The impact of climate change makes the transition to sustainable manufacturing more urgent than ever. This dissertation contributes to that transition by addressing two key challenges: minimizing material waste and reducing CO₂ emissions.nnThe first part focuses on zero-waste manufacturing through intelligent assembly methods. By combining components based on their measured properties, scrap can be significantly reduced. A new hybrid approach merges the strengths of traditional and selective assembly, resulting in less waste and lower operational costs. Additionally, a decision model is developed to help companies choose the most suitable assembly strategy.nnThe second part explores net-zero manufacturing through carbon-aware production planning. As renewable energy becomes more prominent—but also more variable—it is crucial to align production with periods of low CO₂ intensity. This research shows that by considering the time-dependent carbon intensity of the electricity grid and renewable sources, emissions can be substantially reduced.nnTogether, these innovations offer practical strategies for making manufacturing more sustainable, both in terms of materials and energy use.