An Integrated Design Method for Used Product Remanufacturing Process Based on Multi-Objective Optimization Model

The design for the remanufacturing process (DFRP) is a key part of remanufacturing, which directly affects the cost, performance, and carbon emission of used product remanufacturing. However, used parts have various failure forms and defects, which make it hard to rapidly generate the remanufacturing process scheme for simultaneously satisfying remanufacturing requirements regarding cost, performance, and carbon emissions. This causes remanufactured products to lose their energy-saving and emission-reduction benefits. To this end, this paper proposes an integrated design method for the used product remanufacturing process based on the multi-objective optimization model. Firstly, an integrated DFRP framework is constructed, including design information acquisition, the virtual model construction of DFRP solutions, and the multi-objective optimization of the remanufacturing process scheme. Then, the design matrix, sensitivity analysis, and least squares are applied to construct the mapping models between performance, carbon emissions, cost, and remanufacturing process parameters. Meanwhile, a DFRP multi-objective optimization model with performance, carbon emission, and cost as the design objectives is established, and a teaching–learning based adaptive optimization algorithm is employed to solve the optimization model to acquire a DFRP solution satisfying the target information. Finally, the feasibility of the method is verified by the DFRP of the turbine blade as an example. The results show that the optimized remanufacturing process parameters reduce carbon emissions by 11.7% and remanufacturing cost by USD 0.052 compared with the original process parameters, and also improve the tensile strength of the turbine blades, which also indicates that the DFPR method can effectively achieve energy saving and emission reduction and ensure the performance of the remanufactured products. This can greatly reduce the carbon emission credits of the large-scale remanufacturing industry and promote the global industry’s sustainable development; meanwhile, this study is useful for remanufacturing companies and provides remanufacturing process design methodology support.