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Sustainability has raised significant attention in manufacturing research over the last decades and has become a significant driver of the development of innovative technologies and management concepts. The current chapter aims to provide a structured overview of the wide field of research in sustainable manufacturing with a particular focus on manufacturing technology and management. It intends to describe the role of manufacturing in sustainability, outline the complementary approaches necessary for a transition to sustainable manufacturing and specify the need for engaging in interdisciplinary research. Based on a literature review, it provides a structuring framework defining four complementary areas of research focussing on analysis, synthesis and transition solutions. The challenges of the four areas of research manufacturing technologies (“how things are produced”), product development (“what is being produced”), value creation networks (“in which organisational context”) and global manufacturing impacts (“how to make a systemic change”) are highlighted and illustrated with examples from current research initiatives.

Value creation ensures societal prosperity. At the same time, determines the future of global human wellbeing. Both aspects are based on profound environmental, social and economic mechanisms—and both aspects are closely linked. The describes the direct and indirect effects of value creation together with the three dimensions of . This contribution introduces and defines the . The effects and dynamics are exemplarily shown. Eventually, the link to circular economy is drawn. In the future, the can be used as a control model in order to predict consequences of value creation towards environmental, social and economic sustainability.

The challenges associated with achieving sustainable development goals and stabilizing the world’s climate cannot be solved without significant efforts by developing and newly-emerging countries. With respect to climate change mitigation, the main challenge for developing countries lies in avoiding future emissions and lock-ins into emission-intensive technologies, rather than reducing today’s emissions. While first best policy instruments like carbon prices could prevent increasing carbonization, those policies are often rejected by developing countries out of a concern for negative repercussions on development and long-term growth. In addition, policy environments in developing countries impose particular challenges for regulatory policy aiming to incentivize climate change mitigation and sustainable development. This chapter first discusses how climate policy could potentially interact with sustainable development and economic growth. It focuses, in particular, on the role of industrial sector development. The chapter then continues by discussing how effective policy could be designed, specifically taking developing country circumstances into account.

Environmental, economic and social changes of any significant proportions cannot take place without a major shift in the manufacturing sector. In today’s manufacturing processes, economic efficiency is realised through high volumes with the use of specialised machine tools. Change in society, such as in the form of mobility and digitisation, requires a complete overhaul in terms of thinking in the manufacturing industry. Moreover, the manufacturing industry contributes over 19 % to the world’s greenhouse gas emissions. As a consequence of these issues, a demand for sustainable solutions in the production industry is increasing. In particular, the concept of “cost” in manufacturing processes and thus the “system boundaries” within the production of the future has to be changed. That is, a great number of aspects to the machine tool and production technology industries can be improved upon in order to achieve a more sustainable production environment. Within this chapter, the focus lies on microsystem technology enhanced modular machine tool frames, adaptive mechatronic components, as well as on internally-cooled cutting tools. An innovative machine tool concept has been developed recently, featuring a modular machine tool frame using microsystem technology for communication within the frame, which allows for a high level of flexibility. Furthermore, add-on upgrading systems for outdated machine tools—which are particularly relevant for developing and emerging countries—are poised to gain in importance in the upcoming years. The system described here enables the accuracy of outdated machine tools to be increased, thus making these machine tools comparable to modern machine tool systems. Finally, the cutting process requires solutions for dry machining, as the use of cooling lubricants is environmentally damaging and a significant cost contributor in machining processes. One such solution is the use of internally cooled cutting tools.

Welding is the most important joining technology. In the steel construction industry, e.g. production of windmill sections, welding accounts for a main part of the manufacturing costs and resource consumption. Moreover, social issues attached to welding involve working in dangerous environments. This aspect has unfortunately been neglected so far, in light of a predominant focus on economics combined with a lack of suitable assessment methods. In this chapter, exemplary welding processes are presented that reduce the environmental and social impacts of thick metal plate welding. Social and environmental Life Cycle Assessments for a thick metal plate joint are conducted for the purpose of expressing and analysing the social and environmental impacts of welding. Furthermore, it is shown that state-of-the-art technologies like Gas Metal Arc Welding with modified spray arcs and Laser Arc-Hybrid Welding serve to increase social and environmental performance in contrast to common technologies, and therefore offer great potential for sustainable manufacturing.

Musculoskeletal Disorders (MSDs) pose a serious threat to sustainability in manufacturing. In particular, this phenomenon impacts the sustainability indicators of worker health and safety and the Gross Domestic Product (GDP). Effective MSD prevention measures would therefore constitute a remarkable contribution to social and economic sustainability. This chapter provides first an outline of existing methods to prevent MSD at the workplace. Analysis of the approaches yields that effective solutions require earmarked finances as well as qualified personnel, both of which are not affordable for many companies. In pursuit of solutions, Human-centred Automation (HCA), a recent paradigm in manufacturing, proposes the design of manufacturing systems using intelligent technology to support the worker instead of replacing him/her. HCA has the unique potential of reducing the effort needed to implement MSD prevention strategies by simplifying the path to social and economic sustainability. This chapter demonstrates this process with the example of the “Working Posture Controller” (WPC), which illustrates how the HCA concept can be applied. Finally, the lessons learned from the case are outlined, providing a vision of how future workplaces can benefit from HCA.

Corporate approaches towards sustainability integration into product development have significantly evolved since the early 1990s. Ecodesign, defined as the integration of environmental issues into product development, arose in the 1990s as a key concept for the enhancement of products’ environmental performance. An intense development of ecodesign methods and tools could be observed in the 1990–2010 period, leading to successful pilot cases in industry, in which environmental gains were demonstrated. In the 2010s, the need for a systems perspective to solve the environmental crisis has been highlighted, and the concept of product/service-systems started to gain momentum due to the high potential for enhanced environmental performance and improved competitiveness, by means of new business models and dematerialization. Recently, a transition towards Circular Economy and the integration of social innovation into sustainability initiatives can be observed, which leads to strategic and holistic sustainability considerations in the design of complex systems. In this chapter, the evolution of sustainability concepts and their integration into product development is presented and exemplified in three periods: 1990–2010; 2010–2020 and 2020–2030. While the first two periods present the actual development of the field, the last period represents the evaluation and projection of the trends developed by the authors. By analysing the three periods, the authors aim to discuss the journey from ecodesign to sustainable product/service-systems over the last decades, experienced by academia and practitioners, and to highlight their views on how the field is going to develop over the next 10 years.

Sustainable manufacturing is a rising issue. Ensuring both consumer satisfaction and minimal environmental impact is very challenging. In that whole process, it is customary to say that the design stage determines 80 % of the future environmental impact. One way to contain this impact at an acceptable level is to manage the products’ end-of-life from the design activities. This chapter points out product reuse strategies—i.e. —aiming at conserving the added-value of used products as much as possible into new products. The first contribution attempts to provide a state-of-the-art of design for these high added-value end-of-life strategies. Direct reuse and remanufacturing are thus analysed and the principal design guidelines are furthermore given, classified according to three dimensions: product, process and business model. This chapter then contributes to enlarging the spectrum of reuse strategies, presenting an innovative end-of-life strategy: repurposing. It consists of reusing products in other applications after transformations. The main challenges of such a strategy will be discussed.

Figuring in sustainability in product development requires a profound understanding of the cause and effect of engineering decisions along the full spectrum of the product lifecycle and the triple bottomline of sustainability. Sustainability design targets can contribute to mitigating the complexity involved, by means of a formalised problem description. This article discusses how sustainability design targets can be defined and presents methods for systematically implementing these targets into the design process. To that end, different means of decision support mechanisms are presented. They comprise (a) use cases of target breakdowns in subsystems, (b) systematic reduction of solution space and (c) assistance in design activities to ensure achievement of sustainability design targets. This paper explains how interfaces to engineering tools such as Computer Aided Design/Engineering (CAD/CAE) or Product Data/Lifecycle Management (PDM/PLM) can be put in place to make the process of retrieving information and providing decision support more seamless.

In order to achieve systematic change in pursuit of sustainable manufacturing, both a strategic long-term perspective employing methods from future studies and a concrete implementation of the knowledge gained in sustainable business models are necessary. In this chapter, the concepts and exemplary methods for sustainable business model innovation are introduced with a special focus on sustainable manufacturing. Circular Economy-based business models and Product Service Systems are explained as examples of sustainable business models, along with a deduction of sustainability factors for both examples. The fruitful combination of future studies and sustainable business model development is illustrated in the example of a so-called , a modular and adaptive production environment which integrates aspects of Circular Business Models and Product Service Systems.