Vers le Remanufacturing 5.0: une approche méthodologique pour la mise en œuvre de systèmes de refabrication intelligents et durables

Abstract

This thesis addresses the implementation of Industry 5.0 principles in remanufacturing systems to overcome their main challenges. Remanufacturing is a circular economy strategy that, through industrial processes, restores end-of-life products to a condition similar to or better than new. This reduces energy and material consumption compared to manufacturing new products. However, its implementation is challenging because it involves addressing significant intrinsic challenges, such as uncertainty about the quantity, condition, and return rates of used products, the complexity of its processes and products, and consumer distrust, among others. Furthermore, concerns about its sustainability persist, as its implementations prioritize economic criteria over environmental and social ones, neglecting the needs of all stakeholders. In this context, the implementation of Industry 5.0 principles in remanufacturing, which include sustainability, a human-centered approach and system resilience, represents the best alternative to overcome these challenges. It begins by identifying the links between sustainability, stakeholders, and the remanufacturing system. This is achieved by identifying and analyzing its main key performance indicators. From these, a definition of sustainable remanufacturing is formulated, along with a methodological framework that evaluates the disassembly, recycling, and remanufacturing of products sustainably. An smart architecture representing the core of the system is presented. This architecture integrates Industry 5.0 principles and links the business model, stakeholders, and system operations throughout the supply chain using smart systems. Its relevance and applicability are illustrated through a case study on the remanufacturing of electric motors. A reconfigurable cellular remanufacturing architecture is introduced as a productive architecture. This is integrated into a business strategy to address uncertainty in the quantity and condition of used products. A multi-objective optimization model is offered to configure the architecture. The results show that the proposed configurations efficiently manage uncertainty. Remanufacturing 5.0 is introduced through a case study based on the revalorization of lithium-ion batteries from electric vehicles in Quebec, Canada. This includes battery life cycle simulation, lifespan prediction, and a multi-objective optimization model that synthesizes Industry 5.0 principles. The process undertaken helps to understand the system’s operation and provides information on its adoption and implementation. This thesis contributes to the understanding of the integration of Industry 5.0 principles into remanufacturing from a methodological perspective. To this end, it establishes how these principles interact with the remanufacturing system; then integrates them into the system’s structure; and finally, simulates the operation of the Remanufacturing 5.0 system to illustrate its different dimensions and advantages.

Date	5 Jan 2026
Original language	French
Awarding Institution	École de technologie supérieure
Supervisor	Lucas Hof (Supervisor) & Jean-Pierre Kenné (Co-supervisor)