Rethinking Sustainable Operations: A Multi-Level Integration of Circularity, Localization, and Digital Resilience in Manufacturing Systems
Abstract
1. Introduction
1.1. Global Sustainability Crisis and Manufacturing Realignment
1.2. From Efficiency to Resistance–Sustainability Nexus
1.3. Conceptual Gaps: Fragmented Integration in OM Theories
1.4. Integrated Sustainable Operations Strategy (ISOS): A Conceptual Framework
1.5. Paper Structure
2. Theoretical Foundations
2.1. Sustainability Transition in Operations Management
2.2. Circular Economy: Systemic Capability and Regenerative Logic
2.3. Localized Operations and Regional Resilience Framework
2.4. Digital Transformation as an Enabler of Sustainability Adaption
2.5. System Thinking and Triple Bottom Line Convergence
2.6. Research Design of the Conceptual Paper
- Problematization and Theoretical SynthesisThe study begins by identifying key fragmentation points in the current literature on sustainable operations, particularly the disconnects between circularity, localization, and digital transformation. By synthesizing insights from circular economy (CE), regional resilience, and digital adaptation, the study constructs a comprehensive view of what sustainable manufacturing operations require in today’s context.
- Framework Construction and Integration LogicThe conceptual model—Integrated Sustainable Operations System (ISOS)—is developed by aligning multi-level constructs (macro, meso, micro) and mapping them to strategic design drivers and operational outcomes. The framework integrates dimensions that are often discussed in isolation, such as local sourcing, reverse logistics, digital twins, and adaptive policy environments.
- Proposition Development for Future ResearchTo enable empirical advancement, the paper derives a set of theoretical propositions based on the ISOS logic. These propositions serve as testable pathways linking antecedents, capabilities, and sustainability outcomes, offering a roadmap for future empirical validation and theory building.
3. Conceptual Framework and Design Logic
3.1. Research Design as Conceptual Contribution
3.2. Logic of Framework Construction: Antecendents, Drivers, Outcomes
Antecedents: Structural Pressures and Transformational Imperatives
Strategic Design Drivers: Conceptual Mechanisms for Operational Transformation
Intended Outcomes: Triple Bottom Line Sustainability
Conceptual Integration and Boundary Logic
3.3. Key Constructs Definitions and Boundaries
Sustainable Operational Core (SOC)
3.4. Proposed Multi-Level Model: Macro (Policy)—Meso (Operations)—Micro (Processes)
4. Integrated Operational Strategies for Circular and Adaptive Sustainability
4.1. Operationalizing Circularity: Closed-Loop Design and Reverse Logistics
4.2. Localization Strategies: Risk Buffer, Emission Control, and Proximity Value
4.3. Digital Resilience: Real-Time Decisioning and Predictive Monitoring
IoT: Sensory Infrastructure for Operational Visibility
AI: Cognitive Engine for Predictive and Adaptive Control
Blockchain: Trust Infrastructure for Transparency and Traceability
4.4. Workforce and Process Flexibility for Adaptive Sustainability
Workforce Flexibility as a Strategic Sustainability Lever
Process Flexibility: Reconfigurable Systems for Sustainable Adaptation
Interdependence and Strategic Integration
4.5. Synthesis: Interdependency and Trade-Off Management
Strategic Interdependency Across Domains
Systemic Perspective for Strategic Alignment
5. Conceptual Contributions
5.1. Redefining Operational Excellence in the Anthropocene
Integrating Global and Local Operational Logics
Bridging Technological and Organizational Dimensions
Balancing Economic, Social, and Ecological Value
Reframing Excellence as Adaptive Capacity
5.2. Theoretical Implications for Sustainability Science and Operations Management
- Cross-Scalar Integration: From Global Norms to Local Capabilities
- 2.
- Bridging Technological and Organizational Paradigms
- 3.
- Reconceptualizing Operational Value: From Efficiency to Regeneration
Implications for Theory Building in Operations Management
Implications for Sustainability Science
5.3. Managerial and Policy Implications: Strategic Integration over Silos
- For Managers: Operationalizing Integration at the Strategic Core
- (1)
- Initiate cross-functional dialogues to align vision and language;
- (2)
- Conduct operational sustainability audits to map existing silos;
- (3)
- Identify intersection points between circularity, localization, and digital tools;
- (4)
- Co-develop pilot projects in selected business units or facilities.
- 2.
- For Policymakers: Enabling Systemic Transitions Beyond Compliance
Policy Co-Creation
- 3.
- Shared Imperative: Breaking the Trade-off Mentality
Concluding Perspective
5.4. Limitations of Current Framework and Boundary Conditions
- (1)
- Theoretical Scope and Abstraction Level
- (2)
- Sectoral and Institutional Variability
- (3)
- Interdependency Management and Trade-off Complexity
- (4)
- Sustainability Value Interpretation
- (5)
- Need for Empirical Grounding and Evolution
5.5. Practical Indicators of ISOS
5.6. Policy and Stakeholder Roles in ISOS
6. Future Research Agenda
6.1. Propositions for Empoirical Validation
6.2. Methodological Paths: Case-Based Modelling, Simulation, System Dynamics
- (1)
- Case-Based Modelling for Contextualization
- (2)
- Simulation-Based Design for Scenario Testing
- (3)
- System Dynamics for Macro–Meso Integration
6.3. Multi-Stakeholder and Cross-Sector Testing
- 1.
- Proposition P9.
- 2.
- Proposition P10.
- 3.
- Proposition P11.
6.4. Suggested Empirical Designs
7. Conclusions
7.1. Summary of Contributions
7.2. Strategic Relevance and Future Orientation
7.3. Final Reflection: Operational Innovation for Sustainability Transitions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Abbreviations
SDG | Sustainable Development Goals |
OM | Operations Management |
CE | Circular Economy |
TBL | Triple Bottom Line |
ISOS | Integrated Sustainable Operational Strategy |
IoT | Internet of Things |
AI | Artificial Intelligence |
ESG | Environmental, Social, and Governance |
SMEs | Small and Medium Enterprises |
SCM | Supply Chain Management |
ICT | Information and Communication Technology |
LCA | Life Cycle Assessment |
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Concept | Working Definition |
---|---|
Circularity | A regenerative operational model that minimizes waste and maximizes resource reuse through closed-loop systems [12,13,14]. |
Localization | A strategy that emphasizes sourcing, production, and distribution closer to the point of use, aiming to reduce dependency on global supply chains and enhance community resilience [14]. |
Digital Adaptation | The dynamic integration of digital technologies (e.g., IoT, AI, blockchain) to enable flexible, transparent, and responsive operations in uncertain environments [15,16]. |
Strategic Pillar | Definition | Strategic Role in ISOS |
---|---|---|
Circularity | A systemic approach to designing out waste, keeping materials in use, and regenerating natural systems throughout the product lifecycle. | Drives resource efficiency, closed-loop flows, and long-term value regeneration. |
Localization | The strategic realignment of production, sourcing, and decision-making to local or regional levels to enhance adaptability and reduce external dependencies. | Enhances supply chain resilience, reduces emissions, and empowers regional ecosystems. |
Digital Adaptation | The dynamic use of data-driven technologies (e.g., AI, IoT, blockchain) to optimize, monitor, and reconfigure operational processes in real time. | Enables agility, transparency, and integration across complex operational layers. |
Construct | Analytical Definition | Boundary Clarification |
---|---|---|
Circularity | Regenerative operational logic that minimizes waste, optimizes resource loops, and extends product lifecycles via design innovation, reuse, and recycling. | Treated as closed-loop logic; excludes linear or semi-linear eco-efficiency strategies and green practices that do not fundamentally alter material/energy flows. |
Localization | Spatial and institutional reconfiguration toward proximity sourcing, community-based production, and regionally embedded value chains. | Goes beyond decentralization or outsourcing; emphasizes regional identity, embeddedness, and adaptive autonomy. |
Digital Adaptation | Embedding intelligent technologies (e.g., IoT, AI, CPS) into operations for real-time responsiveness, predictive analytics, and systemic efficiency. | Differs from basic automation; entails systemic reconfiguration, organizational learning, and agile restructuring to respond to contextual complexity. |
Sustainable Operational Core (SOC) | Integrative intersection of circularity, localization, and digital adaptation, forming regenerative, regionally resilient, and tech-adaptive operational models. | SOC is an abstract ideal-type construct; not prescriptive, but flexible across industries and geographies. |
Industry Sector | Circular Strategy Focus | Strategic Function |
---|---|---|
Automotive | Remanufacturing and Parts Recovery | Reduces raw material demand; supports modular product innovation |
Consumer Electronics | Design for Disassembly and E-Waste Take-Back | Minimizes toxic landfill impact; enables secondary market channels |
Apparel and Fashion | Recycled Materials and Product-as-a-Service | Builds brand legitimacy; enables recurring revenue models |
Food and Beverage | Bio-packaging and Organic Waste Loops | Reduces landfill fees; appeals to green-conscious consumers |
Pharmaceuticals | Reverse Distribution and Expiry Management | Improves inventory efficiency; aligns with health safety compliance |
Strategic Dimension | Operational Benefits | Potential Trade-offs |
---|---|---|
Risk Buffering | Enhances supply continuity and logistical agility | May increase unit costs due to smaller scale |
Emission Control | Reduces transport-related emissions; improves compliance | May require investment in cleaner local tech |
Proximity Value | Boosts responsiveness, community trust, and local brand equity | May face local regulatory or labor complexities |
Technology | Strategic Role in Operations | Sustainability Contribution |
---|---|---|
IoT | Enables real-time sensing and system-level visibility | Reduces waste, prevents failure, strengthens reverse logistics |
AI | Facilitates predictive control and dynamic adaptation | Optimizes multi-objective performance, reduces emissions |
Blockchain | Secures data integrity and trust in multi-party networks | Ensures traceability, enforces ethical sourcing |
Strategic Pillar | Thematic Focus | Key Proposition |
---|---|---|
Circularity | Resource efficiency and material reuse | Circular practices enhance operational sustainability when supported by traceability and modular design. |
Localization | Regional resilience and adaptive supply | Localization strengthens system resilience and reduces emissions through proximity and redundancy. |
Digital Adaptation | Data-driven agility and optimization | Digital tools improve sustainability alignment through real-time monitoring and predictive decision-making. |
Pillar Interdependency | Trade-off management and systemic synergy | The convergence of all three pillars enables adaptive sustainability through managed tensions and strategic alignment. |
ISOS Pillar | Strategic Focus | Practical Indicators | Illustrative Metrics/Questions |
---|---|---|---|
Circularity | Closed-loop resource use, waste minimization | - % of materials reused or recycled - Product design for disassembly - Reverse logistics presence | What % of production input comes from recycled content? Is there a take-back program in place? |
Localization | Regional sourcing, context-specific responsiveness | - % of procurement from local suppliers - Local workforce ratio - Customization to local needs | How much of the supply chain is domestically embedded? Are local R&D centers active? |
Digitalization | Data-driven operations, intelligent systems | - Adoption of AI/IoT systems - Real-time data visibility across supply chain - Cybersecurity index | Are predictive analytics used in operational decisions? How integrated are digital dashboards? |
Integration Mechanism | Cross-pillar synergy and alignment | - Conflicts or complementarities mapped - % of integrated initiatives - Strategy coordination forum | Are there tensions between local autonomy and centralized digital control? Is there a platform for resolving such tensions? |
Proposition | Underlying Logic | Suggested Empirical Design |
---|---|---|
P1. The integration of circularity practices positively affects sustainable operational performance, mediated by reverse logistics capabilities. | Closed-loop design requires enabling logistics structures to realize sustainability outcomes. | Structural Equation Modeling (SEM); mediation analysis. |
P2. The effectiveness of localization strategies in enhancing resilience is moderated by the level of institutional coordination at the regional level. | Policy coherence and regional governance influence localization’s impact. | Multi-group regression analysis; hierarchical linear modeling. |
P3. The relationship between digital adaptation and sustainability performance is mediated by real-time data utilization. | The impact of IoT and AI on operations depends on effective data decisioning. | Mediation test using PROCESS macro or PLS-SEM. |
P4. Workforce flexibility strengthens the relationship between circularity and operational adaptability. | Human agility enhances the responsiveness of circular systems to disruption. | Moderation analysis; interaction terms in regression. |
P5. Simultaneous pursuit of circularity, localization, and digitalization leads to superior sustainability outcomes, moderated by organizational integration capacity. | Synergistic strategies require internal capability to manage trade-offs. | Moderated mediation or configurational analysis (e.g., fsQCA). |
Research Question (RQ) | Recommended Methodology | Sectoral Focus | Outcome Variable |
---|---|---|---|
RQ1 | Multiple Case Study | Textile/Electronics | Trade-off Resolution Strategies |
RQ2 | Longitudinal Study | Agritech | Adaptive Sustainability Index |
RQ3 | Quasi-Experimental Design | Automotive | Governance–Performance Alignment |
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Setyadi, A.; Pawirosumarto, S.; Damaris, A. Rethinking Sustainable Operations: A Multi-Level Integration of Circularity, Localization, and Digital Resilience in Manufacturing Systems. Sustainability 2025, 17, 6929. https://doi.org/10.3390/su17156929
Setyadi A, Pawirosumarto S, Damaris A. Rethinking Sustainable Operations: A Multi-Level Integration of Circularity, Localization, and Digital Resilience in Manufacturing Systems. Sustainability. 2025; 17(15):6929. https://doi.org/10.3390/su17156929
Chicago/Turabian StyleSetyadi, Antonius, Suharno Pawirosumarto, and Alana Damaris. 2025. "Rethinking Sustainable Operations: A Multi-Level Integration of Circularity, Localization, and Digital Resilience in Manufacturing Systems" Sustainability 17, no. 15: 6929. https://doi.org/10.3390/su17156929
APA StyleSetyadi, A., Pawirosumarto, S., & Damaris, A. (2025). Rethinking Sustainable Operations: A Multi-Level Integration of Circularity, Localization, and Digital Resilience in Manufacturing Systems. Sustainability, 17(15), 6929. https://doi.org/10.3390/su17156929