The Circular Economy: Sustainable Manufacturing and Waste Management

This report explores the concept of circular economy and its technological elements for sustainable manufacturing and waste management. It covers closed loop sustainable manufacturing, 6R application, and the triple bottom line. The report includes a case study on the production of electric mobility scooters for disabled people. It also discusses waste management and the importance of designing products that are recycle-friendly.

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THE CIRCULAR ECONOMY

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Contents
THE CIRCULAR ECONOMY...........................................................................................5
INTRODUCTION...............................................................................................................5
ELECTRIC MOBILITY SCOOTER AND COMPANY.....................................................5
Production....................................................................................................................................6
Components.................................................................................................................................6
Functional Groups.......................................................................................................................6
SUSTAINABLE MANUFACTURING...............................................................................7
Closed Loop Sustainable Manufacturing.....................................................................................8
6R Application – Natural Sequence..........................................................................................11
Sustainable Product Life Cycle.................................................................................................11
TECHNOLOGICAL ELEMENTS OF CIRCULAR ECONOMY...................................12
Technological Elements – Identifying and Developing............................................................12
Extending to Multiple Life cycles or Generations.....................................................................13
Circular Economy Development with Technological Elements...............................................14
Triple Bottom Line....................................................................................................................16
Assessment Application.............................................................................................................17
Exploration of Economy............................................................................................17
WASTE MANAGEMENT INVESTIGATION.................................................................18
Lithium Battery..........................................................................................................................19
Permanent Magnet.....................................................................................................................19
Existing Cases....................................................................................................................20

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FUTURE SUSTAINABLE INDUSTRIAL SYSTEM, IN LIFECYCLE STAGES WITH
CIRCULAR PRODUCTS.............................................................................................................20
Short Term.................................................................................................................................20
Long Term.................................................................................................................................20
CONCLUSION..................................................................................................................21
REFERENCES..................................................................................................................22

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THE CIRCULAR ECONOMY
INTRODUCTION
The Circular Economy concept has been gaining significant momentum, because the
existing linear economy traditional model, which works on the basis of model of ‘TAKE –
MAKE – DISPOSE’ keeps falling to meet the environmental protection, sustained economic
growth and societal wellbeing, all towards increasing sustainability challenges, worldwide. The
circular economy opportunities and socio-political dimensions are pursuing and promoted
towards growth and prosperity of national economy. However, technical aspects and challenges
from the circular economy are not well focused, because of political agenda shadow pushing to a
greater level with no considerations of technological aspects.
Sustainable value is a new and growing concern in multiple means and forms in the
context of manufacturing and strategic significance towards manufacturing process analysis
stands as an engine for any nation’s wealth generation. Both the developed and developing
countries have been showing the manufacturing’s pivotal role, in national economic
advancement, societal well-being and job creation.
Circular economy, historically, is relied heavily upon 3R principles, Reduce, Reuse and
Recycle. Hence, optimum production is aimed with reduced utilization of the natural resources,
emissions, producing minimum pollution and waste with the 3R principle. So, for green
manufacturing 3R stands as a foundation (Wu et al, 2014) and this concept is derived from lean
manufacturing with the basis of 1R or Reduce. So, manufacturing requires lean manufacturing to
green manufacturing to sustainable manufacturing, to achieve sustainable value (Jawahir &,
Dillon2007). However, unfortunately, this is far beyond the simple projections of socio-political,
for any geopolitical region or country’s strategic objective.
To achieve a fullest and complete form of circular economy, it is important to gain in-
depth understanding of the technological framework and integral elements.

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ELECTRIC MOBILITY SCOOTER AND COMPANY
Electric mobility scooter is configured as a motorscooter. It is also known an electric
scooter or power operated scooter or vehicle. The electric scooter, here is designed and
manufactured for disabled people. Having a potential and service oriented product development
vision and mission is expected to extend, by expanding the operation with the vision of
sustainable manufacturing (Gradel, 2011).
The electric mobility scooter consists of one seat, over maximum five wheels, foot plates
or flat area for the feet, delta-style steering or handlebars arrangement to turn the wheels that are
steerable.
Production
The production of the electric mobility scooter is mostly an assembling process. Hence,
most of the components and parts are received by the suppliers, rather than manufacturing the
components. While this is the present process of production, the future process is expected to
have own components to get them assembled (Su et al, 2013).
Components
The production and assembling process of electric mobility scooter for the disabled need
the following components,
1. Structural Components – Chassis, wheels, suspension, seat assembly, etc.
2. Electrical Components – Switches, wires, batteries, circuit boards, etc.
3. Miscellaneous Components – Bodywork, upholstery, tyres, transmission, etc.
There are various models and varied technologies, for energy recovery, brake, average
distance range, for them, globally. Eventually, the specifications also vary. And it is possible to
assert, without losing generality, to assert that the primary variation stays in the technologies of
battery. One important battery is lead battery that has less performance and lower price.
(MacArthur, 2015)
Functional Groups
There are four groups for the electric scooter.
1. Motion systems
2. Electronic & electrical system
3. Powertrain

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4. Structure System
Figure: General Scooter Sketch (Jawahir et al, 2013)
SUSTAINABLE MANUFACTURING
Sustainable manufacturing is a complex system problem, essentially, because it involves
considerations of three integral interacting levels, products, processes and systems (Jayal et al,
2010). There are several insufficient attempts that include integral approach partially and almost
fall short, since they deal largely with processes and products, however fail to emphasize the
three integral elements interconnectivity involved in the system of manufacturing and show the
sustainable value creation basis, for economic growth.
Sustainable manufacturing offers a new production way to make functionally superior
product with the advanced manufacturing methods, sustainable technologies, however, only if
the production, design of supply chain and design of product and enterprise and management
level logistics are well understood, managed and developed in an integrated and holistic ways.

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Figure: Sustainable Manufacturing integrated elements (Jawahir et al, 2006)
Closed Loop Sustainable Manufacturing
Closed loop sustainable manufacturing is a new approach of sustainable manufacturing
that focuses on innovation and broader based methodology of 6R over multiple life-cycles for
products (Jawahir et al, 2006).

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Figure: Sustainable Manufacturing Multiple product life-cycle (Joshi et al, 2006)
In the methodology of 6R, the main focus of Reduce is on the product life-cycle’s first
three stages and refers to the resources reduced usage in pre-manufacturing, reduced materials,
energy and other resources usage during manufacturing and reduction in waste and emissions
during the stage of usage. Here, reuse refers to the product reuse as its components or as a whole,
for first and following life-cycles so that virgin material usage reduction to produce newer
components and products.
The focus of Recycle is on the material conversion process for the materials considered as
waste, into new products or materials. Recover is the process of products collection at the end of
each of the stage of usage, disassembling, cleaning and sorting towards utilization, for further
product life-cycles. The activity of Redesign involves the next generation products redesigning
act that make use of materials, components and resources recovered from the previous products
generation or previous life-cycles (EPA, 2014). The process of Remanufacture is already used
products’ re-processing towards restoration to the like-new form or to their original state form,
through the many parts usage as possible, with no functionality loss.

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Figure: Closed Loop System, based on 6R (Jaafar et al, 2007)
6R based closed loop system enable material flow as ‘near-perpetual’, with the optimal
usage of raw materials, energy and many other resources and able to product reduced emissions
and wastes by the end (Jaafar et al, 2007).

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6R Application – Natural Sequence
Figure: 6R Application Sequencing, within Total Life-cycle with Multiple Close-loops
and Decision Points
Sustainable Product Life Cycle
Sustainable product life cycle is a much modified and amended product life cycle with
several technological added elements.

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Figure: Sustainability Product Life-Cycle
TECHNOLOGICAL ELEMENTS OF CIRCULAR ECONOMY
Technological Elements – Identifying and Developing
A simplified material flow show clear interactions among the activities of 6R and the four
stages, pre-manufacturing, manufacturing, use and post-use stages. Red-coloured flow in the
following diagram shows the first life-cycle and the blue colour process shows subsequent life
cycle, on the basis of 6R elements.

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Figure: 6R Elements Closed-Loop Material Flow
An assumption is made here that the Reduce activity is blended in almost every life cycle
stage. In the post-use stage, the first necessary step is Recover, from which originate all the
remaining four Rs that are based on innovation, Reuse, Redesign, Recycle and Remanufacture.
Here, backbone or technological elements of circular economy is defined and developed by the
principle of 6R, from the simplified flow of closed-loop material. These elements when used in
the circular economy applications lead to the sustainable value creation end goal, ultimately, in
the environment, society and economy. In the sustainability context, this creation of value is
referred as the TBL or Triple Bottom Line that drives the innovation (Nidumolu et al, 2009), got
an impact significantly on the three sustainable manufacturing integral elements: products,
processes and systems (Zhang et al, 2013).
Extending to Multiple Life cycles or Generations
The above material flow process can be extended to the multiple life cycles or multiple
generations, for the product and so the electric scooter for the disabled, with the activity called,
Redesign.
(Bradley, 2015)

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Figure: Material Flow Helical Movement and Technology Advancement through events
of Redesign across Multiple Generations (Bradley, 2015)
It also shows the near-perpetual flow of material to flow from one to another generation.
This Redesign activity progressively concurrent and inevitable and for circular economy
implementation, it needs to think beyond a single circular loop. Helical movement can describe it
best, in both the advancement of technology and material and stands as an essential element for
the circular economy application.
Circular Economy Development with Technological Elements
Mechanisms are must to develop the circular economy with 6R inclusion, so that the
sustainable value creation is driven.

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Figure: Sustainable Value Creation from Circular Economy, through Integral Technology
Elements and Respective Characteristics
These mechanisms are visionary thinking, process or production innovation, novel
methodology and quality education and training. Process or product innovation includes
technology advancements along with current systems, processes and products optimization.
(Jawahir, et al, 2013).
Sustainable value creation can be a viable option and procedure, for education from
formal university, in the respective field and it also demands equal need for the training programs
from technical schools that enable the education and training with new workforce entirely in the
industry, for the following manufacturing generations. Apart from the education, another
prerequisite for the sustainable value creation is the novel methodologies that stand as the
underlying infrastructure. These novel methodologies demand both the qualitative as well as the
quantitative methodologies that define assessment and direction, together. It also demands one
more important mechanism and the most significant probably is the visionary thinking usage.
Apart from drawing map, with different education programs and methodologies to pave the

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circular economy development, there is still another need for visionary thinking that would blend
the creativity along with the established technical basis that stands as the foundation for the
implementable solutions creations to the problems of real world.
Triple Bottom Line
After the relevant mechanisms scope identification and definition, there needs an
implementation of essential element, involving development of the toolkit of assessment. An
assessment is conducted so that the metrics and indicators creation is involved, however, the
methodology of the assessment has to be focused.
Figure: Triple Bottom Line and Elements
These possible methodologies and metrics driving assessment of sustainable value
creation at system, process and product levels, segmented into sustainability’s three pillars. The
economic performance can be assessed with the usage of the cost model, including the 6R
elements, from the total life cycle view. There are certain methodologies that exist today, like
LCA or Life Cycle Assessment. This methodology can be extended and expanded so that the 6R
elements can be incorporated, towards the environmental burden or impact determination. In the
context of society, more scientific and quantitative social indicators and metrics need to be
developed (Gradedel et al, 2011). And these metrics and indicators are used for societal well-

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being assessment. All these processes and assessments are fed back into the stages of
development and also design so that sustainable value is improved.
These assessments and mechanisms can be combined and this development becomes the
primary approach of 6R elements implementation as the basis of technology, for success and
materializing circular economy.
Assessment Application
Exploration of Economy
In this context and paper, only the sustainability economy pillar is considered for
exploring and so the same only is addressed in this report.
Considering that the company is manufacturing the mobility electric scooter for the
disabled. The components are supplied by the suppliers.
Here, the emphasis and opportunity for low impact manufacturing and circular economy
is Recycling. Recycling can be done with different parts, like disposal of accumulators, batteries,
etc. Recycling has the benefits of both protection and healthier human being and environment.
The designer or engineer has to design the product as recycle-friendly and should be done
during the phase of product ‘conceptual design’ (Luttropp & Lagerstedt, 2006).
In the future, the main focus should be on the weight ration of recovery and reuse and
weight ratio of recycle or reuse thresholds. The directive mainlines are basically,
1. Limit the production of waste
2. Organize the collection of waste
3. Organize the treatment of waste
4. Prioritize the waste reuse and recovery
5. Dismantling facilitate, through information on materials and components
6. Evaluation through implementation reports
WASTE MANAGEMENT INVESTIGATION
The company has to initiate dismantle processes, as part of the waste management and
end of life of the electric scooters (Sullivan & Gaines, 2012). The important aspects to consider
are,
1. The normal procedure to the standard of scooter acceptance
It should be accompanied with a certificate, so that the last owner is held harmless and
new life starts as part of waste management.

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2. Disassembly process flow
Disassembly and dismantle process should involve,
a. Safe stock
b. Disassembly of valuable parts, which has higher value of second hand spare parts
market. Some material can be tyres, polymer and metals. And more useful metal for
recycling can be magnesium, aluminium and copper. Polymers can be either used for
thermal recovery or recycling.
c. Hazardous component treatment to remove the fluids, fuel, batteries, oils, etc. Lead
batteries can be recycled as 95% of the lead is considered for the secondary usage in
the vehicle battery market.
3. Treatment of electric scooter

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Figure: Process Flow for Electric Scooter Disposal after End of Life
Lithium Battery
One of the two technologies, Pyrometallurgical or Hydrometallurgical technologies can
be used for lithium battery waste management. It can be reused for many portable technologies,
like full electric vehicles, smartphones or laptops.
Permanent Magnet
Usually iron, neodymium and boron materials are used for permanent magnet. The three
opportunities of recycling can be disposal, using large magnets for electric vehicles, wind
turbines and for magnet manufacturing.

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Existing Cases
1. A new 12th plan of five years, from 2011 – 2015 is proposed and adopted for
social and economic development promotion by circular economy continuous implementation in
industrial sector, in China (Su, et al, 2013).
2. Ellen MacArthur Foundations emphasizes strongly the need for embarking for
Europe, on circular economy, to remain productive and competitive in manufacturing, globally
(McArthur, 2015).
FUTURE SUSTAINABLE INDUSTRIAL SYSTEM, IN LIFECYCLE STAGES WITH
CIRCULAR PRODUCTS
So far it is given that these components are supplied by the suppliers and assembling is
only done in the manufacturing, like many manufacturing companies do. In the future, chassis,
which is the most important for the motor vehicle, is expected to design and manufacture, within
the company.
Regarding the chassis manufacturing, the raw material should be selected in such a way
that every component of it is reliable so that the entire chassis, does not affect or degrade the
performance of the entire chassis and so the electric scooter. And the product life cycle should be
follow each of the precautions specified in the above section.
One important aspect is the waste management, after the chassis becomes dysfunctional.
So, each of the components in it must be separated and the respective parts must be repaired,
reused and recycled, based on the properties of the material. If any of the component material is
not suitable for any of these three Rs, then it should be considered as a landfill and the same
should be done.
Short Term
The immediate step can be to initiate the waste management with the specified processes
and procedures as specified in the above sections in this report.
Long Term
The following is the long term future sustainable electric scooter industrial system.

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1. Raw Materials
Low impact raw materials have to be used for the manufacturing procedures and
processes of mobility electric scooters.
2. Design and Manufacturing
The design must be in the way that every aspect of design must focus towards robustness,
reliability and sturdiness of the product. And manufacturing processes must ensure that
each and every method and sub-operations must not decrease the strength and quality of
each of the parts and overall parts of the scooter.
3. Production
Production methods and procedures of the electric scooter must be potential so that their
usefulness with increased life must be emphasized, so that reliable and long life can be
assured.
4. Retail
Supply chain partnership should be effective and accurate and it should not deteriorate
the quality and strength of each of the supplied components and parts.
5. Consumer Information
Accurate and safe usage of the product can increase the life of any product and so each of
the steps and safety precautions must be clearly and easily communicated to the
consumer, so that the overall life of the electric scooter can be increased to a better extent,
for increase return of investment, both for the manufacturer and customer.
Longetivity protocol must be used as a potential mechanism so that robust ways of testing
and durability of the electric scooter can be obtained.
6. Waste Collection
After the end of life, collection of the waste electric scooters and bringing into one place
is important aspect, as there can be more benefit when higher volume of scrap or waste is
gathered in one place.
7. Reuse or Repair
Separation of the parts is to be done so that each of the part can be repaired and reused
for the electric scooters, in the future, as second hand spare parts. So, the parts can be
used again as normal parts.
8. Recycling

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Recycling is an important aspect to be focused for the parts of electric scooters that
cannot be repaired and reused.
CONCLUSION
Circular Economy is a concept, emphasized and focused globally, considering focus in
three dimensions, socio, political and economy. Though there are several obstacles to implement
circular economy towards low impact manufacturing perspective, governments from several
countries have been emphasizing and encouraging such initiatives. For the manufacturing
industry, such as for electric scooter manufacturing, the opportunities for circular economy are
more, though it becomes a tedious and huge process demanding more time, effort and money.
However, being sustainable manager, the best of the aspects, methodologies, approaches,
methods and opportunities are discussed in the report. Various stages of life cycle of electric
scooter are considered and the best methods and opportunities are explored to justify circular
economy, wherever it is possible. The same exploration is continued for the stage, after end of
the life of the product with best possible waste management aspects, to repair, reuse and recycle
the material used for various components and parts of the electric scooters.
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