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MATERIAL EFFICIENCY MANAGEMENT IN MANUFACTURING
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation. (IPR)ORCID iD: 0000-0002-3390-938X
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Material efficiency is a key solution to provide a reduction in the total environmental impact of global manufacturing, which contributes to avoid generating larger volumes of industrial waste, to reduce extracting and consuming ever more resources and to decrease energy demand and carbon emissions. However, the area of material efficiency in manufacturing has been under-researched and related knowledge is limited.

The research objective of this thesis is to contribute to the existing body of knowledge regarding material efficiency in manufacturing - to increase understanding, describe the existing situation and develop support for improvement. This thesis focuses on value of process and residual materials in material efficiency: to increase homogenous quality of generated waste with higher segregation rate, decreasing the amount of material becoming waste and reduce total virgin raw material consumption without influencing the function and quality of a product or process.

To achieve the objective, material efficiency strategies, existing state of material efficiency in manufacturing and barriers that avert higher material efficiency improvement have been investigated. The results are supported by four structured literature reviews and two [MW1] empirical multiple case studies at large global manufacturing companies in Sweden, mainly automotive. Empirical studies include observations, interviews, waste stream mapping, waste sorting analysis, environmental report reviews and walkthroughs in companies to determine the material efficiency and industrial waste management systems.

The empirical results revealed that material efficiency improvement potential of further waste segregation to gain economic and environmental benefits is still high. Determining different waste segments and relative fractions along with calculating material efficiency performance measurements facilitate improvements in material efficiency. In addition to attempts for waste generation reduction, avoiding blending and correct segregation of different waste fractions is an essential step towards material efficiency. The next step is to improve the value of waste fractions i.e. having more specific cost-effective fractions. Waste Flow Mapping proves to be an effective practical tool to be utilized at manufacturing companies in order to check and explore the improvement opportunities.

In addition, a number of barriers that hinder material efficiency was identified. The most influential material efficiency barriers are Budgetary, Information, Management and Employees. The majority of identified material efficiency barriers are internal, originate inside the company itself and are dependent upon the manufacturing companies’ characteristics. As a result, management and employees’ attitude, environmental knowledge and environmental motivation, as well as their internal communication and information sharing, and companies’ core value and vision are the enablers for material efficiency improvement.

Place, publisher, year, edition, pages
Eskilstuna: Mälardalen University , 2015.
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 210
Keyword [en]
Material efficiency, industrial waste management, manufacturing
National Category
Environmental Management Production Engineering, Human Work Science and Ergonomics
Research subject
Innovation and Design
Identifiers
URN: urn:nbn:se:mdh:diva-28004ISBN: 978-91-7485-214-1 (print)OAI: oai:DiVA.org:mdh-28004DiVA: diva2:813564
Presentation
2015-09-02, Filen, Mälardalens högskola, Eskilstuna, 10:00 (English)
Opponent
Supervisors
Projects
MEMIMAN
Funder
Mistra - The Swedish Foundation for Strategic Environmental Research
Available from: 2015-05-25 Created: 2015-05-22 Last updated: 2015-08-24Bibliographically approved
List of papers
1. Material efficiency in manufacturing: swedish evidence on potential, barriers and strategies
Open this publication in new window or tab >>Material efficiency in manufacturing: swedish evidence on potential, barriers and strategies
(English)Manuscript (preprint) (Other academic)
Abstract [en]

• Importance of higher waste segregation for improving material efficiency.• Presentation of barriers towards improved material efficiency in a new categorization.• Material efficiency barriers are mainly internal.• Lack of material efficiency strategy implementation in the manufacturing companies.

Keyword
Material efficiency, waste segregation, manufacturing sustainability, residual material, automotive, industrial waste management
National Category
Environmental Management
Research subject
Energy- and Environmental Engineering; Industrial Economics and Organisations
Identifiers
urn:nbn:se:mdh:diva-27998 (URN)
Projects
MEMIMANINNOFACTURE
Funder
Mistra - The Swedish Foundation for Strategic Environmental Research, 16135
Available from: 2015-05-22 Created: 2015-05-22 Last updated: 2016-12-21Bibliographically approved
2. A foresight study on future trends influencing material consumption and waste generation in production
Open this publication in new window or tab >>A foresight study on future trends influencing material consumption and waste generation in production
2014 (English)In: Flexible Automation & Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation / [ed] F. Frank Chen, San Antonio, Texas, United States: DEStech Publications, Inc. , 2014Conference paper, Published paper (Refereed)
Abstract [en]

There are boundless upcoming factors that influence future of material waste in production. This broad range of factors needs to be scanned, categorized and analyzed in a structured way. This paper by a foresight study, aims to give an insight and increase awareness about external macro-level future trends concerning raw material consumption and waste generation in production. A limited pilot study indicated that technological forecasting and some reaction upon obvious trends are being taken, although in an ad hoc manner and without structured tools. However, political influences, economic visions and social-cultural shifts were seldom or never discussed. External macro trends and tendencies were examined through PEST analysis to identify potentials and opportunities influencing strategic decisions and innovation initiatives. It is vital to understand the whole picture of possible changes and not only considering the technological trends, but also other relevant development areas that might affect production in different ways.

Place, publisher, year, edition, pages
San Antonio, Texas, United States: DEStech Publications, Inc., 2014
National Category
Engineering and Technology
Identifiers
urn:nbn:se:mdh:diva-25150 (URN)978-1-60595-173-7 (ISBN)
Conference
24th International Conference on Flexible Automation and Intelligent Manufacturing FAIM2014, 20-23 May 2014, San Antonio, Texas, United States
Projects
INNOFACTURE - innovative manufacturing developmentMEMIMAN - Material Efficiency Management in Manufacturing
Available from: 2014-06-09 Created: 2014-06-05 Last updated: 2016-12-28Bibliographically approved
3. Industrial waste management within manufacturing: a comparative study of tools, policies, visions and concepts
Open this publication in new window or tab >>Industrial waste management within manufacturing: a comparative study of tools, policies, visions and concepts
Show others...
2013 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Industrial waste is a key factor when assessing the sustainability of a manufacturing process or company. A multitude of visions, concepts, tools, and policies are used both academically and industrially to improve the environmental effect of manufacturing; a majority of these approaches have a direct bearing on industrial waste. The identified approaches have in this paper been categorised according to application area, goals, organisational entity, life cycle phase, and waste hierarchy stage; the approaches have also been assessed according to academic prevalence, semantic aspects, and overlaps. In many cases the waste management approaches have similar goals and approaches, which cause confusion and disorientation for companies aiming to synthesise their management systems to fit their waste management strategy. Thus, a study was performed on how waste management approaches can be integrated to reach the vision of zero waste in manufacturing.

National Category
Engineering and Technology
Identifiers
urn:nbn:se:mdh:diva-21368 (URN)978-1-907413-23-0 (ISBN)
Conference
The 11th International Conference on Manufacturing Research (ICMR2013), Cranfield UK, 19 September - 20 September 2013
Projects
INNOFACTURE - innovative manufacturing developmentXPRESMEMIMAN
Funder
XPRES - Initiative for excellence in production research
Available from: 2013-09-17 Created: 2013-09-11 Last updated: 2016-02-25Bibliographically approved
4. Waste flow mapping to improve sustainability of waste management: A case study approach
Open this publication in new window or tab >>Waste flow mapping to improve sustainability of waste management: A case study approach
Show others...
2015 (English)In: Journal of Cleaner Production, ISSN 0959-6526, E-ISSN 1879-1786, Vol. 98, no 1, 304-315 p.Article in journal (Refereed) Published
Abstract [en]

Innovative, resource-efficient solutions and effective waste management systems capture value in business and contribute to sustainability. However, due to scattered waste management responsibilities in the vehicle industry and the orientation of operations management and lean tools, which mostly focus on lead-time and labour-time improvements, the requirement of a collaborative method to include material waste efficiency in operational development is identified. The main purpose of this research is to study how operations management and environmental management can be integrated on an operational level and include the waste management supply chain. Based on a literature review of environmental and operational improvement tools and principles, the gaps and needs in current practice were identified. A large case study implementing a waste flow mapping (WFM) method on a set of manufacturing sites revealed potentials in terms of reducing material losses and inefficiencies in the handling of materials and waste. Finally, the integrated WFM method was analysed with respect to the gaps and needs identified in the existing body of tools for operational and environmental improvement. The method combines lean manufacturing tools, such as value stream mapping with cleaner production and material flow cost accounting strategies. The empirical data showed that the WFM method is adequate for current state analysis of waste material efficiency potentials, especially when multiple organisations are involved. However, further development and specific methods are needed such as, for example, logistics inefficiencies, root cause analysis, implementation guidelines for best practice and systems for performance monitoring of actors.

Place, publisher, year, edition, pages
Elsevier, 2015
Keyword
material efficiency;waste flow mapping; waste management services; manufacturing industry; environmental system analysis
National Category
Other Materials Engineering
Research subject
Energy- and Environmental Engineering
Identifiers
urn:nbn:se:mdh:diva-25265 (URN)10.1016/j.jclepro.2014.06.076 (DOI)000356194300031 ()2-s2.0-84929944699 (Scopus ID)
Projects
Memiman
Funder
Mistra - The Swedish Foundation for Strategic Environmental Research
Available from: 2014-07-05 Created: 2014-06-16 Last updated: 2017-12-05Bibliographically approved

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