Improving Material Efficiency for Ultra-efficient Factories in Closed-loop Value Networks

Infinite material circulation without losses in value or volume is a challenge for value networks, where materials are currently destroyed or lost. Today's waste prevention actions are predominantly one-dimensional and potentially create additional waste forms. To reduce waste in all dimensions, this paper first characterizes material waste forms, and then provides an analysis of their interdependencies. From these relationships a causal-loop diagram is derived, and the basis for a future system dynamics simulation model is described. The model will also examine their potential effect of waste minimization on energy consumption and productivity losses to assist manufacturers evaluate the effectiveness of waste minimization efforts.This approach is developed within the “Ultra-Efficient Factory” project funded by the Ministry of the Environment, Climate Protection and the Energy Sector Baden-Württemberg to support efficient manufacturing in small and midsized companies.