Sustainable Production and Waste Management Model Considering Warm-Up Period with Product Recovery

Sustainability is a vital issue in the current global economy, which demands the development of creative models that balance economic viability with the responsible use of environmental resources. The implementation of sustainable manufacturing practices may enable businesses to improve their financial performance while reducing their environmental impact. The study emphasizes the importance of efficient maintenance management, particularly during the warm-up phase in the imperfect production system, which is crucial for minimizing downtime and facilitating a rapid return to optimized operational efficiency. Additionally, this study provides a framework for designing a product recovery management system that aims to support the seamless reintegration of defective and used products into the production process. Further, by systematically categorizing items into reusable, recyclable, and disposable categories through incentivizing consumers, this study contributes to the reduction and conservation of waste and resources. Consumers are starting to become more responsible in terms of the products they purchase, looking not only at price but also towards environmental impact. As a result, the proposed model considers price- and environment-sensitive demand. Under global carbon reduction objectives, the proposed study offers a complete evaluation of carbon emissions across the product lifetime, comprising manufacturing, remanufacturing, storage, and disposal activities under the carbon-tax policy. A carefully planned waste reduction system is integrated to eliminate surplus in production and remanufacturing processes, ushering in an era of lean and sustainable operations. Numerical examples and sensitivity analysis have been performed to demonstrate the practical application of the suggested model and provide important managerial insights to decision-makers. Additionally, a comparative analysis underscores the importance of integrating product recovery, waste reduction, and environmental investment to achieve significant economic and environmental benefits. Among these, product recovery emerges as the most critical feature, as its inclusion results in a remarkable 25.17% increase in profit. Notably, the fully integrated model, which combines all three elements, achieves the highest profitability with a 9.17% increase compared to models lacking these features, while demonstrating its superior environmental performance by reducing waste and emissions, and highlighting its exceptional balance of economic and ecological advantages.