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About this book

This book presents a concept for fostering resource efficient manufacturing. The protection of our environment demands a more responsible use of natural resources, and a higher degree of transparency along manufacturing value chains will be required in order to make significant advances in this context. Industrial decision makers must be provided with adequate methods and tools to simultaneously and systematically pursue technical, economic and environmental targets. Building on established and complementary methods, such as material and energy flow analysis (MEFA), value stream mapping (VSM), life cycle costing (LCC) and environmental life cycle assessment (LCA), this book introduces a concept that allows a holistic modeling and multi-dimensional performance assessment of manufacturing systems on different levels – from processes up to entire value chains and product life cycles. It also demonstrates the application of the concept using two case studies from the metal mechanic industry.

Table of Contents

Frontmatter

Chapter 1. Introduction

Abstract
In this introduction, the general need to increase resource efficiency in manufacturing value chains is outlined, substantiating the demand for adequate decision support in Sect. 1.1. Based on this, research questions are derived and the structure of this work is introduced in Sect. 1.2.
Stefan Alexander Blume

Chapter 2. Resource Efficiency in Manufacturing Value Chains

Abstract
This chapter presents general background information about resource efficiency in manufacturing value chains. In Sect. 2.1 a general introduction into industrial production and manufacturing with its inherent structure, challenges and meaningful indicators for performance measurement is provided. The term of resource efficiency in the context of manufacturing is then described in Sect. 2.2, emphasizing suitable improvement strategies. In Sect. 2.3, the relevance of decision support for a more resource efficient manufacturing is substantiated and suitable methods and tools for decision making are discussed. Finally, an overview about well-established methods to model manufacturing systems is given in Sect. 2.4.
Stefan Alexander Blume

Chapter 3. Existing Holistic Approaches to Increase Resource Efficiency in Manufacturing

Abstract
This chapter presents an overview about existing research approaches to systematically improve resource efficiency in manufacturing. Due to the high relevance of this research topic for both scientific community and industry, various approaches have already been developed. They apply different methods and put different focuses. Because of the diversity of approaches, a rigorous definition of selection criteria is needed in order to identify relevant work in line with the research questions described in Sect. 1.​2. Starting with Sect. 3.1, suitable selection criteria are derived and described. Approaches, which do not match with all criteria but are regarded as valuable contribution towards the research objectives, are briefly named. In Sect. 3.2, evaluation criteria to assess the suitability of relevant approaches for solving the challenges stated in Chap. 1 are introduced. In Sect. 3.3, the approaches are classified, described in detail and compared with respect to the fulfillment of evaluation criteria. As result, the research demand to be covered with a new approach is described in Sect. 3.4.
Stefan Alexander Blume

Chapter 4. Concept to Increase Resource Efficiency in Manufacturing Value Chains

Abstract
In this chapter, a new concept to increase resource efficiency in manufacturing value chains is presented. Section 4.1 deals with the translation of research demands into specific requirements for a new concept. In Sect. 4.2, an overview about the new concept and its inherent phases and steps is provided, followed by a detailed description of its three consecutive phases in Sects. 4.3, 4.4 and 4.5. Finally, in Sect. 4.6 implications for an operationalization of the concept into a decision support toolbox are summarized.
Stefan Alexander Blume

Chapter 5. Concept Implementation

Abstract
This chapter deals with the software implementation of the new concept as decision support toolbox, starting with the description of requirements for the tool in Sect. 5.1. Subsequently, the implementation into a selected software environment is described in Sect. 5.2 for all three modules – modeling, evaluation and improvement. In order to allow for a high applicability, the intended workflow from a user perspective is outlined in Sect. 5.3. The chapter closes with a description of the applied verification and validation procedures to ensure the correctness of results generated with the tool in Sect. 5.4.
Stefan Alexander Blume

Chapter 6. Concept Application in the Metal Mechanic Industry

Abstract
This chapter focuses on the application of the new concept to real-world industrial use cases with the objective to increase the resource efficiency of involved factories. In Sect. 6.1, a piston rod manufacturing is presented as first use case, involving multiple factories along a value chain from the metal mechanic sector. This case study has partly been carried out within the frame of the MEMAN (Integral Material and Energy Flow Management in Manufacturing Metal Mechanic Sector) project, which has received funding from the European Union under the research program Horizon 2020. The case study is used to demonstrate the whole potential of the developed concept for a holistic assessment of entire value chains, taking into account the whole product life cycle. In Sect. 6.2, an axle journal manufacturing as second case study is presented, focusing on a single factory perspective and selected resource flows.
Stefan Alexander Blume

Chapter 7. Summary and Outlook

Abstract
In this chapter, a summary of the presented concept is first provided in Sect. 7.1. It is then evaluated in Sect. 7.2 with focus on criteria applied to state of the art approaches and on identified research gaps. Finally, an outlook on possible future research is given in Sect. 7.3.
Stefan Alexander Blume
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