FLASH-COMP framework presents zero-defect, zero-waste composites manufacturing approach

Source | FLASHCOMP

A paper published in Sustainability, authored by partners of the EU-funded FLASH-COMP project, offers an important contribution to the transition challenge to zero-defect and zero-waste manufacturing (ZWM) in the composites industry. It does this through the demonstration of how eco-efficiency assessments can be used as a practical lever to move from abstract ambition to practical decision-making, a perspective that strongly reinforces the approach and outcomes being developed within FLASH-COMP itself.

At its core, writers Flavia Barbosa, Sara Pinto and Marcelo Sousa (Inegi) and Venus Hydar (Azimut) argue that waste is not simply an environmental problem, but a visible symptom of deeper inefficiencies within manufacturing systems. Defects, rework, scrap, excess energy use and unnecessary material consumption are all interconnected. Addressing them effectively requires assessment frameworks that move beyond siloed indicators and instead combine environmental performance with operational and economic metrics.

The authors present an eco-efficiency assessment methodology designed to evaluate manufacturing processes holistically, capturing both value creation and value loss. Rather than treating sustainability as a downstream reporting exercise, the framework positions eco-efficiency as a decision-support tool that can guide process optimization and continuous improvement. This is particularly relevant to FLASH-COMP’s work on liquid resin infusion (LRI) processes, where small deviations in process parameters can lead to defects, material waste and increased environmental impact. By making inefficiencies visible and measurable, the approach supports earlier intervention that prevents waste before it occurs, rather than managing later down the line.

A key insight from the paper is the importance of linking environmental indicators directly to operational performance. Traditional assessments often quantify emissions, energy use or material consumption in isolation, making it difficult for manufacturers to act on the results in a meaningful way. In contrast, the proposed framework aligns eco-efficiency indicators with production metrics that engineers and operators already understand.

This alignment is central to FLASH-COMP’s ZDM philosophy, where real-time monitoring, data analytics and digital tools are used to connect process behavior with quality outcomes. In both cases, the objective is the same: To ensure that sustainability considerations are embedded within day-to-day manufacturing decisions, not layered on top of them.

Zero-defect manufacturing and zero-waste manufacturing are inseparable goals.

The paper also reinforces the idea that ZWM is not a fixed end state, but a continuous improvement process. Eco-efficiency assessment is presented as a dynamic mechanism that enables benchmarking, learning and iterative optimization over time. This resonates with FLASH-COMP’s development of digital twins, simulation environments and adaptive control strategies, which allow manufacturers to test, refine and improve processes virtually before implementing changes on the shop floor.

Importantly, the study highlights that achieving zero-waste outcomes requires systemic thinking. Waste reduction cannot be achieved through isolated technological fixes alone; it depends on understanding interactions across materials, energy, equipment and process control. This systemic perspective underpins FLASH-COMP’s integrated approach, where sensing technologies, defect estimation and process optimization tools are combined to deliver measurable reductions in scrap, rework and resource use. The paper provides a robust conceptual and analytical foundation that helps explain why such integrated solutions are necessary and how their impact can be assessed credibly and transparently.

In this context, the publication serves as more than an academic contribution. It strengthens the narrative that FLASH-COMP is advancing: that zero-defect manufacturing and zero-waste manufacturing are inseparable goals, and that eco-efficiency provides a common language for linking quality, sustainability and competitiveness.

Learn more about the FLASH-COMP project.