Date of Award

5-2025

Document Type

Dissertation

Degree Name

Doctor of Philosophy (PhD)

Department

Mechanical and Civil Engineering

First Advisor

Anand Balu Nellippallil

Second Advisor

Chiradeep Sen

Third Advisor

Ilya Mingareev

Fourth Advisor

Luis Daniel Otero

Abstract

Manufacturing systems (MSs) comprise various stakeholders associated with the manufacture and supply of products required by customers and are interrelated by the flow of materials and information. The interrelated stakeholders make system-specific decisions and stakeholder-specific decisions across multiple levels of a decision hierarchy to satisfy many conflicting system-specific and stakeholder-specific requirements that define system and stakeholder performances. Given the stakeholder interrelations and conflicting nature of system-specific and stakeholder-specific requirements, system and stakeholder performances are correlated and conflicting.

In the Industry 5.0 era, there is an increased emphasis on the creation and equitable distribution of value among all the stakeholders in MSs. This emphasis on equitable distribution of value in the Industry 5.0 era necessitates designing MSs to simultaneously realize stakeholder performances along with system performance, termed ‘co-realization.’ Moreover, uncertainties and disruptions in the operating environment adversely impact system and stakeholder performances.

Co-realizing system and stakeholder performances requires support for ‘co-designing’ to enable stakeholders (decision-makers) in MSs to work collaboratively to satisfy system-specific and stakeholder-specific requirements. Co-designing MSs to co-realize system and stakeholder performances is challenging due to their conflicting and correlated nature and the impacts of uncertainties and disruptions. The foundational premise of this dissertation is that systems-based design techniques, in combination with robust design principles, graph theory principles, and inventory and recovery policies, provide a potential pathway to facilitate the co-realization of conflicting system and stakeholder performances while considering the performance correlations and the impacts of uncertainties and disruptions. In this dissertation, systems-based strategies, specifically, frameworks for co-designing MSs for robustness to uncertainties and resilience to disruptions, are established to help ensure system and stakeholder performances under uncertainties and disruptions. The efficacy of these frameworks is demonstrated using the hot rod rolling of steel and steel manufacturing supply network examples.

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