this domain are optimization techniques. Future research directions are also identified and presented. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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31 pages, 3611 KiB  
Review
Application of Life Cycle Sustainability Assessment in the Construction Sector: A Systematic Literature Review
by Jana Gerta Backes and Marzia Traverso
Processes 2021, 9(7), 1248; https://doi.org/10.3390/pr9071248 - 19 Jul 2021
Cited by 48 | Viewed by 5971
Abstract
This paper reviews actual sustainability assessments in the construction sector to define whether and how a Life Cycle Sustainability Assessment (LCSA) is applied and interpreted in this sector today. This industry has large shares in global energy (33%), raw material consumption (40%) and [...] Read more.
This paper reviews actual sustainability assessments in the construction sector to define whether and how a Life Cycle Sustainability Assessment (LCSA) is applied and interpreted in this sector today. This industry has large shares in global energy (33%), raw material consumption (40%) and solid waste generation (40%). Simultaneously, it drives the economy and provides jobs. The LCSA is a method to identify environmental, social and economic impacts of products/services along their life cycles. The results of this study showed a mismatch between sectoral emissions and the number of LCSA-based impact evaluations. It was found that only 11% of papers reviewed assessed all three sustainability pillars. The economic and especially the social pillars were partly neglected. In Life Cycle Assessments (LCAs), 100% made use of Global Warming Potential (GWP) but only 30% assessed more than five indicators in total. In Life Cycle Costing (LCC), there were a variety of costs assessed. Depreciation and lifetime were mainly neglected. We found that 42% made use of Net Present Value (NPV), while over 50% assessed individual indicators. For the Social Life Cycle Assessment (S-LCA), the focus was on the production stage; even the system boundaries were defined as cradle-to-use and -grave. Future approaches are relevant but there is no need to innovate: a proposal for a LCSA approach is made. Full article
(This article belongs to the Special Issue Advances in Green Manufacturing and Optimization)
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