Product reuse and repurpose in circular manufacturing: a critical review of key challenges, shortcomings and future directions

Abstract

Abstract This paper explores the transformative potential of reuse and repurposing strategies in the manufacturing industry, with a focus on sustainability and circular economy principles. Through an extensive review of 115 articles from Scopus using 6 different queries for broad topic coverage, the study provides a comprehensive analysis of reuse and repurposing frameworks, highlighting their benefits and challenges. The research identifies three essential pillars for successful implementation: product design, operational processes, and consumer acceptance. The study emphasizes the significance of modular designs, lifecycle extensions, and advanced cost models to maximize resource efficiency and sustainability. The paper also discusses the integration of advanced technologies, such as blockchain, artificial intelligence, and IoT-enabled systems, to enhance traceability, streamline reverse logistics, and optimize predictive maintenance. Automated disassembly and collaborative robotics are highlighted as critical enablers for efficient and scalable reuse operations. Furthermore, the study advocates for flexible supply chains and real-time data analytics to address uncertainties in core acquisition and product variability. Despite the progress, the lack of standardized frameworks and metrics remains a significant barrier to widespread adoption. The paper concludes by proposing a cohesive framework that incorporates technological advancements, regulatory support, and collaborative approaches to overcome these limitations. This study provides actionable insights to foster a scalable, transparent, and sustainable manufacturing ecosystem.