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Towards Circular Manufacturing Systems implementation: A Complex Adaptive Systems perspective using modelling and simulation as a quantitative analysis tool
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Manufacturing and Metrology Systems.ORCID iD: 0000-0002-1965-5571
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Manufacturing and Metrology Systems.ORCID iD: 0000-0002-1365-667x
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Manufacturing and Metrology Systems.ORCID iD: 0000-0002-8745-7905
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2022 (English)In: Sustainable Production and Consumption, ISSN 2352-5509, Vol. 31, p. 97-112Article in journal (Refereed) Published
Abstract [en]

A transition towards circular manufacturing systems (CMS) has brought awareness of untapped economic and environmental benefits for the manufacturing industry. Conventional manufacturing systems already present a high level of complexity in terms of physical flows of materials and products as well as information and financial flows linked to them. Closing the loop of materials and products through multiple lifecycles, as proposed in CMS, increases this complexity manifold. To support practitioners in implementing CMS through enhanced decision-making, this research studies CMS from a complex adaptive systems (CAS) perspective and proposes to exploit methods and tools used in the study of CAS to characterise, model and analyse CMS. By viewing CMS as CAS composed of autonomous, interacting agents, this research proposes a multi-method model architecture for modelling and simulating CMS. The different CMS stakeholders are modelled individually as autonomous agents by integrating agent-based, discrete-event, and/or system dynamics modules within each agent to capture their diverse and heterogeneous nature. The applicability of the proposed multi-method approach is illustrated through a case study of a white goods manufacturing company implementing CMS in practice. This case study shows the relevance and feasibility of the proposed multi-method approach as a decision support tool for the systemic exploration and quantification of CMS. It also shows how a transition towards CMS necessitates a lifecycle approach in terms of costs, revenues and environmental impacts to identify hotspots and, therefore, design circular systems that are viable in both economic and environmental terms. In fact, the analyses of the simulation results indicate how decisions in terms of business models, product design, and supply chain affected the CMS performance of the case company. For instance, implementing a service-based model led to a high number of usecycles (on average six usecycles per washing machine), which, in turn, led to high lifecycle costs and emissions due to more frequent transportation and recovery operations. Similarly, the deployment of long-lasting washing machines, which is a core principle of CMS, led to high manufacturing costs. Due to the high initial costs and a time mismatch between revenues and costs in the service-based model, it required a longer time for the company to reach the break-even point (approximately 23 months). Overall, the case study shows that multi-method simulation modelling can provide decision-making support for a successful implementation of CMS.

Place, publisher, year, edition, pages
Elsevier BV , 2022. Vol. 31, p. 97-112
Keywords [en]
circular economy, circular manufacturing systems, complex adaptive systems, lifecycle costing, lifecycle revenues, multi-method simulation
National Category
Mechanical Engineering Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-308982DOI: 10.1016/j.spc.2022.01.033ISI: 000789396500008Scopus ID: 2-s2.0-85124533935OAI: oai:DiVA.org:kth-308982DiVA, id: diva2:1638874
Note

QC 20220223

Available from: 2022-02-17 Created: 2022-02-17 Last updated: 2026-10-06Bibliographically approved
In thesis
1. Circular Manufacturing Systems: Complex systems modelling and simulation for enhanced decision-making
Open this publication in new window or tab >>Circular Manufacturing Systems: Complex systems modelling and simulation for enhanced decision-making
2022 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

A transition towards circular manufacturing systems (CMS) has brought awareness of untapped economic and environmental benefits for the manufacturing industry. Despite this increased interest, the implementation of CMS is still in its infancy stage. To support the manufacturing industry in implementing CMS in practice, this research seeks to (1) explore the main characteristics of CMS and their needs for a successful implementation in the context of the manufacturing industry, and (2) develop quantitative analysis tools to support decision-making in implementing CMS with a concurrent focus on economic and environmental performance. By viewing CMS as complex adaptive systems (CAS), this research proposes to exploit complex system modelling and simulation used in the study of CAS to characterise, model, and analyse CMS. In this regard, a multi-method simulation model architecture that combines features of agent-based, discrete-event, and system dynamics modelling methods is proposed to model and simulate CMS as different abstraction levels are needed to capture the complex and dynamic interactions among the elements of the system. The resulting multi-method simulation tool aims at providing systemic quantification of CMS in terms of economic performance (e.g., lifecycle costs, lifecycle revenues, and lifecycle profits), environmental performance (e.g., lifecycle environmental impact), and technical performance (e.g., quality, quantity and timing of product return flows), and therefore, facilitates decision-making for industrial organizations implementing CMS in practice.

Abstract [sv]

En övergång till cirkulära tillverkningssystem (CMS) har skapat medvetenhet om outnyttjade ekonomiska och miljörelaterade fördelar för tillverkningsindustrin. Trots det ökade intresset är implementeringen av CMS fortfarande i sin linda. För att stödja tillverkningsindustrin med att implementera CMS i praktiken, strävar denna forskning efter att (1) utforska de viktigaste egenskaperna hos CMS och de behov som finns för att en framgångsrik implementering av CMS i tillverkningsindustrin ska kunna ske, och (2) utveckla kvantitativa analysverktyg som kan användas som beslutstöd vid implementering av CMS med samtidigt fokus på ekonomisk och miljömässig prestanda. Genom att behandla CMS som komplexa adaptiva system (CAS), föreslår denna forskning att utnyttja komplex systemmodellering och simulering som används i CAS för att karaktärisera, modellera och analysera CMS. I detta avseende föreslås en arkitektur för multimetodisk simuleringsmodell som kombinerar egenskaper från agentbaserade, diskret händelsestyrda, och systemdynamiska modelleringsmetoder för att modellera och simulera CMS. Denna kombination är nödvändig för att fånga de komplexa och ömsesidiga interaktionerna mellan delarna i systemet. Den resulterande multi-metodiska simuleringsmodellen syftar till att ge insikter om hur CMS beter sig i termer av ekonomi (t.ex. livscykelkostnader, livscykelintäkter och livscykelvinster), miljömässighet (t.ex. miljöpåverkan under livscykeln) och teknisk prestanda (t.ex. kvalitet, kvantitet och tidpunkt för produktreturflöden) och därigenom underlättar beslutsfattande för industriella organisationer som vill implementerar CMS.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2022. p. 127
Series
TRITA-ITM-AVL ; 2022:38
Keywords
circular economy; circular manufacturing systems; complex adaptive systems; multi-method simulation modelling; lifecycle costing; lifecycle revenues; lifecycle environmental impact
National Category
Engineering and Technology
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-321577 (URN)978-91-8040-430-3 (ISBN)
Public defence
2022-12-09, Kollegiesalen / https://kth-se.zoom.us/j/64628471501, Brinellvägen 8, Stockholm, 09:00 (English)
Opponent
Supervisors
Projects
ReCiPSS Resource-Efficient Circular Product-Service Systems
Funder
EU, Horizon 2020, 776577-2
Available from: 2022-11-17 Created: 2022-11-17 Last updated: 2022-12-06Bibliographically approved
2. Circular Supply Chains: A Multi-Method Simulation Framework for Performance Evaluation and Informed Decision-Making
Open this publication in new window or tab >>Circular Supply Chains: A Multi-Method Simulation Framework for Performance Evaluation and Informed Decision-Making
2026 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Transition to Circular Manufacturing Systems (CMS) is crucial for sustainable growth,resource conservation, and mitigation of environmental impacts. This shift requiresa systemic approach that integrates value propositions, product design, and supplychains, supported by digital technologies. Circular supply chains (CSCs) emerge as acore pillar of CMS, demanding deliberate design to close the loop beyond simply addingend-of-life recovery to linear models. CSCs are inherently complex; however, currentresearch often fails to capture these aspects, overlooking the systemic approach to interdependenceamong the value proposition, product design, and supply chain. Furthermore,most studies are theoretical, lacking the necessary quantitative and empiricalanalysis to evaluate CSC’s performance. This research aims to conceptualize CSCswithin the CMS context, identifying their complexity aspects, and develop an analysistool to capture these complexities and evaluate CSCs’ technical, economic, and environmentalperformance to support informed decision-making. This thesis proposesan analysis framework with two modules. The first, Conceptualization, provides anoverview of CSCs implementation challenges, stakeholders’ roles and relationships,and how value proposition, product design, and transparency influence CSCs’ structure,uncertainties, and stakeholders’ footprints. Building on this, the second module,Analysis and Implementation, quantifies CSCs’ performance through a multimethodsimulation model, combining agent-based, discrete-event, and system-dynamics. Theframework’s applicability is illustrated through two distinct case studies.

Abstract [sv]

Övergången till Cirkulära Tillverkningssystem (CMS) är avgörande för hållbar tillväxt,resurshushållning och mildring av miljöpåverkan. Denna omställning kräver ett systematisktsynsätt som integrerar värdeerbjudanden, produktdesign och leveranskedjor,med stöd av digital teknik. Cirkulära Leveranskedjor (CSCs) framträder som en kärnpelarei CMS och kräver medveten design för att sluta kretsloppet, bortom att bara läggatill återvinningsaktiviteter i slutet av linjära modeller. CSCs är till sin natur komplexa,men nuvarande forskning misslyckas ofta med att fånga dessa aspekter och bortserfrån det systematiska synsättet på beroendet mellan värdeerbjudandet, produktdesignenoch leveranskedjan. Dessutom är de flesta studier teoretiska och saknar den kvantitativaoch empiriska analys som krävs för att utvärdera CSCs prestanda. Denna forskningsyftar till att konceptualisera CSCs inom CMS-sammanhanget, identifiera deraskomplexitetsaspekter och utveckla ett analysverktyg för att fånga dessa komplexiteteroch utvärdera CSCs tekniska, ekonomiska och miljömässiga prestanda för att stödjavälgrundat beslutsfattande. Denna avhandling föreslår ett analysramverk med två moduler.Den första, Konceptualisering, ger en översikt över utmaningar vid implementeringav CSCs, intressenternas roller och relationer, samt hur värdeerbjudande, produktdesignoch transparens påverkar CSCs struktur, osäkerheter och intressenternasfotavtryck. Med denna grund kvantifierar den andra modulen, Analys och Implementering,CSCs prestanda genom en simuleringsmodell med flera metoder, som kombineraragentbaserad, diskret händelsestyrd och systemdynamisk modellering. Ramverketstillämpbarhet illustreras genom två distinkta fallstudier.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2026. p. 105
Series
TRITA-ITM-AVL ; 2026:25
Keywords
Circular economy, Circular manufacturing systems, Circular supply chains, Multi-method simulation modeling, Complexity, Framework, Cirkulär ekonomi, Cirkulära tillverkningssystem, Cirkulära leveranskedjor, Multimetodssimuleringsmodellering, Komplexitet, Ramverk
National Category
Other Environmental Engineering
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-390286 (URN)978-91-8106-699-9 (ISBN)
Public defence
2026-11-13, F3, Lindstedtsvägen 26-28, KTH, Stockholm, 09:00 (English)
Opponent
Supervisors
Available from: 2026-10-09 Created: 2026-10-06 Last updated: 2026-10-12Bibliographically approved

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Roci, MalvinaSalehi, NiloufarShoaib-ul-Hasan, SayyedAbdullah Asif, Farazee MohammadRashid, Amir

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