Design and implementation of a circular remanufacturing production line

Cente Lovato, Ever Alexander (author), Valentinčič, Joško (mentor), Rejeb, Helmi Ben (comentor)

The growing concern over resource scarcity and environmental damage has exposed the limitations of linear production models “take-make-dispose”. On this basis, circular economy and remanufacturing, provide effective solutions by extending product lifecycle, value preservation, and reducing the energy and materials consumption. This thesis presents the design and implementation of a pilot remanufacturing production line, with the objective of demonstrating its viability and evaluating its performance. A hydro turbine was selected as case study, and the remanufacturing stages – disassembly, diagnostic, cleaning, repairing, kitting, reassembly and quality control – were physically implemented, simulated and tested. Lean manufacturing principles were applied to improve workflow, while Industry 4.0 technologies were integrated to improve accuracy, ergonomics, quality, data management and decision-making. The experiments of remanufacturing confirmed the technical feasibility of circular remanufacturing chains and demonstrated their potential advantages over linear models. Measured indicators such as value-added time, Material Circularity Index, and carbon footprint revealed improvements in productivity, quality, and sustainability. Overall, the thesis contributes to bringing together theory and practice in circular economy by offering a replicable framework for research and education, supporting the ecological transition towards more sustainable and digitalized manufacturing systems.

• Language: English
• Keywords: remanufacturing, circular economy, industry 4.0, sustainable manufacturing, production line
• Work type: Master's thesis/paper
• Typology: 2.09 - Master's Thesis
• Organization: FS - Faculty of Mechanical Engineering
• Year: 2025
• Number of pages: XXV, 77 str.
• PID: 20.500.12556/RUL-176366
• UDC: 658.51:502:621.224-027.33(043.2)
• COBISS.SI-ID: 261620739
• Publication date in RUL: 28.11.2025

Secondary language

• Language: Slovenian
• Title: Zasnova in izvedba krožne proizvodne linije za predelavo

Abstract

Naraščajoča zaskrbljenost zaradi pomanjkanja virov in okoljske škode je razkrila omejitve linearnih proizvodnih modelov »vzemi-izdelaj-zavrzi«. Na tej podlagi krožno gospodarstvo in predelava zagotavljata učinkovite rešitve s podaljševanjem življenjskega cikla izdelkov, ohranjanjem vrednosti ter zmanjšanjem porabe energije in materialov. Ta diplomska naloga predstavlja zasnovo in izvedbo krožne proizvodne linije za predelavo s ciljem prikazati njeno izvedljivost in oceniti njeno delovanje. Kot študija primera je bila izbrana hidroturbina, faze predelave – demontaža, diagnostika, čiščenje, popravilo, kompletiranje, ponovna montaža in nadzor kakovosti – pa so bile fizično izvedene, simulirane in preizkušene. Za izboljšanje poteka dela so bila uporabljena načela vitke proizvodnje, tehnologije Industrije 4.0 pa so bile integrirane za izboljšanje natančnosti, ergonomije, kakovosti, upravljanja podatkov in odločanja. Poskusi predelave so potrdili tehnično izvedljivost krožnih verig predelave in pokazali njihove potencialne prednosti pred linearnimi modeli. Izmerjeni kazalniki, kot so čas dodane vrednosti, indeks krožnosti materialov in ogljični odtis, so pokazali izboljšave v produktivnosti, kakovosti in trajnosti. Na splošno diplomsko delo prispeva k povezovanju teorije in prakse v krožnem gospodarstvu, saj ponuja ponovljiv okvir za raziskave in izobraževanje ter podpira ekološki prehod k bolj trajnostnim in digitaliziranim proizvodnim sistemom.

• Keywords: ponovna izdelava, krožno gospodarstvo, industrija 4.0, trajnostna proizvodnja, proizvodna linija