Simulation Method for Remanufacturing with Recycling – Testing and Project Dimensioning

Abstract

The article addresses the challenges associated with the Product-as-a-Service (PaaS) concept in the context of the circular economy. The use of simulation technologies within this concept can accelerate the adoption of circular economy principles in companies. It enables faster modelling and optimisation of value-retention processes such as remanufacturing and refurbishment. The aim of the paper is to propose a simulation approach that allows engineers to develop simulation models (digital twins) in the same way they design and redesign closed-loop manufacturing systems. A further objective is to highlight the specific requirements for testing such simulation models and for sizing planned digital-twin projects. The article presents the development of a hybrid model that combines discrete piece-flow for remanufacturing with mass flow (in kilograms) for recycling, using household appliances as an example and identifying sources of uncertainty that affect the organisation of PaaS processes, particularly remanufacturing and recycling. The main contribution is the development of a hybrid simulation approach based on operations in the PaaS domain, i.e. closed-loop manufacturing with the 6R framework, and the application of the COSMIC methodology to size simulation projects. The article also discusses methods for simulation modelling of individual sources of uncertainty and uses an operation-based simulation method instead of conventional discrete-event simulation.