António Baptista

Abstract
Lean and green (L&G) manufacturing in Industry 4.0 (I4.0) has brought many advantages in manufacturing industries by minimizing waste and maximizing efficiency with integration of renewable energy sources and sustainable materials. Multi-layer Stream Mapping (MSM) is a new framework for the performance assessment of complex manufacturing processes. MSM is used for multi-domain analysis of manufacturing processes to assess resources, and processes, that are used to identify Non-ValueAdded (NVA) procedures or steps that consume unnecessary time and resources, and/or release emissions and waste that can no longer be reused or recycled to be eliminated or replaced to create a Value Added (VA) process flow that avoids waste in a clean, green and environmental friendly manner. This paper presents the implementation of the L&G strategy through MSM in metal working production systems. In metalworking production systems, the variables of operational performance and resources consumption considered are process time, number of operators, consumables, raw material, and energy. These can be suitably used for reduction in water emissions, gas emissions, solid waste and scrap generated in metalworking production systems.

Abstract
To address the increasing complexity of product characteristics, demand fluctuations, and higher costs of raw materials, along with pressures for fast-er integration of decarbonized energy resources, manufacturing companies require flexible production systems. These systems should minimize waste, achieve faster cycle times, and deliver high-quality products to stay competitive. In this regard, Product Design-for-Excellence (DfX) principles have gained significant importance in recent years. DfX enables all management levels to perform quick and comprehensive design inputs and performance evaluations, leveraging product lifecycle management platforms. LeanDfX, a dedicated Lean approach for product development performance assessment, has been previously proposed. This work builds upon LeanDfX by presenting a multi-dimensional approach to support design and performance assessment of production systems throughout its lifecycle. This approach coherently integrates different production knowledge areas and strategic foundations (e.g., Lean Manufacturing, Strategic Aspects, Sustainability, and Circular Economy) for the effectiveness and efficiency evaluation of production systems. The research hypothesis revolves around the translational strategy of extending and transforming the LeanDfX methodology for application in production system design within factory operations. This new architecture is presented in the context of the European project RENÉE, devoted to designing and deploying remanufacturing processes for a more sustainable, circular, and competitive industry. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.

Abstract
As the need for enhanced material performance continues to escalate in several sectors, addressing complex parameters such as economic feasibility, ease of manufacturing, and production volume, rises the need for multidomain decision-making tools. In order to explore and streamline this process, this study employed the novel Material Design-for-eXcellence methodology to investigate polymer material selection in aeronautical and power transformer components, using additive manufacturing. The study assessed the X's selected (mechanical, thermal, physical, cost, dielectric, and environmental) by assigning weights to these factors, and identifying the optimal materials for each application. In the aeronautical context, PEI+GF30 was chosen as the best solution, attaining an overall effectiveness of 79 %, primarily due to its exceptional mechanical characteristics. The use of a thermoplastic can lead to lighter components while ensuring the same technical performance, enabling longer flight duration. Conversely, in the energy sector for power transformers, PSU obtained a 78 % score, largely attributable to its outstanding dielectric properties. The application of additive methods on transformers' insulating parts leads to optimized channels for the mineral oil, enhancing its thermal and dielectric performance. The obtained results underscored the importance of tailored material selection approaches, adjusted to specific application requirements. The importance of comprehending and adapting to diverse contexts for effective material design and implementation is also highlighted.

Abstract
Coffee capsules have gained high levels of popularity in the last decades due to their convenience of use, flavour choices, and consistent extraction quality. As governmental bodies are promoting more circular solutions for packaging products, concerns have been raised regarding the environmental impacts of single-use coffee capsules, namely their end-of-life treatment and effective recyclability. This paper presents a novel design based on thin steel sheet material application for new packaging solutions that can support a more circular economy. To validate this new design, a framework was presented for a cross-assessment of Life Cycle Assessment with Circularity Analysis to compare the new tinplate capsule with conventional polypropylene and aluminium capsules. The novel design is more circular (0.97 in the material circularity indicator), in comparison with the polypropylene (0.1) and aluminium (0.80) conventional capsules, due to the ferromagnetic properties that allow for better effectiveness during sorting in urban packaging recycling facilities. As for the environmental assessment, the tinplate has higher environmental impacts than the aluminium and the polypropylene capsules (more 63 % and more 92 %, respectively) due to the high energy intensity processes required to produce this material. These results demonstrate that the novel tinplate capsule should complement the strong results in circularity with further improvements in its environmental performance, namely by the transition of the steel industry to the upcoming generation of decarbonized steel production.

Abstract
The transportation industry focuses on reducing vehicle weight for fuel economy and emissions. This emphasis promotes the use of coaches, which raises concerns about passenger safety in frontal collisions. The proposal is to correlate the crashworthiness of coaches with the replacement of fibreglass composite materials by a state-of-the-art polymer (DCPD). Based on the ECE R29 standard, FEM models solved by Pamcrash (R) assess the vehicle's crashworthiness. Cross-referencing these results with the Eco-Design X technique, two models are evaluated in terms of environmental impact. The LeanDfX methodology involves multiple analyses for design domains, including model optimisation, manufacturing processes, and eco-design. On a performance scale of 0% to 100%, different 'X' domains are evaluated. The Eco-Design study allowed the assessing the environmental impacts of the proposed solution compared to the original models, is conducted using Simapro v9.2.0.2 and the ReCiPe 2016 methodology. The novel design proposed modifications to the models resulted in significant structural behaviour improvements for driver's physical integrity. The cross results of Design-for-Crashworthiness and Design-for-Eco-Design using the innovative LeanDfX framework provide a new perspective to be integrated into the automotive industry. The use of DCPD is expected to lead to a more crashworthy and environmentally friendly design, while ensuring passenger safety.