Browsing by Author "Rybicka, Justyna"

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    Capturing composites manufacturing waste flows through process mapping
    (Elsevier, 2014-12-16) Rybicka, Justyna; Tiwari, Ashutosh; Alvarez Del Campo, Pedro; Howarth, Jack
    The necessity of high performance materials has become latent in high technology sectors such as aerospace, automotive, renewable energy, nuclear engineering and sports. The expanding impact on future manufacturing of the EU waste management legislation and increasing price of current waste management methods stress the importance of an efficient and sustainable way of recycling waste generated in the composites industry. Aerospace companies estimated that 30e50% of materials in aircraft production are scrapped due to the way it is manufactured. Companies need to pay for landfilling the composite materials that otherwise can be a valuable resource. In a view that looking at individual production waste outputs could maximise the material reuse or recycling capability, gaining information about the type of scrap materials could inform the development of composite reuse/recycling supply chain. This research paper focuses on understanding the scale of scrap created in individual composites manufacturing processes to assess its potential value in terms of reuse/recycle capabilities. A Material flow analysis based data collection workshop has been performed with four composite manufacturers. Through the case studies it has been identified that there are three fibre related waste outputs captured: dry fibres, fibre material sheet off-cuts, and curried composite off-cuts. The captured information allows for the material specification development. This allows bridging the gap between the manufacturers and the waste processors in composites to address the lack of infrastructure and lack of waste material specification barriers outlined by the Composites Strategy 2009.
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    Data supporting Technology readiness level assessment of composites recycling technologies article
    (Cranfield University, 2016-06-17 11:27) Rybicka, Justyna; Tiwari, Ashutosh; Leeke, Gary
    Data supporting Technology readiness level assessment of composites recycling technologies article
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    Integrating models for calculating component sustainability metrics
    (Cranfield University, 2024-06-07) Kirkwood, Leigh; Abu-Monshar, Anees; Norman, Beth; Crook, Robert; Barlow, Ed; Hayes, Cai; Rybicka, Justyna
    This paper reports on the development of models for calculating sustainability metrics at a per part level, developed for the LEAD factory project. While many organisations collect site level data for sustainability, there is a notable lack of support to calculate at a per part level. This scope difference requires different methods, but part level information can aid organisations in making production changes to achieve sustainability KPI’s. A cradle-to-gate approach was used that links raw-material, the transportation of materials and details on the production processes. To achieve this, a toolset of different models was designed and built to address key activities in the value-chain, to both support potentially independent analysis of just that value-chain link or the more complete cradle-to-gate analysis. Integration of model outputs and planning of information flow within the toolset is the primary focus of this paper. This is part 1 of a 2 part paper: this paper focuses on how the models were integrated and the design of the wider toolset. Part 2 focuses on the benchmarking using the model-set and comparing the “JENI” system developed as part of the LEAD factory project.
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    Modelling flexible manufacturing systems through discrete event simulation
    (2017-04) Rybicka, Justyna; Tiwari, Ashutosh
    As customisation and product diversification are becoming standard, industry is looking for strategies to become more adaptable in responding to customer’s needs. Flexible manufacturing systems (FMS) provide a unique capability where there is a need to provide efficiency through production flexibility. Full potential of FMS development is difficult to achieve due to the variability of components within this complex manufacturing system. It has been recognised that there is a requirement for decision support tools to address different aspects of FMS development. Discrete event simulation (DES) is the most common tool used in manufacturing sector for solving complex problems. Through systematic literature review, the need for a conceptual framework for decision support in FMS using DES has been identified. Within this thesis, the conceptual framework (CF) for decision support for FMS using DES has been proposed. The CF is designed based on decision-making areas identified for FMS development in literature and through industry stakeholder feedback: set-up, flexibility and schedule configuration. The CF has been validated through four industrial simulation case studies developed as a part of implementation of a new FMS plant in automotive sector. The research focuses on: (1) a method for primary data collection for simulation validated through a case study of material handling robot behaviour in FMS; (2) an approach for evaluation of optimal production set-up for industrial FMS with DES; (3) a DES based approach for testing FMS flexibility levels; (4) an approach for testing scheduling in FMS with the use of DES. The study has supported the development of systematic approach for decision making in FMS development using DES. The approach provided tools for evidence based decision making in FMS.
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    Technology readiness level assessment of composites recycling technologies
    (Elsevier, 2015-09-03) Rybicka, Justyna; Tiwari, Ashutosh; Leeke, Gary A.
    Composite materials made of glass and carbon fibres have revolutionised many industries. Demand for composites is experiencing rapid growth and global demand is expected to double. As demand for composites grows it is clear that waste management will become an important issue for businesses. Technically composite materials evoke difficult recycling challenges due to the heterogeneity of their composition. As current waste management practices in composites are dominated by landfilling, governments and businesses themselves foresee that this will need to change in the future. The recycling of composites will play a vital role in the future especially for the aerospace, automotive, construction and marine sectors. These industries will require different recycling options for their products based on compliance with current legislation, the business model as well as cost effectiveness. In order to be able to evaluate waste management strategies for composites, a review of recycling technologies has been conducted based on technology readiness levels and waste management hierarchy. This paper analyses 56 research projects to identify growing trends in composite recycling technologies with pyrolysis, solvolysis and mechanical grinding as the most prominent technologies. These recycling technologies attained high scores on the waste management hierarchy (either recycling or reuse applications) suggesting potential development as future viable alternatives to composite landfilling. The research concluded that recycling as a waste management strategy is most popular exploration area. It was found mechanical grinding to be most mature for glass fibre applications while pyrolysis has been most mature in the context of carbon fibre. The paper also highlights the need to understand the use of reclaimed material as important assessment element of recycling efforts. This paper contributes to the widening and systematising knowledge on maturity and understanding composites recycling technologies.