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A special issue of Sustainability (ISSN 2071-1050).

Deadline for manuscript submissions: closed (25 April 2021) | Viewed by 54798

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Special Issue Editors

Dr. Lin Li

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Guest Editor

Department of Mechanical and Industrial Engineering, University of Illinois at Chicago, Chicago, IL 60607, USA
Interests: energy-efficient manufacturing; electricity demand response of manufcaturing systems; environmental sustainability of additive manufcaturing; economic viability of renewable energy manufacturing; electric vehicle battery remanufacturing

Prof. Dr. Karl Haapala

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Guest Editor

School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, Corvallis, OR 97331-6001, USA
Interests: sustainable design and manufacturing; life cycle engineering; manufacturing process modeling for environmental performance improvement; sustainable manufacturing systems; engineering education and workforce development

Prof. Dr. Sophie I. Hallstedt

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Guest Editor

Department of Strategic Sustainable Development, Faculty of Engineering, Blekinge Institute of Technology (BTH), Karlskrona, Sweden
Interests: sustainable product development process; decision support in early engineering design; socio-ecological sustainability; sustainability integration and implementation; risk and requirement management; portfolio development; design for social sustainability
Special Issues, Collections and Topics in MDPI journals

Dr. Yiran (Emma) Yang

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Guest Editor

University of Texas at Arlington, Arlington, TX, USA
Interests: Sustainability of additive manufacturing; waste recycling and end-of-life management in additive manufactruing; environmental impact assessment; sustainable design for additive manufacturing

Special Issue Information

Dear Colleagues,

Conventionally, improving productivity has been the primary focus of product design and manufacturing research reported in the literature. However, over the past two decades, increasing attention has been paid to the systematic study of the complex issue of simultaneously reducing energy consumption, production costs, and environmental and social impacts during product design and manufacturing. In response to increasing legislative pressures, calls for environmental responsibility, and need to meet changing customer preferences, product design and manufacturing companies are facing tremendous challenges to improve their sustainability-related competitiveness in the global market. As such, sustainable product design and manufacturing is not only about reducing energy consumption and greenhouse gas emissions, but also about strategically considering the full range of environmental and social aspects alongside economic aspects in the development of new products, processes, and services. This Special Issue is devoted to the broad field of sustainable product design and manufacturing, which requires simultaneous consideration of economic, environmental, and social aspects during the design, production, and delivery of goods, as well as strategies for product takeback and recovery. Such efforts will result in a deeper understanding of the optimal operational structure of product design and manufacturing systems for enabling a sustainable world. Our objective with this Special Issue is to collect papers that explore recent research into the concepts, methods, models, tools, and applications for sustainable product design and manufacturing. Topical areas for consideration include, but are not limited to, life cycle engineering; design for sustainable manufacturing; design for sustainable solutions; sustainable product development; green manufacturing; cleaner production; reconfigurable manufacturing systems; sustainable manufacturing with cyber–physical systems; smart factories; sustainability of additive manufacturing; high-efficiency subtractive manufacturing processes; industrial energy use and efficiency; advanced energy technology; food–energy–water nexus; renewable energy manufacturing; resource and energy management; standardization and regulation for sustainable design and manufacturing; and related topics.

Dr. Lin Li
Prof. Dr. Karl R. Haapala
Prof. Dr. Sophie I. Hallstedt
Dr. Yiran (Emma) Yang
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. Sustainability is an international peer-reviewed open access semimonthly 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

sustainable product development
design for sustainable solutions
design for sustainable manufacturing
green manufacturing
cleaner production
sustainability of additive manufacturing
sustainability of subtractive manufacturing
industrial energy use and efficiency
socio-ecological sustainability
food–energy–water nexus
life cycle engineering
sustainability implementation

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Published Papers (9 papers)

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Research

30 pages, 3139 KiB

Open AccessArticle

Green Scheduling of Identical Parallel Machines with Release Date, Delivery Time and No-Idle Machine Constraints

by Lotfi Hidri, Ali Alqahtani, Achraf Gazdar and Belgacem Ben Youssef

Sustainability 2021, 13(16), 9277; https://doi.org/10.3390/su13169277 - 18 Aug 2021

Cited by 7 | Viewed by 2925

Abstract

Global warming and climate change are threatening life on earth. These changes are due to human activities resulting in the emission of greenhouse gases. This is caused by intensive industrial activities and excessive fuel energy consumption. Recently, the scheduling of production systems has been judged to be an effective way to reduce energy consumption. This is the field of green scheduling, which aims to allocate jobs to machines in order to minimize total costs, with a focus on the sustainable use of energy. Several studies have investigated parallel-machine shops, with a special focus on reducing and minimizing the total consumed energy. Few studies explicitly include the idle energy of parallel machines, which is the energy consumed when the machines are idle. In addition, very few studies have considered the elimination of idle machine times as an efficient way to reduce the total consumed energy. This is the no-idle machine constraint, which is the green aspect of the research. In this context, this paper addresses the green parallel-machine scheduling problem, including release dates, delivery times, and no-idle machines, with the objective of minimizing the maximum completion time. This problem is of practical interest since it is encountered in several industry processes, such as the steel and automobile industries. A mixed-integer linear programming (MILP) model is proposed for use in obtaining exact solutions for small-sized instances. Due to the NP-hardness of the studied problem, and encouraged by the successful adaptation of metaheuristics for green scheduling problems, three genetic algorithms (GAs) using three different crossover operators and a simulated annealing algorithm (SA) were developed for large-sized problems. A new family of lower bounds is proposed. This was intended for the evaluation of the performance of the proposed algorithms over the average percent of relative deviation (ARPD). In addition, the green aspect was evaluated over the percentage of saved energy, while eliminating the idle-machine times. An extensive experimental study was carried out on a benchmark of test problems with up to 200 jobs and eight machines. This experimental study showed that one GA variant dominated the other proposed procedures. Furthermore, the obtained numerical results provide strong evidence that the proposed GA variant outperformed the existing procedures from the literature. The experimental study also showed that the adoption of the no-idle machine time constraints made it possible to reduce the total consumed energy by 29.57%, while the makespan (cost) increased by only 0.12%. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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19 pages, 7337 KiB

Open AccessArticle

A Systems Approach of Topology Optimization for Bioinspired Material Structures Design Using Additive Manufacturing

by William Patrick Ryan-Johnson, Larson Curtis Wolfe, Christopher Roder Byron, Jacquelyn Kay Nagel and Hao Zhang

Sustainability 2021, 13(14), 8013; https://doi.org/10.3390/su13148013 - 18 Jul 2021

Cited by 9 | Viewed by 3927

Abstract

Bioinspired design has been applied in sustainable design (e.g., lightweight structures) to learn from nature and support material structure functionalities. Natural structures usually require modification in practice because they were evolved in natural environmental conditions that can be different from industrial applications. Topology optimization is a method to find the optimal design solution by considering the material external physical environment. Therefore, integrating topology optimization into bioinspired design can benefit sustainable material structure designers in meeting the purpose of using bioinspired concepts to find the optimal solution in the material functional environment. Current research in both sustainable design and materials science, however, has not led to a method to assist material structure designers to design structures with bioinspired concepts and use topology optimization to find the optimal solution. Systems thinking can seamlessly fill this gap and provide a systemic methodology to achieve this goal. The objective of this research is to develop a systems approach that incorporates topology optimization into bioinspired design, and simultaneously takes into consideration additive manufacturing processing conditions to ensure the material structure functionality. The method is demonstrated with three lightweight material structure designs: spiderweb, turtle shell, and maze. Environmental impact assessment and finite element analysis were conducted to evaluate the functionality and emissions of the designs. This research contributes to the sustainable design knowledge by providing an innovative systems thinking-based bioinspired design of material structures. In addition, the research results enhance materials knowledge with an understanding of mechanical properties of three material structures: turtle shell, spiderweb, and maze. This research systemically connects four disciplines, including bioinspired design, manufacturing, systems thinking, and lightweight structure materials. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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14 pages, 1670 KiB

Open AccessArticle

Optimization of Sintering Process of Alumina Ceramics Using Response Surface Methodology

by Darko Landek, Lidija Ćurković, Ivana Gabelica, Mihone Kerolli Mustafa and Irena Žmak

Sustainability 2021, 13(12), 6739; https://doi.org/10.3390/su13126739 - 14 Jun 2021

Cited by 12 | Viewed by 4889

Abstract

In this work, alumina (Al₂O₃) ceramics were prepared using an environmentally friendly slip casting method. To this end, highly concentrated (70 wt.%) aqueous suspensions of alumina (Al₂O₃) were prepared with different amounts of the ammonium salt of a polycarboxylic acid, Dolapix CE 64, as an electrosteric dispersant. The stability of highly concentrated Al₂O₃ aqueous suspensions was monitored by viscosity measurements. Green bodies (ceramics before sintering) were obtained by pouring the stable Al₂O₃ aqueous suspensions into dry porous plaster molds. The obtained Al₂O₃ ceramic green bodies were sintered in the electric furnace. Analysis of the effect of three sintering parameters (sintering temperature, heating rate and holding time) on the density of alumina ceramics was performed using the response surface methodology (RSM), based on experimental data obtained according to Box–Behnken experimental design, using the software Design-Expert. From the statistical analysis, linear and nonlinear models with added first-order interaction were developed for prediction and optimization of density-dependent variables: sintering temperature, heating rate and holding time. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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26 pages, 1206 KiB

Open AccessArticle

Three-Echelon Closed-Loop Supply Chain Network Equilibrium under Cap-and-Trade Regulation

by Guitao Zhang, Xiao Zhang, Hao Sun and Xinyu Zhao

Sustainability 2021, 13(11), 6472; https://doi.org/10.3390/su13116472 - 7 Jun 2021

Cited by 16 | Viewed by 2427

Abstract

This paper investigates the impacts of cap-and-trade (CAT) regulation on a three-echelon closed-loop supply chain network (CLSCN) that consists of suppliers, high-emission and low-emission manufacturers, demand markets and carbon trading centers. The presented CLSCN model includes both product trading and carbon trading subnets. Combining variational inequality theory (VI) with complementary theory, we first characterize the optimal conditions for members in each tier first, and then derive that of the entire CLSCN. In addition, we focus on the effects of carbon caps and EOL collection rate target on CLSCN performances with numerical examples. The results reveal that, in some cases, there is a consistency between carbon emission reduction target of the government and the profit target of enterprises. The government should choose reasonable and moderate carbon caps for all the enterprises to balance the CLSCN members’ economic interests, carbon emissions, as well as resources utilization rate. Moreover, the government should not blindly pursue a high collection rate target. The above conclusions can provide practical guidance for governments and enterprises in a CLSCN under CAT regulation. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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17 pages, 4241 KiB

Open AccessArticle

Cost Modeling and Evaluation of Direct Metal Laser Sintering with Integrated Dynamic Process Planning

by Lei Di and Yiran Yang

Sustainability 2021, 13(1), 319; https://doi.org/10.3390/su13010319 - 31 Dec 2020

Cited by 13 | Viewed by 4202

Abstract

Additive manufacturing technologies have been adopted in a wide range of industries such as automotive, aerospace, and consumer products. Currently, additive manufacturing is mainly used for small-scale, low volume productions due to its limitations such as high unit cost. To enhance the scalability of additive manufacturing, it is critical to evaluate and preferably reduce the cost of adopting additive manufacturing for production. The current literature on additive manufacturing cost mainly adopts empirical approaches and does not sufficiently explore the cost-saving potentials enabled by leveraging different process planning algorithms. In this article, a mathematical cost model is established to quantify the different cost components in the direct metal laser sintering process, and it is applicable for evaluating the cost performance when adopting dynamic process planning with different layer-wise process parameters. The case study results indicate that 12.73% of the total production cost could be potentially reduced when applying the proposed dynamic process planning algorithm based on the complexity level of geometries. In addition, the sensitivity analysis results suggest that the raw material price and the overhead cost are the two key cost drivers in the current additive manufacturing market. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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26 pages, 2230 KiB

Open AccessArticle

The Need for New Product Development Capabilities from Digitalization, Sustainability, and Servitization Trends

by Sophie I. Hallstedt, Ola Isaksson and Anna Öhrwall Rönnbäck

Sustainability 2020, 12(23), 10222; https://doi.org/10.3390/su122310222 - 7 Dec 2020

Cited by 65 | Viewed by 9259

Abstract

Apparent from the latest pandemic, the dynamics and rate of change in society accelerate on a global scale. Ongoing mega-trends in society, such as digitalization, sustainability, and servitization, fundamentally changes the conditions for manufacturers when developing and providing new products. This study clarifies the combined impact and consequences on product development capabilities in manufacturing firms of the three mega-trends: (i) digitalization, (ii) sustainability, and (iii) servitization. The research is based on a pre-study, complemented with a semi-structured interview study at small, medium-sized, and large Swedish-based manufacturing companies, and a systematic literature review. The research makes evident that the main challenge is to empower engineers and development teams to model, present, evaluate, and develop expected and smart digitalized solutions in a time-limited environment and prioritize the most resource efficient and sustainable solution. Therefore, four complementary support resources are suggested: (i) a knowledge management platform, (ii) a data management platform, (iii) a set of criteria and metrics measuring progression, and (iv) support methods and tools to define, model, and evaluate solutions. When integrated into a digital platform, developers can simultaneously access and process the necessary information needed for sustainable, digitalized, and servitized solutions. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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28 pages, 4245 KiB

Open AccessArticle

A Research Roadmap for Sustainable Design Methods and Tools

by Jeremy Faludi, Steven Hoffenson, Sze Yin Kwok, Michael Saidani, Sophie I. Hallstedt, Cassandra Telenko and Victor Martinez

Sustainability 2020, 12(19), 8174; https://doi.org/10.3390/su12198174 - 3 Oct 2020

Cited by 39 | Viewed by 19140

Abstract

Sustainable design methods and tools abound, but their implementation in practice remains marginal. This article brings together results from previous literature reviews and analyses of sustainable design methods and tools, as well as input from design researchers and professional practitioners to identify the needs and gaps in the area. It results in a shared vision of how sustainable design methods and tools can be more tightly integrated into mainstream product design and development, as well as the current state of practice and research in relation to four central questions: What are the needs and values of industry regarding sustainable design? What improvements in sustainable design methods and tools would most drive industry forward? How should researchers move forward with developing more useful sustainable design methods and tools? How can sustainable design be more effectively integrated into industry? A roadmap for the international sustainable design research community is proposed with descriptions of short-, medium-, and long-term tasks for addressing each question. The purpose is to support collective progress and discussions on method and tool development and adoption, and to enable more tangible success in mainstreaming sustainable design practices in industry. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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27 pages, 5252 KiB

Open AccessArticle

Modeling and Analysis of Electric Vehicle-Power Grid-Manufacturing Facility (EPM) Energy Sharing System under Time-of-Use Electricity Tariff

by Xiaolin Chu, Yuntian Ge, Xue Zhou, Lin Li and Dong Yang

Sustainability 2020, 12(12), 4836; https://doi.org/10.3390/su12124836 - 13 Jun 2020

Cited by 6 | Viewed by 2880

Abstract

Electric vehicles (EVs) have obtained increasing public interest due to the associated economic and environmental benefits. Recently, studies regarding the economic advantages of adopting EVs as energy storages for commercial/residential buildings are emerging. In fact, according to the U.S. Energy Information Administration, the industrial sector consumes more energy than all of the other sectors combined, which is about 54% of the world’s total delivered energy. The energy consumption pattern in manufacturing facilities is based on production schedules and the heat transfer between machines and the ambient surroundings, thus, differs greatly from commercial/residential buildings. However, little research attention has been given to analyse the synergies of integrating EVs and manufacturing facilities to improve energy efficiency. To fill this research gap, in this study, a comprehensive model is established to evaluate the economic and environmental performance of an energy sharing system that consists of the EVs, power grid, and manufacturing facilities (EPM) under Time-of-Use (TOU) electricity tariff. The model is formulated as a mixed integer nonlinear programming format by considering practical production schedules, heat exchange between machines and ambient surroundings, as well as the heating, ventilation, and air conditioning (HVAC) system. The case study results indicate that the presented EPM energy sharing system has great potential to reduce energy cost and CO₂ emissions. In addition, compared to the results from winter scenarios, it is shown that more cost savings can be achieved in summer days. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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22 pages, 2756 KiB

Open AccessArticle

A Bi-Objective Approach to Minimize Makespan and Energy Consumption in Flow Shops with Peak Demand Constraint

by Weiwei Cui and Biao Lu

Sustainability 2020, 12(10), 4110; https://doi.org/10.3390/su12104110 - 18 May 2020

Cited by 14 | Viewed by 2923

Abstract

With the growing concern of energy shortage and environment pollution, the energy aware operation management problem has emerged as a hot topic in industrial engineering recently. An integrated model consisting of production scheduling, preventive maintenance (PM) planning, and energy controlling is established for the flow shops with the PM constraint and peak demand constraint. The machine’s on/off and the speed level selection are considered to save the energy consumption in this problem. To minimize the makespan and the total energy consumption simultaneously, a multi-objective algorithm founded on NSGA-II is designed to solve the model effectively. The key decision variables are coded into the chromosome, while the others are obtained heuristically using the proposed decoding method when evaluating the chromosome. Numerical experiments were conducted to validate the effectiveness and efficiency by comparing the proposed algorithm and the traditional rules in manufacturing plant. The impacts of constraints on the Pareto frontier are also shown when analyzing the tradeoff between two objectives, which can be used to explicitly assess the energy consumption. Full article

(This article belongs to the Special Issue Sustainable Product Design and Manufacturing)

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