Enabling the vision of a perpetual innovative product – predicting function fulfillment of new product generations in a circular factory

Abstract The need for sustainability is driving the transition from linear to circular production. Customers, driven by the desire for innovation, prefer new products with the latest cutting-edge functions and design. The problem is that used products from older product generations are hence less attractive, leading to a limited market for remanufactured products and generating less revenue than their new counterparts. Therefore, this research addresses the problem of reprocessing and technologically updating used products into the newest product generation. To address this problem of reprocessing and technological updating with a Circular Factory, the product’s function fulfillment must be predicted in different situations in a Circular Factory. Three key challenges in which the function fulfillment must be predicted are identified as: Analysis and Diagnostics of Used Products and Subsystems , Prediction for Pairing and Reprocess of the Embodiment and Design for Circular Factory . A model-based approach is presented to address these three key challenges by predicting product function fulfillment to enable cross-generational use of subsystems and components. Five different types of models are proposed: A Functional Model , a Reliability Model and a Reference Architecture Model at the high level of general product modeling, as well as a Digital Twin of an object instance and a Tolerance Scheme at the level of individual instances. A theoretical case study shows the possible application in a Circular Factory using the example of an angle grinder. However, it’s essential to acknowledge that substantial work is needed for the enhancement or development of these models before practical application. Successful application of these models allows the Circular Factory not only to maintain but also to increase the value of reprocessed products to enable offering on the primary market and contribute to the vision of realizing a perpetual innovative product.