Design and implementation of a circular remanufacturing production line

The growing concern over resource scarcity and environmental damage has exposed the limitations of linear production models “take-make-dispose”. On this basis, circular economy and remanufacturing, provide effective solutions by extending product lifecycle, value preservation, and reducing the energy and materials consumption. This thesis presents the design and implementation of a pilot remanufacturing production line, with the objective of demonstrating its viability and evaluating its performance. A hydro turbine was selected as case study, and the remanufacturing stages – disassembly, diagnostic, cleaning, repairing, kitting, reassembly and quality control – were physically implemented, simulated and tested. Lean manufacturing principles were applied to improve workflow, while Industry 4.0 technologies were integrated to improve accuracy, ergonomics, quality, data management and decision-making. The experiments of remanufacturing confirmed the technical feasibility of circular remanufacturing chains and demonstrated their potential advantages over linear models. Measured indicators such as value-added time, Material Circularity Index, and carbon footprint revealed improvements in productivity, quality, and sustainability. Overall, the thesis contributes to bringing together theory and practice in circular economy by offering a replicable framework for research and education, supporting the ecological transition towards more sustainable and digitalized manufacturing systems.