The Plooto Material
This section is dedicated to providing open access to all deliverables and relevant materials produced as part of the PLOOTO European Project. Here, you can explore and download reports, research findings, presentations, and other documentation that highlight the progress and outcomes of our initiatives. Our goal is to ensure transparency and foster collaboration by sharing knowledge with stakeholders and the broader community.
Start exploring the resources below to learn more about the PLOOTO project and its contributions!
Deliverables
The detailed methodological approach with configuration guidelines and the pilot-specific deployments. This deliverable incorporates the operational scenarios, the reference scenarios for materials handling and needs for monitoring and operating a “product passport” in circular supply chains. Download Link
The final iteration of the methodological approach and business cases specifications with adoptions and updates identified during the implementation phase and the results of the 1st pilot operation.
A set of KPIs with cause-and-effect relationships where organizations can “assess” the performance of their supply chains in terms of economic, environmental, social and other criteria. This framework will be the basis for the tool to be developed in WP3. Download Link
The final iteration of the balanced scorecard with adoptions and updates identified during the implementation phase and the results of the 1st pilot operation.
The functional and non-functional aspects of the CRIS information system. This deliverable includes also the architecture blocks and their inter-relationships. Download Link
The final iteration of the CRIS specifications with adoptions and updates identified during the implementation phase and the results of the 1st pilot operation.
This Deliverable presents the Conceptual Architecture, Modelling, and IDS connectors tailored to the needs of the three pilot cases (1st iteration).
This deliverable presents the Conceptual Architecture, Modelling, and IDS connectors tailored to the needs of the three pilot cases (final iteration).
This deliverable is the Initial version of Plooto services supporting monitoring the complete supply chain and realizing the concept of product passport.
The final version of Plooto service supporting monitoring the complete supply chain and realizing the concept of product passport.
The initial version of the product passport tool accompanied by procedures supporting the certification of the RM handling processes (per pilot case) and user documentation.
The final version of the product passport tool is accompanied with procedures supporting the certification of the RM handling processes (per pilot case) and user documentation.
The initial version of the integrated platform. It includes the functionalities deployed in the pilot cases and will be accompanied by a report of the main functions.
The final version of the integrated platform. It includes the functionalities deployed in the pilot cases and will be accompanied by a report of the main functions.
The initial version of the Balanced Scorecard (following the framework defined in WP1) and user documentation.
The final version of the Balanced Scorecard (following the framework defined in WP1) and user documentation.
Methodology to assess the impact and performance of the pilots.
Report about the pilots’ implementation, with links to the corresponding demonstrators, and the operations conducted in the execution of the different pilot sites. The initial version concerns the first iteration.
Report about the pilots’ implementation, with links to the corresponding demonstrators, and the operations conducted in the execution of the different pilot sites. The final version concerns the second and final iteration.
Report on the assessment of pilot operation applying the methodology of D4.1.
This document will contain guidelines for deployment, adaptation and scale-up.
This document will describe in detail the dissemination, standardization and marketing plan that will be established in the project. Download Link
Report on dissemination, standardization and marketing activities until M12. Download Link
Report on dissemination, standardization and marketing activities until M24.
Report on dissemination, standardization and marketing activities until M36.
Guidelines, strategies and plans for activities to identify the business models, exploitation and sustainability plans. Download Link
Guidelines, strategies and plans for activities to identify the business models, exploitation and sustainability plans.
Guidelines, strategies and plans for activities to identify the business models, exploitation and sustainability plans.
Overall feasibility analysis and models with economic, social and environmental impact of Plooto in the EU industry.
The created open educational resources produced within Plooto, as well as the outcome/evaluation of the conducted lifelong-learning courses and industrial training.
This report will describe all necessary project management procedures and tools to be employed in order to ensure proper implementation and management of the project, including strategies and methods to be adopted in order to ensure proper implementation of the risk management procedures and the quality of the project outcomes.
This report will describe the research data generated in the project and how they will be published. Download Link
This report will describe the research data generated in the project and how they will be published.
The beneficiary must evaluate the ethics risks related to AI and describe the measures set in place to prevent/mitigate any potential negative personal and social impacts during the research, deployment and post-deployment phase. The assessment and the risk mitigation plan must be submitted as a deliverable before the start of the relevant activities.
Scientific Publications
Abstract: The recovery of Waste from Electrical and Electronic Equipment (WEEE) poses a significant challenge in the realm of solid waste management. With the global urgency to develop innovative disposal methods for WEEE, the creation of value chains that facilitate the recovery of valuable secondary raw materials is crucial. This paper explores a value network formulated specifically for the recovery and reuse of magnets from WEEE. To this direction, we introduce a holistic Mixed Integer Linear Programming (MILP) model, capable to optimise the material flows and the total cost incurred within the value network. Interestingly, our model integrates the proposed policies and directives of the European Commission (EC), aiming to devise a strategy that efficiently blends secondary and virgin magnetic materials to minimize total energy costs. We validate our modeling approach through a set of computational results, applying sensitivity analysis to assess the robustness of the proposed solutions under specific fluctuations in the energy cost. We conclude with the introduction of a two-stage stochastic model that extends the deterministic framework of the MILP, offering broader applicability and resilience in planning.
Farmakis, T., Koukopoulos, A., Zois, G., Mourtos, I., Lounis, S., Kalaboukas, K. (2024). Developing a Circular and Resilient Information System: A Design Science Approach. In: Thürer, M., Riedel, R., von Cieminski, G., Romero, D. (eds) Advances in Production Management Systems. Production Management Systems for Volatile, Uncertain, Complex, and Ambiguous Environments. APMS 2024. IFIP Advances in Information and Communication Technology, vol 728. Springer, Cham. https://doi.org/10.1007/978-3-031-71622-5_5
Abstract: Nowadays, circularity and resiliency are crucial for manufacturing. There is a need for collaboration across the value chain, deployment of critical enablers, and connection of traceability to sustainability and business objectives to accelerate the shift towards circular and resilient production processes. This study reviews circular economy and resilient manufacturing by further analyzing the literature on circular and resilient information systems (IS). We identify key performance indicators for circularity and resiliency and utilize a design science research approach to design the circular and resilient information system (CRIS) conceptual architecture. We further propose leveraging cutting-edge technologies and tools to enable real-time decision-making, monitoring, and certification of materials and products, facilitating sustainable and resilient manufacturing practices. The deployment of CRIS as part of digital transformation efforts represents a strategic move to meet the growing demands for sustainability and resilience.
Psarommatis, F., Konstantinidis, F.K., Azamfirei, V., May, G. (2024). Advancing Circular Economy: The Product Circularity Index as a Tool for Sustainable Design. In: Ivanov, V., Trojanowska, J., Pavlenko, I., Rauch, E., Piteľ, J. (eds) Advances in Design, Simulation and Manufacturing VII. DSMIE 2024. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-61797-3_5
Abstract: The rise of the fast-consuming era, marked by manufacturers continuously increasing production rates, has led to the design and manufacturing of products without due consideration for sustainability aspects. Despite the overall reduction in production costs, this approach harms the environment and circumvents circularity methodologies. To bridge the gap between traditional design practices and sustainability, we propose a structural method for measuring circularity in design. The introduced Product Circularity Index (ProdCircIn) serves as a quantifiable measure to assess a product’s alignment with circular economy principles and functions as a key performance indicator (KPI) for evaluating and comparing products based on their circularity attributes. Specifically, ProdCircIn evaluates products in six pillars: design philosophy, usage of materials, design for manufacturing, design for quality, design for warranty, and design for the future. These pillars are quantified through relevant questionnaires, as analytical solutions and formulas could be more practical due to the distinct characteristics of each product.
Foivos Psarommatis, Gokan May, The role and benefits of Digital Product Passport in the remanufacturing process in the era of Zero Defect Re-manufacturing, Procedia CIRP, Volume 130, 2024, Pages 695-700, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2024.10.150.
Abstract: The implementation of Digital Product Passports (DPPs) has become a game-changing strategy in the pursuit of sustainable manufacturing methods, especially in the remanufacturing industry. The goal of this research is to achieve Zero Defect Manufacturing (ZDM) in the circular economy by examining the functions and advantages of DPPs in remanufacturing processes. Through a comprehensive study, including a detailed case analysis in the automotive industry, we elucidate the significant efficiency gains and cost savings facilitated by DPPs. Our findings reveal a substantial reduction in remanufacturing time by 39.07 percent, and a corresponding decrease in costs, highlighting the DPP’s potential to enhance operational efficiency and sustainability across various sectors. Even with the potential advantages, there are still obstacles to overcome when implementing DPPs, such as the initial setup costs, the requirement for digital infrastructure, and worries about data security. But these difficulties also present chances for creativity and teamwork, highlighting how crucial it is to create standardized data procedures and security safeguards. This paper adds to the conversation on sustainable manufacturing by outlining the DPP’s critical role in advancing the circular economy, outlining potential directions for further study, and arguing in favor of the creation of international standards to encourage broad adoption.
Aryblia Maria, Sifakis Nikolaos, Tsinarakis George, Arampatzis George, Enhancing Manufacturing Sustainability through Integrated Digital Product Passports and the Sustainability Balanced Scorecard, ISAG2024 Link
Abstract: This study investigates the implementation and impact of the Process Simulation and Modelling (PSM) tool within the Plooto project, emphasizing its role in enhancing the integration of Secondary Raw Materials (SRMs) into manufacturing processes. The research focuses on the PSM tool’s ability to comprehensively map material flows throughout various production stages, aligning with circular economy principles. The findings reveal that the PSM tool, through its dynamic and interactive models, significantly improves resource optimization and waste reduction and can be effective on calculating the relevant Key Performance Indicators (KPIs). This development is attributed to the tool’s comprehensive approach to modelling material, data, and energy flows. The PSM tool’s multifaceted features, including graphical model design, detailed flow specifications, and comprehensive KPI generation, facilitate strategic decision-making for sustainable manufacturing practices. The research underscores the PSM tool’s crucial contribution to the Plooto project as a driver of sustainable & circular manufacturing innovation. It highlights the tool’s effectiveness in implementing and integrating circular economy practices within industrial operations, demonstrating a shift towards more sustainable manufacturing concepts. The study promises for broader application and exploration of the PSM tool’s capabilities across diverse manufacturing settings to fully exploit its potential in promoting sustainable manufacturing solutions
Psarommatis F, May G. Digital Product Passport: A Pathway to Circularity and Sustainability in Modern Manufacturing. Sustainability. 2024; 16(1):396. https://doi.org/10.3390/su16010396
Abstract: The primary aim of this study is to explore and understand the potential benefits and applications of the Digital Product Passport (DPP) system within the modern manufacturing industry. To achieve this, we developed a unique methodology, model, and a template for creating a DPP, identifying the key characteristics essential for effective implementation. Our approach involved an analysis of the literature and the formulation of a unified DPP framework, tailored to enhance supply chain transparency and support sustainable manufacturing practices. The empirical findings from our research demonstrate the DPP’s impact on supply chain transparency, providing crucial product lifecycle information that bolsters decision-making and facilitates optimal resource management. Additionally, our study suggests that the DPP model, when applied to sectors such as electronics manufacturing, promises transformative results. This research underpins the pivotal role of DPPs in the future of manufacturing, highlighting their potential to catalyze a shift towards greater transparency and sustainability. Actionable guidelines are provided for manufacturers considering the adoption of this innovative system.
Foivos Psarommatis, Gokan May, Optimization of zero defect manufacturing strategies: A comparative study on simplified modeling approaches for enhanced efficiency and accuracy, Computers & Industrial Engineering, Volume 187, 2024, 109783, ISSN 0360-8352, https://doi.org/10.1016/j.cie.2023.109783.
Abstract: This paper presents a comparative analysis of three distinct Zero Defect Manufacturing (ZDM) strategies: Detection – Repair (DR), Detection – Prevention (DP), and Prediction – Prevention (PP). We evaluated these strategies based on their effectiveness in optimizing ZDM parameters, considering the specific needs and constraints of various manufacturing setups. Our analysis found that while DR and DP simulation models closely reflected original results, PP models demonstrated lower predictability, underscoring the need for further research and specialized modeling approaches. Nonetheless, the selection of an optimal strategy was determined to be context-dependent, hinging on the characteristics of the manufacturing system. The study also highlights the necessity of validating these strategies across diverse manufacturing setups to assess their performance and suitability. This research augments the existing body of knowledge on ZDM, offering insights to drive future investigations for the development of robust, accurate, and efficient ZDM modeling techniques. The ultimate objective is to move modern manufacturing industries towards a zero-defect environment, thereby enhancing their efficiency, reliability, and overall productivity.
Aryblia, Maria; Sarantinoudis, Nikolaos; Tsinarakis, George; Arampatzis, George Αdvancing sustainability in industrial supply chains by embracing circular approaches & Digital transformation, IEES 2023, International Ecological Engineering Society Conference, 10.2023. Link
Abstract: Sustainable growth has been assuredly connected with the integration of circularity, sustainability, innovation and resiliency into the value chains. Towards this path drives the recently updated European Circular Economy Action Plan (CEAP, 2020), a fundamental component of Europe’s agenda for sustainability and resiliency, the European Green Deal (EU Green Deal, 2019). On the other hand, Europe foresees achieving both a green transition and digital transition during the Digital Decade, focusing mainly on high energy-consuming industrial facilities towards a net-zero industries concept. The green transition, as being reinforced by circularity, is called to accompany the digital transition towards climate neutrality, a target that has been underlined as a key requirement in the EU’s green agenda (Digital Europe, 2022). The industrial environments, as an intensive energy consumer, aspires to move towards green and digital transition, where the efficient management of resources, the need for prevention and the circular designing and planning, have shown the path towards alternative approaches, new technologies and services, and cutting-edge solutions. Digitalisation technologies, circular supply chains, secondary raw materials, integrated sustainability frameworks and standards, digital twins and cognitive digital twins, the newly introduced DPPs – Digital Product Passports, are some of the solutions and tools that assemble to facilitate a green and digital transition, considering the circular economy aspects, and targeting to resiliency and sustainability. Under this scope, the Horizon Europe Plooto project valorises on available sustainability and governance frameworks and models to design and develop an integrated methodological approach for “closing-the-loop” in industrial value chains, the Sustainability Balanced Scorecard Framework. This framework is demonstrated in three robust use cases, representing the food and manufacturing sectors. The ordinary supply chains of a citrus juice company in Greece, the processes of managing Waste Electrical and Electronic Equipment (WEEE) for magnets and Carbon Fiber Reinforced Polymer (CFRP) for drones, are assessed using the Sustainability Balanced Scorecard, to empower the business opportunities, to enhance traceability and lead to sustained value chains.
Aryblia M., Sarantinoudis N., Tsinarakis G., Arampatzis G., Enabling sustainability and resilience in industries through the value chains’ circularity and digitalisation, International Conference on Environmental Science and Technology (CEST) Link
Psarommatis F, May G. A Systematic Analysis for Mapping Product-Oriented and Process-Oriented Zero-Defect Manufacturing (ZDM) in the Industry 4.0 Era. Sustainability. 2023; 15(16):12251. https://doi.org/10.3390/su151612251
Abstract: Quality is a key aspect in the era of Industry 4.0. Zero-defect manufacturing (ZDM) as the latest quality assurance approach. It can be implemented in two different approaches: the product-oriented and the process-oriented ZDM. It is important to know how and when to consider adopting one approach over the other. To achieve that there is the need for analyzing the differences of the two ZDM approaches. However, the current literature lacks a detailed analysis and comparison of these two approaches to ZDM implementation. Earlier studies on the topic have adopted one of these approaches over the other without evaluating how it fits with specific cases. The literature of the last decade indicates a movement towards product-oriented approaches, but it has not shown proof why product oriented was used over process oriented. Guided by these gaps, this research work creates a model for quantifying the effects of the implementation of both the product-oriented and process-oriented ZDM approaches. The proposed model considers all the critical parameters that affect the problem and serves as an assisting tool to engineers during the design or re-configure manufacturing systems, for choosing the most efficient ZDM approach for their specific cases. The robustness of the model was analyzed using the design of experiments method. The results from both the designed experiments and an industrial use case illustrate that in most cases, product-oriented ZDM performs better than the process-oriented approach. Nevertheless, in our analysis, we also highlight strong interactions between some factors that make the selection between product-oriented and process-oriented ZDM difficult and complex.
Psarommatis, F., May, G., Azamfirei, V., Magnanini, M.C., Powell, D. (2024). A Readiness Level Assessment Framework for Zero Defect Manufacturing (ZDM). In: Silva, F.J.G., Ferreira, L.P., Sá, J.C., Pereira, M.T., Pinto, C.M.A. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38165-2_53
Abstract: In this study, a comprehensive framework for assessing the readiness of production systems for Zero Defect Manufacturing (ZDM) has been developed and presented. The framework includes four pillars of ZDM readiness, namely Personnel, Procedures, Infrastructure, and Company Culture, to help companies understand their level of readiness and plan for successful implementation of ZDM. We argue that a manufacturing company will be better equipped to embrace ZDM if it performs well in these four areas. We propose a tool that uses yes/no questionnaires to assess a manufacturing system’s readiness for ZDM. The results of the questionnaire will objectively show the true level of cultural readiness for ZDM adoption, and the level of investment required for implementation will depend on the level of readiness. This tool can help companies gain a clear understanding of their readiness and create a plan for implementing ZDM. Overall, our framework and tool can help manufacturers improve the quality of their products and be ready for ZDM adoption.
Azamfirei, V., Psarommatis, F., Lagrosen, Y. (2024). Human Factors in the Design of Advanced Quality Inspection Systems in the Era of Zero-Defect Manufacturing. In: Silva, F.J.G., Ferreira, L.P., Sá, J.C., Pereira, M.T., Pinto, C.M.A. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38165-2_92
Abstract: Manufacturing companies around the world are under constant pressure to perform effectively and sustainably. Incidental processes, such as Quality Inspection (QI), are needed to achieve Zero-Defects Manufacturing (ZDM). This study aimed to identify the Human Factors and Ergonomics (HF&E) in the design of advanced automation, QI systems, and ZDM through selected papers and empirical observations. Our presented model is built around the six main dimensions, i.e., top management, manager (project owner), designers, engineers (internal and suppliers), and operators. The commitment of top management, the openness of the manager, the design-friendly nature of the technological system, and the constant updating of knowledge by engineers are important for the success of ZDM. Researchers need to be familiar with cognitive and organisational human factors to align theory with specific cases. Operators face physical and cognitive challenges, and their environment and health must be considered for their successful contribution to the design of advanced QI systems.
Koukopoulos Anastasios, Lounis Stavros, Farmakis Timoleon, Vrechopoulos Adam, Doukidis Georgios, D&C for EU Funded Projects: Towards an Integrated Omnichannel Dissemination and Communication Framework, 11th International Conference on Contemporary Marketing Issues, 2.2023, Link
Abstract: In an ever-changing environment, technological progress is at the frontline. Through European-funded projects, research is conducted in various fields, aiming to tackle Europe’s biggest challenges in various sectors. In the course of materializing these new advancements, exploitable outcomes are designed and developed that, in turn, need to be optimally introduced to the market. In order for that to happen, the first thing needed is to make the developments widely known so that they start the journey of diffusion toward adoption, for which Dissemination and Communication is key. However, Dissemination and Communication actions are quite often underperforming. This research proposes a new approach to Dissemination and Communication actions by introducing an Integrated Omnichannel Dissemination and Communication (IODC) Framework relying upon Integrated Communications, capitalizing on and Omnichannel approach to optimally address all potentially interested stakeholders (through the Quintuple helix) that can help European Funded projects’ partners effectively structure their Dissemination and Communication strategy and actions
Abstract:
Foivos Psarommatis, Victor Azamfirei, Fotios K Konstantinidis, A Rula-based Assessment Framework based on Machine Vision and Zero-Defect Manufacturing 4.0 Initiative, 3rd IFSA Winter Conference on Automation, Robotics & Communications for Industry 4.0 / 5.0 (ARCI’ 2023)
Foivos Psarommatis, Gökan May, Victor Azamfirei, Envisioning maintenance 5.0: Insights from a systematic literature review of Industry 4.0 and a proposed framework,
Journal of Manufacturing Systems, Volume 68, 2023, Pages 376-399, ISSN 0278-6125, https://doi.org/10.1016/j.jmsy.2023.04.009.
Abstract: To provide direction and advice for future research on Industry 4.0 maintenance, we conducted a comprehensive analysis of 344 eligible journal papers published between 2013 and 2022. Our systematic literature review identifies key trends in advanced maintenance techniques and the consolidation of traditional maintenance concepts, which are driven by the increasing adoption of Industry 4.0 technologies and the need to optimize manufacturing systems’ performance and reliability. In light of our findings, we highlight the importance of addressing sustainability factors, human aspects, and the implementation of environmental KPIs in future research. Building upon these insights, we introduce the Maintenance 5.0 framework, which emphasizes the integration of human-centered and AI-driven strategies for achieving efficient and sustainable maintenance in Zero-Defect Manufacturing (ZDM) systems. We propose a novel framework that links traditional and advanced maintenance policies for small and medium-sized enterprises (SMEs) to facilitate the adoption of Industry 4.0 technologies in the maintenance field. This work underscores the need for future research to bridge the gap between these policies, enabling a seamless transition for SMEs towards Industry 4.0 maintenance practices, while fostering sustainable and socially responsible operations.
Plooto Press-Kit
Discover everything you need to know about the PLOOTO European Project in one convenient place. Download our press kit, which includes key information, logos, images, and project highlights. You’ll also find assorted materials to support media coverage, presentations, and stakeholder engagement. Stay informed and help us share the vision and achievements of PLOOTO!