Material Flow Research Articles

Data model to enable multidimensional process mining for data farming based value stream planning in production networks

AbstractInternational industrial companies operate complex value streams within production networks. Therefore, strategic network design aims to identify an efficient value stream from several value stream scenarios. For this purpose, Value Stream Mapping (VSM) is a well-established methodology from Lean Management. However, the complexity and variety of value streams in production networks can lead to high manual effort when using pen-and-paper-based VSM. Therefore, data-driven VSM based on process mining has to be applied. To create a comprehensive data-driven VSM, it is necessary to transparently understand the correlations between different dimensions, such as the material flow, the information flow, and the inventory, which requires a multidimensional process mining approach. Simulation experiments can generate the necessary data for each value stream scenario using a data farming based planning approach to conduct a data-driven VSM in strategic network design. However, no data model currently supports storing comprehensive datasets for multiple scenarios to enable multidimensional process mining. To overcome this shortcoming, this article presents a data model for applying multidimensional process mining that is scalable to multiple dimensions and scenarios. The data model is constructed based on the theoretical principles of data cubes and multidimensional process mining. The applicability is demonstrated by a case study of a production network from the automotive industry.

A novel integrated material flow cost accounting (MFCA)- IoT-lean management system approach to improving water use efficiency and reducing costs in the beverage industry

The purpose of this study is to present a novel approach of integrating Material Flow Cost Accounting (MFCA), Internet of Things (IoT) and lean management systems to improve water use efficiency and reduce costs in the beverage industry. The positive and negative product costs of water purification, syrup manufacture, concentrate mixing, and packing were analyzed. The MFCA analysis showed 78.5% positive and 21.5% negative product costs. The use of the Power BI application to display real-time positive and negative costs in each process, scenario modeling and simulation was able to promote water savings and cost reductions, as well as supporting factory team ideation for choosing one of three improvement plans: 1) RO flushing water recovery in water purification; 2) water conservation with automated pH correction at packaging warmer; or 3) wastewater treatment and reuse of the rejected RO brine. According to our two-scenario water conservation testing, an automation process could improve pH adjustment in the packaging process, while MFCA, IoT, and lean management systems could be applied to improve industrial water use efficiency, demonstrating the potential for sustainable water use. The beverage-industry case in the present study validated this approach, resulting in a 24.1% production rate increase and a 4.5% cost reduction of 71,010 THB savings per year.

Pathways to a net zero building sector in Colombia: Insights from a circular economy perspective

The rapid urbanization and economic growth in Colombia have made the residential sector one of the largest energy and material consumers in the country. Circular economy (CE) strategies are a promising alternative to decouple the sector from resource depletion and climate change. The analysis shown here is based on the RECC model framework, a dynamic material flow analysis (dMFA) model. Our results suggest that by 2050 without CE strategies, residential building stock will reach 2.5 billion m2 and emit between 13 and 25 Mt CO2/yr, depending on whether carbon forest sequestration is included or not. A complete implementation of CE strategies and lower floor space can reduce 2020–2050 cumulative primary material production, waste generation, and GHG emissions by 48, 5, and 49 %, respectively. There is a potential to achieve net zero emissions by 2050 if, in addition to the measures mentioned above, more wood materials and forest sequestration are considered.

Construction and Optimization Strategies for Rural Residential Spatial Models Based on the Concept of Resource Metabolism: A Case Study of Rural Areas in the Shandong Plain

Rural communities can be conceptualized as spatial organisms interconnected by optimized resource utilization systems. Investigating the efficient utilization of rural resources and spatial construction methods grounded in resource metabolism is a pivotal step toward achieving the ecological transformation of rural spaces. This paper examined rural settlements in the Shandong Plain as a case study, exploring the relationships among three scales: village, neighborhoods, and courtyards. This analysis was based on elucidating the interaction mechanisms between “space and resource” and the integration of key resources and spatial elements. From the perspective of resource circulation and metabolism, this study aimed to elucidate the equilibrium of each resource element within three resource metabolism subsystems: the agricultural production system (core element), the ecological technology system (technological link), and the human life system (spatial carrier) in Shandong Plain’s villages, considering general climatic conditions. To achieve this, this research utilized the resource production volume, the utilization and transformation volume of resource metabolism technology facilities per unit area, and the average per capita resource consumption as fundamental measurement units. The concept of a rationing relationship is introduced to clarify resource allocation. Combining the aforementioned research on spatial resource metabolism in ecological villages in Shandong Province with the material flow analysis method, this study constructed a bottom–up spatial model of resource metabolism at three scales, courtyards, neighborhoods, and villages, under various resource metabolism scenarios. This study is anticipated to significantly contribute to the theoretical understanding of rural habitat environments, offering novel methods and perspectives for constructing ecological rural settlements.

Personalized 3D Printing of Artificial Vertebrae: A Predictive Bone Density Modeling Approach for Robotic Cutting Applications

Robotic vertebral plate cutting poses significant challenges due to the complex bone structures of the lumbar spine, which consist of varying densities in cortical and cancellous regions. This study addresses these challenges by developing a predictive model for robotic vertebral plate cutting force and bone quality recognition through the fabrication of artificial vertebrae with controlled, consistent bone density. To address the variability in bone density between cortical and cancellous regions, CT data are utilized to predict target bone density, serving as a foundation for determining the optimal 3D printing process parameters. The proposed methodology integrates a Response Surface Methodology (RSM), Back Propagation (BP) neural network, and genetic algorithm (GA) to systematically evaluate the effects of key process parameters, such as the filling density, material flow rate, and layer thickness, on the printed vertebrae’s density. A one-factor experimental approach and RSM-based central composite design are applied to build an initial bone density prediction model, followed by Sobol’s sensitivity analysis to quantify the influence of each parameter. The GA-BP neural network model is then employed to rapidly and accurately identify optimal printing parameters for different bone layer densities. The resulting optimized models are used to fabricate personalized artificial lumbar vertebrae, which are subsequently validated through robotic cutting experiments. This research not only contributes to the advancement in personalized 3D printing technology but also provides a reliable framework for developing patient-specific surgical planning models in robot-assisted orthopedic surgery.

3D printing of metal parts using a highly-filled thermoplastic filament

Purpose This study aims to develop a highly loaded filament with spherical metallic particles for fused filament fabrication (FFF) technology. The research focuses on optimizing powder loading, printing parameters and final processes, including debinding and sintering, to produce successful metal parts. Design/methodology/approach The optimal powder loading was identified by measuring mixing torque and viscosity at various temperatures. The filament was extruded, and printing parameters − particularly printing speed to ensure proper material flow − were optimized. Different filling patterns were also examined. After printing, the polymeric binder was removed and the parts were sintered to form the final metal components. Findings The optimal powder loading was determined to be 55 vol.%. The best surface quality was achieved with an optimized printing speed of 5 mm/s. Parts printed with various infill patterns were studied for differences in open, closed and total porosity, showing a strong link between porosity and infill pattern. Originality/value This comprehensive study provides new insights into manufacturing metal parts using FFF technology. It fills a gap in the literature regarding feedstock viscosity and shear rate in highly loaded metal filaments during FFF. Additionally, it uniquely examines the open, closed and total porosity of metal parts printed with different infill patterns.

Convection flow of NE-phase change material-water mixture in evacuated tube solar collector manifold: Numerical analysis of MHD double-diffusive convection and exothermic reaction

This study investigates the convection flow of nano-encapsulated phase change material (NEPCM)-water mixture in an evacuated tube solar collector manifold, focusing on the effects of magnetohydrodynamic (MHD) double-diffusive convection and exothermic reaction. Computational fluid dynamics simulations using the Galerkin finite element method were employed to analyze temperature and concentration distributions, fluid flow, melting zone of PCM nanocapsules, Nusselt number, Sherwood number, entropy generation, and thermal performance. The numerical analysis considers a range of dimensionless parameters, including Rayleigh number (Ra=103−105), Lewis number (Le=0.1−10), buoyancy ratio (Nz=1−5), nanoparticle concentration (ϕ=0.01−0.035), fusion temperature (ϴf=0.1−0.9), Stefan number (Ste=0.1−0.9), Hartmann number (Ha=0−50), magnetic field inclination angle (γ=0°−90°), and Frank-Kamenetskii number (FK=0−2.5). Results show that increasing Ra enhances the average Nusselt number (Nuav) by up to 156.1 % and the average Sherwood number (Shav) by up to 104.5 %, while increasing the total entropy generation by up to 13,155 %. Increasing FK reduces Nuav by up to 42.2 % but increases Shav by up to 13.1 %. The Lewis number and buoyancy ratio significantly influence the hydrothermal performance, with Nuav exhibiting non-monotonic behavior and Shav increasing by up to 240.9 % as Le increases. The nanoparticle concentration enhances Nuav by up to 49.7 %. Interestingly, the magnetic field effects are less pronounced than in previous studies, with Ha having a minor impact on Nuav and Shav. These findings have significant implications for the design and optimization of evacuated tube solar collectors and other thermal energy storage systems, potentially leading to improved efficiency and performance in real-world applications.

Integrating material flow analysis and supply chain resilience analysis to study silicon carbide

AbstractSilicon carbide (SiC) is a niche nonmetallic material that is essential in many industrial processes. Here, we integrate material flow analysis and supply chain resilience analysis to understand global SiC stocks and flows and to assess its supply chain. We use industry interviews to fill data gaps and collect information on the SiC system to overcome data scarcity. We find that globally around 1000 kt of SiC is produced each year. The biggest use of SiC is the abrasives industry (40%), followed by metallurgy (28%), refractories (20%), technical ceramics (0.7%), other uses (0.7%), and semiconductors (0.01%). As an energy‐intensive material, the SiC supply chain is under pressure, increasing the relevance of resilience considerations. Besides typical supply chain risks such as low diversity of supply and geopolitical trade restrictions, SiC particularly faces risks due to its energy‐intensive production process and associated emissions. In the SiC semiconductor supply chain, losses of nearly 75% are a particular issue. Due to high demand in the SiC market, stockpiles are negligible, and substitution is difficult in most sectors. We find that in the case of SiC, sustainability measures such as use reduction, recycling, or decreasing energy use or emissions would also positively contribute to supply chain resilience. This article met the requirements for a gold‐gold JIE data openness badge described at http://jie.click/badges.

PLOMAT: plotting material flows of ‘commonplace’ Late Bronze Age seals in western Eurasia

Abstract Since the mid-twentieth century, the study of designs on seals has often focused on exotica and elite items. The PLOMAT project investigates visual and material communication outside of elite exchange networks during the Late Bronze Age in western Eurasia. The authors present results from plotting flows of ‘commonplace’ cylinder seals and those classified as ‘Common-Style Mittani’.

Connecting environmental systems analysis to manufacturing technology: A catalogue of the world's steel and aluminium components

In pursuit of greenhouse gas emissions reductions, the environmental systems community has developed material flow analyses to describe the transformation of resources into goods, while the manufacturing technology community has developed innovations that can affect the production of individual components. However, these two communities have remained disconnected, because neither is able to relate their insights to their point of common interest: the global production of components. For the first time, this paper connects global analyses of the use of steel and aluminium to the production of components, classified by the metal forming processes which shape them. The results demonstrate the proportions of steel and aluminium used in ten distinct component groups, at global level, and for the major product groups which drive demand for these two metals. This helps both to prioritise requirements for innovation in design and manufacturing and to evaluate of the emissions potential of such innovations.

THE RELATIONSHIP BETWEEN SUSTAINABLE MANUFACTURING OPERATIONS AND ENVIRONMENTAL PERFORMANCE OF PLASTICS AND RUBBER MANUFACTURERS IN KENYA: THE MODERATING EFFECT OF ECO-INNOVATIONS

Objective: This study aimed to expose the effect of sustainable manufacturing operations on performance of plastics and rubber manufacturing firms in Kenya. Theoretical Framework: The main concepts and theories that support the research were conveyed. The study employed the natural resource-based view and ecological modernisation theory. Method: The study employed descriptive research survey that targeted all the 90 plastics and rubber manufacturing firms registered by the Kenya Association of manufacturers. A structured questionnaire as well as a data collection form were useful in collecting data. For data analysis descriptive and inferential statistics were used with the precise inclusion of partial least squares structural equation modeling method. Results and Discussion: There was a statistically significant influence of eco-innovations on the effect of sustainable manufacturing operations on environmental performance. However, the individual eco-innovations indicators namely eco-product innovations, eco-process innovations, green system innovations and material flow innovations yielded varied results. Research Implications: The findings confirm previous studies that indeed there are positive gains made from the moderating role of eco-innovations in the correlation between sustainable manufacturing operations and performance of the environment. Originality/Value: These results are expected to benefit stakeholders such as policy makers in government, plastic and rubber manufacturers and academia in augmenting the existing knowledge.

Emergy-Based Evaluation of Xiaolangdi Reservoir’s Impact on the Ecosystem Health and Services of the Lower Yellow River

The disturbance in river ecosystems caused by reservoirs and dams has become a critical topic, attracting increasing attention. However, the extent to which reservoir and dam construction and operation impact downstream river ecosystem health and ecosystem service functions is not fully understood. This research examines the Xiaolangdi Reservoir and the Lower Yellow River (LYR) ecosystem in China as a case study. We analyzed the complex material and energy flows in the LYR ecosystem using emergy theory and developed a set of emergy-based indicators for the quantitative assessment of river ecosystem health and services under reservoir operation interference. The results indicate that the total natural capital and environmental endowments of the LYR ecosystem have remained relatively stable after the operation of the Xiaolangdi Reservoir, with an increase in renewable emergy input. The ecosystem’s vigor decreased slightly, while the biomass emergy diversity index remained stable. However, the total emergy inputs increased significantly, with external feedback inputs becoming the most important emergy source for the LYR ecosystem. The resilience of the LYR ecosystem improved, with a significant increase in emergy density and a decrease in the emergy sustainability index. These findings suggest that although the river ecosystem continues to provide supporting services to human society, the extent of these services has diminished compared to pre-perturbation levels. In this research, a methodology for analyzing the impact of key reservoir operations on the ecosystem health and services of a large river is proposed to provide support for large river sustainable development studies.

Study on the Process of Preparing Aluminum Foam Sandwich Panel Precursor by Friction Stir Welding

In recent years, high-performance lightweight and multifunctional aluminum foam sandwiches (AFSs) can be successfully applied to spacecraft, automobiles, and high-speed trains. Friction stir welding (FSW) has been proposed as a new method for the preparation of AFS precursors in order to improve the cost-effectiveness and productivity of the preparation of AFS. In this study, the AFS precursors were prepared using the FSW process. The distribution of foaming agents in the AFS precursors and the structure and morphology of AFS were observed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray energy dispersive spectroscopy (EDS). The effects of the temperature and material flow on the distribution of the foaming agent during the FSW process were analyzed through experimental study and numerical simulation using ANSYS Fluent 19.0 software. The results show that the uniform distribution of the foaming agent in the matrix and excellent densification of AFS precursor can be prepared when the rotation speed is 1500 r/min, the travel speed is 25 mm/min, the tool plunge depth is 0.2 mm, and the tool moves along the retreating side (RS). In addition, the experimental and numerical simulations show that increasing the welding temperature improves the uniformity of foaming agent distribution and the area of AFS precursor prepared by single welding, shortening the thread length inhibits the foaming agent from reaching the upper sandwich plate and moving along the RS leads to a more uniform distribution of the foaming agent. Finally, the AFS with porosity of 74.55%, roundness of 0.97, and average pore diameter of 1.192 mm is prepared.

Simulation of container discharge dynamics using modified cellular automata

In the field of physical logistics, efficient and precise control of material flow during the emptying of containers such as silos and wagons is crucial. This study introduces a not conventional cellular automaton model to simulate spillage from containers. The model is implemented using Excel macros, providing a user-friendly and accessible platform for logistics professionals. By modifying the traditional cellular automaton framework, the simulation can accurately represents the dynamics of material flow during container emptying processes. The proposed method allows for fine-tuned control over the spillage by integrating specific constraints and parameters, enhancing operational efficiency and reducing material loss. The versatility of the model makes it applicable to a wide range of logistical scenarios, demonstrating its potential as a valuable tool in physical logistics management.

Effects of triflute pin geometry on defect formation and material flow in FSW using CEL approach

Complicated tool pin designs in Friction Stir Welding (FSW) need to be considered in terms of material flow and defect formation. This study investigates the effects of the triflute tool's geometrical parameters on temperature, strain, void formation, and material mixing using a numerical method. The numerical model employs a coupled Eulerian-Lagrangian (CEL) formulation and successfully predicts void formation and material mixing during friction stir welding (FSW). Four tool pin designs are considered for material flow, including one cylindrical pin and three triflute pins with flute radii of 1 mm, 1.5 mm, and 2 mm. The findings indicate that the stir zone is divided into shoulder-driven and pin-driven zones, each exhibiting distinct material flow patterns. In the shoulder-driven zone, material flow toward the advancing side is dominant, while in the pin-driven zone, it flows toward the retreating side. Flutes on the FSW pin tool increase the sweeping rate, strain, and material movement in the stir zone. However, flutes with a larger radius sweep a greater amount of material and thus require more softened material to facilitate movement. Therefore, for defect-free joint formation, a higher rotational speed of the tool will be required, which may adversely affect tool lifespan and joint mechanical properties. The effectiveness of flutes with a smaller radius of 1 mm is significantly greater than that of those with a larger radius (1.5 or 2 mm) in enhancing material flow and achieving defect-free welding.

Influence of different wrought processes on the microstructure and texture evolution in AZ31 magnesium alloy

AZ31 magnesium alloys were deformed by five wrought processes (forging, rolling, extrusion, equal-channel-angular-extrusion (ECAE), and caliber rolling) under the condition of an introduced equivalent plastic strain of approximately 1.5 at 573 K. The strain components induced by these wrought processes were computed using the finite element method (FEM). By combining the calculation results with the microstructure observations, the texture and microstructure evolution were discussed from the viewpoint of the strain state. The FEM showed that approximately the same equivalent strain was induced at the center of the alloys where observations were performed. Therefore, as the values of the equivalent plastic strain were fixed in all wrought processes, the effect of the strain component could be compared. The forged and rolled alloys had an intensive basal texture perpendicular to the compression and normal directions, respectively. In the others, a basal fiber texture parallel to the material flow direction was observed. These basal textures were oriented perpendicular to the compressive strain, and their intensities strengthened with an increase in the strain component. The microstructure became more refined and homogenized as the magnitude of the minimum principal strain decreased. This decrease corresponds to the transition of the deformation mode from the uniaxial compression mode to the multidirectional deformation mode as long as the same equivalent strain is induced. This result demonstrates that the microstructure obtained through dynamic recrystallization depends on the deformation mode, separately from the effect of the conventionally reported equivalent plastic strain.

A socio-economic assessment of an emerging technology in the mining industry

Abstract Purpose This article provides methodological insights to evaluate the socio-economic risk of an emerging froth flotation technology for the mining sector with the goal of guiding the design and development process. This technology is used to separate valuable particles based on surface properties among minerals and, if properly developed, could be used to valorize fine particles that currently existing technology cannot separate and thus become waste material. Methods The Social Hotspot assessment utilized the Product Social Impact Life Cycle Assessment (PSILCA) database to analyze social hotspots in the relevant industrial sector. In addition, a survey captured the viewpoints of technology developers regarding additional potential social risk and opportunities. The final results were defined by combining these two analyses, conducted according to the 2020 UNEP guidelines for Social Life Cycle Assessment of Products and Organizations. For the economic assessment, the Material Flow Cost Accounting (MFCA) methodology (ISO14051) was applied, considering material costs, system costs, energy costs, and waste management costs for both the current situation and a future industrial-scale scenario. Results and discussion The study emphasizes the importance of tailoring methodological approaches for case studies involving low Technology Readiness Level (TRL) technologies based on available data. The state of technology development has led to different results for the economic and social analyses, primarily due to the difficulty in accurately predicting potential social impacts at this stage. The social analysis identified potential risks and 28 subcategories of impacts across different stakeholder categories. The economic assessment found that energy costs (49%) were the highest contributor to the MFCA cost of the future scenario, followed by system costs (29%). Conclusions and recommendations The study concludes that conducting a socio-economic analysis during the developmental stage of a technology is valuable for identifying critical hotspots that require monitoring, effectively guiding the research and development phase. This application represents a unique case in the mining sector and could be a first step in defining a methodological approach suitable for low TRL technologies. Analyzing both social and economic risks provides a more comprehensive perspective on sustainability, complementing environmental risk assessments.

Perancangan Tata Letak Fasilitas Kaos V-Neck untuk Peningkatan Daya Saing

Purpose: The purpose of this study was to address the numerous complaints received by PTRT management concerning the production process of V-Neck t-shirts in six divisions during 2023. The goal was to redesign the layout, particularly the process-oriented layout, to improve the efficiency and reduce operational costs. Research Methodology: The management employed a quantitative approach to redesign the layout. The analysis involved calculating and comparing the total number of movements in the production process before and after the redesign. The methodology focused on reducing the number of movements required to enhance the efficiency. Results: The redesigned layout resulted in a reduction of 300 movements per week, equating to a 1.8% decrease from the initial total of 16,800 to 16,500 movements. This reduction also led to a corresponding decrease in the cost of movement, thereby reducing Rp. Three hundred per week, a 1.8% reduction in costs. Limitations: The study is limited by the scope of data, which is specific to the production of V-Neck t-shirts in 2023 within the six divisions. The results may not be generalizable to other products or time periods, and the analysis focused solely on movement efficiency without considering other potential factors, such as employee productivity or material flow. Contribution: The redesign of the layout contributes to the overall competitiveness of PTRT management by streamlining the production process, reducing costs, and potentially minimizing complaints related to the production of V-neck t-shirts. This process-oriented approach to layout design can serve as a model for future improvement in other production areas.

Understanding the Level of Integration in Existing Chemical Clusters: Case Study in the Port of Rotterdam

AbstractThe petrochemical industry is composed of several interconnected processes that use fossil-based feedstock for producing chemicals. These processes are typically geographically clustered and often belong to different parties. Reducing the environmental impacts of the petrochemical industry is not straightforward due to, on the one hand, their reliance on fossil fuels for energy and as a feedstock and, on the other hand, the significant level of interconnected energy and material flows among processes. Current methods for analyzing changes to existing processes cannot capture the multitude and level of interactions. The goal of this paper is to create a model of a petrochemical cluster and analyze its physical characteristics and performance. This paper addresses this goal by developing an assessment method that combines process simulations, multiplex graph analysis, and key performance indicators. The method is applied to a case study based on the petrochemical cluster in the Port of Rotterdam, resulting in a uniquely highly detailed model of a petrochemical cluster. The network analysis results show that only some of the processes are very interconnected. From the performance analysis, it can be observed that the olefins process is the most carbon-intense and has high CO2 emissions. Additionally, the results showed the importance of considering existing interconnections when assessing the current performance of existing petrochemical clusters or the performance due to future changes to chemical processes. For instance, some changes would occur to an industrial cluster by introducing alternative carbon sources, such as biomass or CO2.

The environmental costs of clean cycles: Quantitative analysis for the case of PVC window profile recycling in Germany

AbstractRecycling schemes for long‐lived products are challenged by the presence of “legacy substances,” which have been used in production in the past, but are nowadays classified as substances of concern. This study quantitatively evaluates the trade‐offs between phasing out legacy substances, increasing circularity levels, and reducing life cycle impacts of polyvinylchloride (PVC) window profiles recycling in Germany based on a comprehensive dynamic material and substance flow analysis coupled with a prospective life cycle assessment. Scenario results indicate that although lead had been phased out in virgin PVC by 2015, lead concentrations in end‐of‐life PVC window profiles will remain above 0.3% until the end of the century without a restriction of lead in recycled PVC and will be by factor 3–5 higher compared to a restriction as stipulated by EU 2023/923. However, the latter is associated with lower recycling rates and higher life cycle environmental impacts of PVC window frame waste management, which cannot be fully compensated by the introduction of new waste treatment pathways using currently available technologies. The study serves to introduce a new comprehensive modeling framework, which allows for the consideration of trade‐offs between substance, material, and environmental impact dimensions as a basis for discussing and developing sustainable waste management strategies.