Use of simulation and modelling to develop a sustainable production system

This paper seeks to establish a practical definition of the term sustainable development, and relate it to a company's performance. Simulation and modelling tools are applied to gain a holistic view of the activities associated with a metal casting company, which includes production, transportation and recycling. In the simulation model, four case scenarios are investigated, including the comparison of original and re‐designed cast products of 20% runner weight reduction, and the recycling of scrap metal at two different remelters. The focus of the case study is to monitor the amount of scrap, dross, carbon dioxide emissions from both energy consumption and transportation, productivity and costs during the metal material cycle. From the case study, various ‘sustainability indicators’ are highlighted. Copyright © 2006 John Wiley & Sons, Ltd and ERP Environment.