Pursuing manufacturing competitiveness in the dynamic industrial landscape necessitates implementing changeable and reconfigurable manufacturing systems (RMS) capable of rapid adaptation to varying functionalities and capacities. However, current manufacturing system development methods often overlook product-driven changes during the system's life cycle, hindering companies from effectively responding to shifting demands and technological advancements. Consequently, this research paper proposes a systematic methodology for designing and developing changeable and reconfigurable manufacturing systems to address this gap. The proposed methodology is derived from a synthesis of design theory, reconfigurability theory, and practical insights to guide the development process from conception to implementation. The four-step development method adopts a system life cycle-wide perspective, encompassing (i) identification and clarification of the need for reconfigurability, (ii) formulation of reconfigurable concepts, (iii) detailed design of the reconfigurable system, and (iv) successful implementation and utilization of reconfigurability. Crucially, the development method blends existing RMS development tools and novel tools co-created with industry partners, ensuring its pragmatic and holistic applicability. Each step incorporates specific activities and supporting tools, rendering the methodology flexible and adaptable to diverse manufacturing environments. The proposed methodology was validated through case studies in seven diverse manufacturing companies. The primary contributions of this research lie in integrating new and existing development tools into a comprehensive and practical development method, facilitating a system life cycle-wide approach to RMS design, and promoting industry-specific adaptability. The validation across multiple manufacturing companies ensures the effectiveness and broad applicability of the proposed methodology. Consequently, this paper is a valuable resource for manufacturing companies aiming to enhance competitiveness by adopting changeable and reconfigurable manufacturing systems.@en

In this study, two moving-bed biofilm reactors (MBBR1 and MBBR2) filled with different size of carrier media (Kaldnes K1 and Kaldnes K1 micro, respectively) were subjected to soluble (sugar and sodium acetate (Ac)) substrate and mixture of soluble and particulate (particulate potato starch (PS)) substrate in a very high organic loading rate (12 kgCOD/m3·d) at different temperatures (26 and 15°C, in MBBR1 and MBBR2, respectively). The effects of carrier type and substrate on biofilm structure and reactor performance have been studied. Starch was removed by adsorption at the biofilm surface and hydrolyzed which caused substrate gradient in MBBR1, however, hydrolyzed uniformly within biofilm in MBBR2. The biofilm of MBBR1 was irregular due to filamentous structure growth due to the substrate gradient, while, it was regular in MBBR2 due to uniform distribution of substrate. The performance of both MBBRs in ammonium, COD and TN removal decreased significantly when the amount of small particles in the reactor increased owing to feeding by starch, which led to biomass density decline. The type of media affected the quantity and distribution of attached biomass, which in turn influenced the activity of specific microbial functional groups in the biofilm. The biofilm in MBBR2 was thicker and consequently nitrogen removal by denitrification was much higher. The lower temperature did not affect negatively the reactor performance in MBBR2.@en