Circular Economy Strategies for Equipment Lifetime Extension: A Systematic Review
Abstract
:1. Introduction
- Which is the state of research related to equipment lifetime extension strategies and their definition?
- Which are the possible elements to be extracted from literature to implement the LCES from the technical and business point of view?
2. Review Methodology and Trend Analysis
2.1. Review Methodology
2.1.1. Gathering the Publications and Patents
2.1.2. Identifying Topic References
2.1.3. Taxonomy Definition
2.1.4. Classification Through the Taxonomy
2.2. Trend Analysis
2.2.1. Paper Trend Analysis
2.2.2. Patent Trend Analysis
3. Analysis of the Literature
3.1. Analysis via the Defined Taxonomy
3.2. Maintenance and Remanufacturing Standards
4. Discussion
4.1. Life Cycle Extension Strategies and Definitions
4.2. The Strategy Characterization Framework
- Target: it reports which is the focus of the strategy. Specifically, a strategy may concern the whole equipment or parts of it such as assemblies, components or the materials constituting the product.
- Life cycle phases involved: it considers the possible life cycle phase of the production equipment that are affected/involved by the strategy. As already shown, LCES are not only affecting the EoL phase of the equipment but could require intervention in many other product life span moments, starting from the design phase.
- Stakeholder involved: it is meant to list the stakeholders mainly involved in the strategy implementation. This field of the SCF is meant to provide a view on the different actors that are actively or passively involved in the LCES, both in its implementation and during the functioning of the strategy.
- Stakeholder contribution: it describes for each stakeholder their contribution to the strategy implementation and functioning. After identifying the involved partners, their specific role, active or more passive, has to be precisely recognized so that the Original Equipment Manufacturers have a map to know how and when a stakeholder has to be activated or addressed.
- Hierarchy: it identifies the hierarchy distinguishing short loop (where product remains close to the user and its original function), medium-long loop (where products are upgraded and, at least a part of them, may be moved away from their first installation place) and long loop (where products lose their original function or components are mainly exploited as monitored sources of materials). This field offers a rapid, qualitative overview on how much the strategy is oriented to a strict application of the CE approach, where the short loop strategies are the ones aimed to prolong the life cycle of the equipment as a whole, with few interventions and new components needed.
- Ownership model: it indicates the owner of the machinery after the execution of the actions related to a given strategy. The field is meant to distinguish strategies based on a more traditional business model, where the ownership is retained by the equipment user, to the ones that are promoting servitization, where the ownership of the machine is maintained by the OEM.
- Equipment condition after the implementation of the strategy: it indicates the state of the equipment after the application of a certain strategy. The condition of the product can correspond to: the original one, a decreased quality of the whole machine and their components, enhanced performances or even a completely different function for the machine subjected to the strategy implementation.
- Enabling elements/technologies: it shows the elements that enable the strategy deployment. Many LCES requires the deployment of technologies (IoT, augmented and virtual reality, recycling technologies...) and/or methodologies (design for re-manufacturing, pay per use approach) in order to actually put in place the strategy in a specific industrial application.
- Closing loop management model: it indicates the life cycle loop management approach promoted by the strategy. In the context of CE and LCES it is improper to talk about End of Life of the equipment or of its components, even though during life cycle extension some parts are discharged. The closing loop management model can thus assume a unique approach (100% reuse) or a blended one (70% reuse, 30% recycle for unrecovered parts).
- Circular BM involved: this field is meant to identify which are the possible Circular Business Models related to the strategy application. This is a focal point in order to make companies understand how life cycle extension can generate profit.
- Strategy Implementation Actions: it lists the action needed to implement a strategy starting from the blank page. This field of the SCF is meant to provide valuable support to companies interested in the actual implementation of LCES since they could exploit the list checking their as-is status, evaluating their maturity level in respect of a specific methodology and plan next steps and concrete activities in order to put in place the desired approach to equipment life cycle extension.
4.3. Recommendation for Future Literature Investigations
5. Conclusions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Boundary | Description |
---|---|
Database used | Science direct (Elsevier); Web of Science; Lens patent; Google patent. |
Research Keywords | Circular economy strategies, Lifecycle extension strategies, Lifecycle extension industrial/production equipment, Digitalization and lifetime extension. |
Year considered | From 2002 up to 2020, with the majority of the studies concentrated from 2010. The only exception is a 1995 publication, considered as the ancestor of life extension topic. |
Language | Scientific articles in English were considered for the analysis. |
Article type | Scientific papers and conference papers. |
Publication status | Published. |
Patent status | Granted. |
Taxonomy Field | Research Question | Field Scope |
---|---|---|
Literature Review | State of research | It is meant to select the papers that are providing an extensive literature review on the LCES or on the related topics. |
Life cycle Extension | State of research | It investigates whether the publication is considering the life cycle extension concept, directly or indirectly mentioning it. |
Production Equipment | State of research | It discriminates if the publication is specifically dealing with production equipment. |
Strategies | State of research | It is discriminating if the publication in analysis is presenting strategies to extend the life cycle of products. |
Definition | State of research | It allows identifying the papers providing a precise definition of the LCES. This field was introduced since a preliminary analysis of the research results revealed that some unclear or even conflicting definitions of strategies are proposed in the literature. |
Description and Implementation Guidelines | Implementation | It is meant to establish whether the publication in analysis is providing a description of the strategy application in the industrial context, or even is proposing guidelines that could actually support the implementation of the strategy presented. |
Metrics and Evaluation Methodologies | Implementation | It investigates if the paper is presenting metrics and indicators to evaluate the effects of the strategy implementation from the economic and environmental point of view, or evaluation methodologies enabling discrimination between the diverse LCES. |
Business Models | Implementation | It is meant to identify the publications presenting a business view related to the LCES application in the form of a possible business model to be concretely applied in the industrial application. |
Digitalization and Lifetime Extension | Implementation | It describes how digitalization plays a crucial role to enable more sustainable Circular Economy and how a product’s lifetime is extended thanks to digital innovation, with a specific focus on the extension of the lifespan of machinery, equipment and product. |
Taxonomy Field | Publications |
---|---|
Literature Review | [24], [25], [26], [27], [28], [29], [30], [31], [32], [33], [34], [35] |
Life cycle Extension | [24], [25], [26], [27], [28], [29], [36], [37], [38], [39], [40], [41], [42], [43], [44], [45], [46], [47], [48], [49], [50], [51], [52], [53], [54], [55], [56], [57], [58], [59], [60], [61], [62], [63] |
Production Equipment | [62] |
Strategies | [24], [25], [26], [27], [28], [30], [31], [32], [34], [36], [37], [38], [39], [40], [41], [42], [43], [44], [45], [46], [47], [48], [49], [50], [51], [52], [57], [58], [59], [60], [61], [62], [64], [65], [66], [67], [68], [69] |
Definition | [25], [27], [28], [30], [33], [36], [37], [40], [42], [43], [44], [45], [46], [47], [48], [49] |
Description and Implementation Guidelines | [25], [28], [31], [33], [35], [39], [40], [41], [42], [44], [43], [45], [46], [47], [48], [49], [50], [51], [52], [57], [61], [70], [65], [63], [66], [67], [71], [72], [73], [74] |
Metrics and Evaluation Methodologies | [27], [29], [31], [32], [34], [36], [47], [48], [49], [50], [53], [54], [55], [58], [59], [60], [64], [68], [69], [71], [72], [73], [74], [75] |
Business Models | [25], [26], [30], [35], [45], [46], [57] |
Digitalization and Lifetime Extension | [11], [26], [30], [45], [76], [77], [78], [79], [80], [81], [82], [83], [84], [85], [86], [87], [15], [88], [89], [90], [91] |
TOTAL | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 |
---|---|---|---|---|---|---|---|---|---|---|
Digitalization | 81,095 | 87,005 | 94,714 | 95,286 | 98,637 | 108,230 | 119,506 | 129,364 | 150,279 | 168,301 |
Lifetime extension | 804 | 811 | 993 | 972 | 1149 | 1198 | 1340 | 1328 | 1494 | 1661 |
Digitalization & lifetime extension | 12 | 3 | 19 | 29 | 42 | 25 | 51 | 73 | 91 | 160 |
# | Strategy |
---|---|
1 | Design for durability/reliability |
2 | Design for modularity and part standardization |
3 | Design for ease of maintenance and repair |
4 | Design for upgradability |
5 | Design for disassembly and reassembly |
6 | Resell–Reuse |
7 | Repair or Corrective Maintenance |
8 | Preventive maintenance |
9 | Predictive maintenance (preventive) |
10 | Time-based maintenance (preventive) |
11 | Condition-based maintenance (preventive) |
12 | Remanufacture |
13 | Recondition |
14 | Refurbish |
15 | Cannibalization |
16 | Recycle |
Strategy | Revised Definition | References |
---|---|---|
Design for durability/reliability | The ability of a product to perform the function (s) it was designed and built for an extended period of time or a specified period without experiencing failure or excessive wear and tear, considering also its environmental performances. | [26], [43], [46] |
Design for modularity and part standardization | Design approach that is meant to achieve the maximum level of simplification and standardization in product design with common product platform and more efficient use of resources. In manufacturing fields, universalization, serialization and modularization are the three most important metrics. | [25], [43], [68] |
Design for ease of maintenance and repair | This approach allows the products and parts to be maintained and repaired easily in order to retain the functional capability of a product or restore the working condition of a damaged product. | [25], [30], [31], [43], [63] |
Design for upgradability | Approach to the design meant to facilitate the enhancement of a product’s functional as well as physical fitness for ease of upgrade. | [25], [35], [43], [46] |
Design for disassembly and reassembly | The characteristics of this approach allow for the separation and reassembly of products and parts in the most efficient way, i.e., the most suitable sequence is determined with minimal removal of components, ensuring environmental safety and avoiding future costly environmental liabilities | [25], [34], [43] |
Design for component recovery | It includes design for refurbishment and design for remanufacture. The concept of recovery stems from the fact that a certain number of parts or subassemblies have a design life that exceeds the life of the product itself, making the idea of reuse practical. | [43] |
Resell–Reuse | Reuse and resell can be defined as the second or further use by another consumer of a discarded product that is still in good condition and does not require any correction or repair action. The resold or reused products retain their function and identity. | [25], [40], [41], [42], [44], [46], [47], [49], [52], [62] |
Repair or Corrective Maintenance | Set of activities performed on a defective product so it can be used with its original function. Repair is also making a broken product operational again through fixing/replacing failed parts. The objective of repair is “bringing back to working order”, “making it as good as new”, “recreating its original function after minor defects”, “replacing broken parts”. | [25], [28], [30], [33], [40], [41], [42], [46], [47], [48], [49], [52] |
Preventive maintenance | Preventative maintenance is the performance of inspection and/or servicing tasks that were pre-planned for accomplishment at specific points in time to retain the functional capabilities of operating equipment or systems and to reduce the probability of failure or prevent degradation of the functioning of a product. | [25], [46], [49] |
Predictive maintenance (preventive) | A condition-driven preventative maintenance program. It uses direct monitoring of the mechanical condition, system efficiency, and other indicators to determine the actual mean time to failure or loss of efficiency. | [25], [46], [49] |
Time-based maintenance (preventive) | A preventive maintenance consisting of restoring or replacing a component regardless of the condition of the product. This can happen based on time (predetermined time intervals) or based on the operating time of machines/components or on the remaining useful life (in this case a dedicated system is required to support data collection and maintenance planning). | [25], [46], [49] |
Condition-based maintenance (preventive) | A strategy based on the component restoration or replacement based on a measured condition compared to a defined standard (thresholds). Condition data can then be collected through non-invasive measurements, visual inspection, performance data, and scheduled testing. | [25], [46], [49] |
Remanufacture | Remanufacture (or second-life production) is a strategy that implies using parts of discarded products in a new product with the same function. Used products are brought at least to original equipment manufacturer performance specification. Remanufactured products guarantee the same quality as original products. Remanufacture applies where the full structure of a multi-component product is disassembled, checked, cleaned and when necessary replaced or repaired in an industrial process. | [25], [28], [30], [40], [41], [42], [44], [46], [47], [48], [49], [52], [62] |
Recondition | Reconditioning involves taking a product and restoring all critical modules that are inspected and upgrade it to specified quality level, typically less than virgin standard. Any warranties issued are typically less than a warranty given to a virgin product. | [28], [47], [48] |
Refurbish | Refurbish means restoring an old product and bringing it up to date. In general, refurbished products are upgraded and brought back to specified quality standards or satisfactory working and/or cosmetic conditions and have to fulfill extensive testing. Occasionally, refurbishing is combined with technology upgrading by replacing outdated modules and parts with technologically superior ones. | [25], [28], [36], [40], [41], [42], [48], [52] |
Cannibalization | Cannibalization is the activity of recovering parts from returned products. Recovered parts are used in repair, refurbishing, reconditioning and remanufacturing of other products. | [25], [36], [41], [42] |
Recycle | Recycling is the processing of materials to obtain the same (high-grade), or lower (low-grade), quality of recycled materials. The purpose of recycling is to reuse materials from used products and components. These materials can be reused in production of original parts if the quality of materials is high, or else in production of other parts. Recycling begins when used products and components are disassembled into parts. These parts are separated into distinct material categories. These separated materials are subsequently reused in the production of new parts. | [25], [28], [36], [40], [41], [42], [47], [49], [52], [62] |
Field | Resell–Reuse Strategy |
---|---|
Revised definition | Reuse and resell can be defined as the second or further use by another consumer of a discarded product that is still in good condition and does not require any correction or repair action. The resold or reused products retain their function and identity. |
Typology of strategy | Closing loop |
Target | Equipment |
Stakeholder involved | 1. Customer 2. Retailer 3. OEM or an alternative one 4. Reverse logistic partners |
Stakeholder contribution | 1. Buying second hand, or 1. Sell equipment that was not or hardly in use, after some cleaning or minor adaptations restoration; 2. Resell used equipment with quality inspections, cleaning and small repairs; 2. Resell of unsold returns or products with damaged packaging; 2. Multiple re-uses of (transport) packaging; 3. Collect and resell used equipment; 4. Collection of used equipment and delivery to the new owner. |
Lifecycle phases involved | EoL/Retailing |
Hierarchy | Short loop |
Ownership model | OEM / Consumer (depending on the related BM) |
Equipment condition after the implementation of the strategy | Original |
Enabling elements / technologies | Sharing platforms (online consumer-to-consumer auctions for used products) |
Closing loop management model | Oriented to extend original equipment lifecycle → Reuse 100% |
Circular BM involved | Lifespan extension |
Strategy implementation actions | Design phase: Modular design that allows the upgrade of critical components or assemblies or the replacement of components subject to wear; Plan to make some components available for a long time. Manufacturing phase: Flexible internal production process (to guarantee the spare parts production); Flexible purchasing process to guarantee the acquisition of the spare parts; Repair the damaged components and reuse them. Logistic phase: Organize reverse logistics of out of date or damaged components; Organize the distribution of the updated components or spare parts. Equipment operation phase: Introduction of IoT devices to monitor the working conditions of critical components; Introduction of monitoring systems and decision support tools (automated) related to the IoT devices. Maintenance phase: Introduction of maintenance services able to replace worn components and upgrade machinery; User of monitoring systems. It may decide to introduce IoT devices and create monitor systems. It may decide to change some pieces. End of “first” Life phase: See reverse logistic in the Logistic process phase; Repairable / Reusable Component: Repair and reuse in different equipment; Waste components: send them for recycling; Dispose of damaged spare parts. |
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Fontana, A.; Barni, A.; Leone, D.; Spirito, M.; Tringale, A.; Ferraris, M.; Reis, J.; Goncalves, G. Circular Economy Strategies for Equipment Lifetime Extension: A Systematic Review. Sustainability 2021, 13, 1117. https://doi.org/10.3390/su13031117
Fontana A, Barni A, Leone D, Spirito M, Tringale A, Ferraris M, Reis J, Goncalves G. Circular Economy Strategies for Equipment Lifetime Extension: A Systematic Review. Sustainability. 2021; 13(3):1117. https://doi.org/10.3390/su13031117
Chicago/Turabian StyleFontana, Alessandro, Andrea Barni, Deborah Leone, Maurizio Spirito, Agata Tringale, Matteo Ferraris, Joao Reis, and Gil Goncalves. 2021. "Circular Economy Strategies for Equipment Lifetime Extension: A Systematic Review" Sustainability 13, no. 3: 1117. https://doi.org/10.3390/su13031117
APA StyleFontana, A., Barni, A., Leone, D., Spirito, M., Tringale, A., Ferraris, M., Reis, J., & Goncalves, G. (2021). Circular Economy Strategies for Equipment Lifetime Extension: A Systematic Review. Sustainability, 13(3), 1117. https://doi.org/10.3390/su13031117