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Zero Defect Manufacturing is a disruptive concept that has the potential to entirely reshape the manufacturing ideology. Building on the same quality management philosophy that underpins both lean production and Six Sigma, the Zero Defect Manufacturing paradigm has in recent years developed significantly, given the onset of Industry 4.0 and the increasing maturity of its digital technologies. In this paper, we review contemporary advances in Zero Defect Manufacturing using structured literature review. We explore emergent themes and present important directions for future development in this continuously emerging field of research and practice. We highlight two specific Zero Defect Manufacturing strategy types: defect prevention, and defect compensation; as well as identify two important themes for future ZDM research, namely advancing ZDM research (particularly with a view to progressing from zero-defect processes to zero-waste value chain strategies) and overcoming the global application challenges of ZDM (with emphasis on cyber-security and the extension of defect prevention and compensation strategies to less explored manufacturing processes).

Manufacturing has to cope with the continuously increasing variety of products, change of volumes and shortening product life cycles. These trends also affect the automotive sector: the frequent introduction of new models, materials and assembly technologies put the suppliers of make-to-order parts under pressure. In this context, the design of assembly systems and their management are of paramount importance for the companies’ competitiveness. In this paper, we propose an approach for the design and reconfiguration of modular assembly systems through the integration of different computational tools addressing the design of the system, the optimization of the layout, the planning of reconfiguration actions as well as production planning. Integrating these computational tools and iterating through the resulting workflow and feedback allow to consider the outcomes and dependencies of alternative decision sequences holistically with the objective of an effective and efficient approach to production system design and management. The viability of the approach is demonstrated through the application to an automotive case study.

Printed Circuit Boards (PCBs) are called "urban mineral resources" since 25%-30% in weight of their composition is made of valuable metals and rare earths. PCBs recycling is a very challenging task that has not been solved yet from a technological and business model sustainability point of view. Most of the current approaches are based on the combination of thermal and chemical processes, which require considerable energy and generate negative environmental impacts. Moreover, currently many critical raw materials found in small concentrations in PCBs but in considerable concentrations in specific components are not recovered and usually end-up in the fraction going to landfill. To overcome these limitations, the "Zero Waste PCBs" project aims at developing a systemic solution integrating technological and business model innovations to achieve a more sustainable end-of-life treatment of PCBs. Automatic components disassembly and intelligent mechanical shredding and separation processes are integrated to achieve a high purity mixture of metal and non-metal fractions to be further treated by chemical recovery processes. Moreover, methods to re-use the non-metal fractions are investigated, under a zero-waste view. This paper presents the major intermediate results of the project and the application potentials of the methodological and technological innovations.

The number of scientific papers in the field of Sustainable Manufacturing (SM) shows a strong growth of interest in this topic in the last 20 years. Despite this huge number of publications, a clear statement of the profound meaning of Sustainable Manufacturing, or at least a strong theoretical support, is still missing. The 6R framework seems to be a first attempt to rationalize this issue, as it is an axiomatic identification of its true nature. Recognizing the pursuing of one or more of the Reduce-Recycle-Reuse-Recover-Redesign-Remanufacture principles allows users to identify if any manufacturing action is in the right direction of sustainability. In the paper, the authors speculate on the use of this framework and its possible extension by referring to all the existing scientific contributions on Sustainable Manufacturing in the SCOPUS® databases as a source of data. Starting from the measurement of the distribution of the scientific papers allocated onto the 6Rs dimensions, by using both author keywords and automatically extracted multiword from texts, the distribution of the scientific papers among the 6R was derived. A new framework is proposed based on analytical text tools to compare the affinity of the applied research activities of the Italian Technologist network SOSTENERE to sustainable manufacturing and provide also a benchmarking view to describe the Italian way to SM with respect to the rest of existing applications.

The rapid growth of technological products has led to an increasing volume of waste electrical and electronic equipments WEEE, which could represent a valuable source of critical raw materials. However, current mechanical separation processes for recycling are typically poorly operated, making it impossible to modify the process parameters as a function of the materials under treatment, thus resulting in untapped separation potentials. Corona electrostatic separation CES is one of the most popular processes for separating fine metal and nonmetal particles derived from WEEE. In order to optimize the process operating conditions i.e., variables for a given multi-material mixture under treatment, several technological and economical criteria should be jointly considered. This translates into a complex optimization problem that can be hardly solved by a purely experimental approach. As a result, practitioners tend to assign process parameters by few experiments based on a small material sample and to keep these parameters fixed during the process life-cycle. The use of computer experiments for parameter optimization is a mostly unexplored area in this field. In this work, a computer-aided approach is proposed to the problem of optimizing the operational parameters in CES processes. Three metamodels, developed starting from a multi-body simulation model of the process physics, are presented and compared by means of a numerical and simulation study. Our approach proves to be an effective framework to optimize the CES process performance. Furthermore, by comparing the predicted response surfaces of the metamodels, additional insight into the process behavior over the operating region is obtained. Copyright © 2015 John Wiley & Sons, Ltd.