MECHANIC SECTOR Joseba Bilbatua Primary MEMAN Coordinator Senior - - PowerPoint PPT Presentation

INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR

Joseba Bilbatua

Primary MEMAN Coordinator Senior Manager International Projects MONDRAGON CORPORATION RESER 2017 September 8, 2017 – Bilbao

1 Introduction 2 Concept & Implementation 4 Exemplary Application 5 Exploitable Results 3 Background

Agenda

Introduction

The energy and material consumption in manufacturing over the next 20 years is expected to increase by 40% Strategies to improve the economic and environmental performance of companies are usually pursued from a local perspective

Imagine you are the production manager of a producing factory, which is embbedded in a value chain with two other factories.

You

Introduction

You are very motivated to reduce resource demands. We have commited to save MONEY and the ENVIRONMENT!

Introduction

You convince your CEO about your new idea.

We change

• ur raw

material supplier!

The new material is less costly.

Introduction

Meanwhile, at the factory of your industrial customer… We need to

• rder more

raw parts! We have lots of defective parts now! We’ll miss our sustainability targets…

KPI

Introduction

Have you taken a good decision? Who benefits and who loses? ? ? ? ?

Methods and tools are needed to…  Identify interdependencies & target conflicts  Avoid problem shiftings  Find hidden resource saving potentials

Introduction

MEMAN is developing a toolbox to enhance resource and energy efficiency for single factories and entire value chains alike

1

Introduction

2

Concept & Implementation

4

Exemplary Application

5

Exploitable Results

3

Background

Agenda

criterion MEFA LCA EVSM Simulation dynamic system behavior economic performance environmental performance technical performance changes in product/material flow simplicity (time & knowledge) life cycle phases decision support degree of application approach

Selected methods to analyse resource efficiency & sustainability of production systems:

• MEFA (Material & Energy Flow Analysis):

Analysis of material & energy input/output balances

• LCA (Life Cycle Assessment):

Analysis of environmental impacts due to resource consumptions & emissions

• EVSM (Energy Value Stream

Management): Analysis of manifold wastages along the value stream

• Factory Simulation:

Analysis of dynamic consumption patterns

Background

Focus of methods regarding life cycle phases

Raw Material Production Manufacturing Product Use End of Life

Gate to gate Cradle to grave MEFA EVSM Simulation LCA

Background

criterion MEFA LCA EVSM Simulation dynamic system behavior economic performance environmental performance technical performance changes in product/material flow simplicity (time & knowledge) life cycle phases decision support degree of application approach

Selected methods to analyse resource efficiency & sustainability of production systems:

• MEFA (Material & Energy Flow Analysis):

Analysis of material & energy input/output balances

• LCA (Life Cycle Assessment):

Analysis of environmental impacts due to resource consumptions & emissions

• EVSM (Energy Value Stream Management):

Analysis of manifold wastages along the value stream

• Factory Simulation:

Analysis of dynamic consumption patterns

Background

Complementary methods

 Combine them to allow for a holistic assessment of factories & value chains

1

Introduction

2

Concept & Implementation

4

Exemplary Application

5

Exploitable Results

3

Background

Agenda

Project „MEMAN“: Design and apply toolbox to reveal resource saving potentials in value chains of European metal mechanic industry.

• Funded by European Comission
• Runtime: 2015 – 2018 (42 months)
• Budget: ~ 6 mio. €
• Beneficiaries: 14 + 11 Linked Third Parties

72% (18) are industries both Large and SMEs 23% (7) are RTD partners

Concept & Implementation - Project Background & Approach

www.meman.eu

Product: Piston rod, Steel (42CrMo4), used in caterpillars & cranes

Image Source: http://www.directindustry.de/

Exemplary Application – Configuration of Value Chain (Use cases)

Product: Structural aerospae components (Aluminium, Titanium)

Image Source: http://www.figeac-aero.com/

Product: Control arm for automotive (Aluminium),

Project „MEMAN“: Design and apply toolbox to reveal resource saving potentials in value chains of European metal mechanic industry.

Local Factory Data Global Improvement Recommendations

Decision-making Toolbox

• calculates saving potentials
• identifies interdependencies

& target conflicts

Concept & Implementation - Project Background & Approach

www.meman.eu

 Paths applied independently or combined (depending on targets & data availability)

Decision-making Toolbox 3 application paths

Concept & Implementation – Toolbox Concept

 Paths applied independently or combined (depending on targets & data availability)  Fed with consistent data

Decision-making Toolbox 3 application paths

Concept & Implementation – Toolbox Concept

 Paths applied independently or combined (depending on targets & data availability)  Fed with consistent data  Results consolidated for decision support

3 application paths

Concept & Implementation – Toolbox Concept

 Capacities / Bottlenecks (static)  Product Quality  Energy Demands  Costs Results Quick hotspot identification

EVSM*

Concept & Implementation – Application Paths

* Energy Value Stream Management

 Capacities / Bottlenecks (static)  Product Quality  Energy Demands  Costs Results Quick hotspot identification

EVSM*

Concept & Implementation – Application Paths

* Energy Value Stream Management

Dynamic system behaviour understanding  Demand profiles  Inventories  Machine utilisation  Lead Times Results

Factory Simulation

Concept & Implementation – Application Paths

Factory Load Profile Machine Load Profiles Energy per Batch Lead Times per Batch Machine Queing Times

Dynamic system behaviour understanding  Demand profiles  Inventories  Machine utilisation  Lead Times Results

Factory Simulation

Concept & Implementation – Application Paths

Factory Load Profile Machine Load Profiles Energy per Batch Lead Times per Batch Machine Queing Times

Environmental impact assessment  Carbon Footprint  Toxicity  Eutrophication  … Results

MEFA* & LCA**

Concept & Implementation – Application Paths

* Material & Energy Flow Analysis ** Life Cycle Assessment

Environmental impact assessment  Carbon Footprint  Toxicity  Eutrophication  … Results

MEFA* & LCA**

Concept & Implementation – Application Paths

* Material & Energy Flow Analysis ** Life Cycle Assessment

Overview for all calculations

KPI Monitor

Concept & Implementation – Application Paths

Overview for all calculations

KPI Monitor

Concept & Implementation – Application Paths

Overview for all calculations

KPI Monitor

Concept & Implementation – Application Paths

1

Introduction

2

Concept & Implementation

4

Exemplary Application

5

Exploitable Results

3

Background

Agenda

Product: Piston rod, Steel (42CrMo4), used in caterpillars & cranes

Image Source: http://www.directindustry.de/

Exemplary Application – Configuration of Value Chain (Use cases)

Product: Structural aerospae components (Aluminium),

Image Source: http://www.figeac-aero.com/

Product: Control arm for automotive (Aluminium),

Product: Control Arm , Aluminium, used in automotive applications

Exemplary Application – Base Scenario

CONVENTIONAL SOLID CASTING HOLLOW CASTING Central single feeding Multiple feeding points Simple cooling circuits for solidification Sophisticated passive and active thermal management based solutions for solidification Higher productivity Higher effort in design phase

Product: Control Arm , Aluminium, used in automotive applications

Exemplary Application – Base Scenario

Basque partners involved in MEMAN within the CASTING Cluster

Concept & Implementation - Project Background & Approach

Primary Coordinator Pilot - Validator Mould/Tooling producer Cloud & TICs Sand core machine Oven manufacturer

Product: Control Arm , Aluminium, used in automotive applications

Vacuum casting Melting ovens Chips recycling Sand recycling

Inputs Outputs Main Processes:

Finished Products Emissions Waste Raw Aluminium Energies Tooling Sand core making Water Auxiliaries Workforce

Exemplary Application – Base Scenario

Improved scenario*

*Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

Base scenario

+ 7,6 %

Exemplary Application – Alternative Scenarios

+ 7,6 %

• 9,8 %

Exemplary Application – Alternative Scenarios

Improved scenario* Base scenario

*Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

+ 7,6 %

• 9,8 %
• 1,4 %

Exemplary Application – Alternative Scenarios

Improved scenario* Base scenario

*Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

1

Introduction

2

Concept & Implementation

4

Exemplary Application

5

Exploitable Results

3

Background

Agenda

Exploitable Results

Partner Name of innovation Type of innovation Characterization Current TRL End of project TRL Time to "market" (years after project)

Mecanic Vallée Predictive maintenance Service/consulting Consulting service 3-4 4-5 2-3 Technofi Ressource effciency diagnosis Service/consulting Consulting service 8-9 9 <1 Cetim Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Acciona Internal consulting service Service/consulting Consulting service 4-5 6-7 <2 Eiffo Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 6-7 <2 VMT Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Loramendi More efficient core making machines Product New product 4-6 6 <2 Insertec New furnace Product New product 3-4 6 <1 MSI Common data cloud interface Product/software New product 5-6 6-7 <1 TUBS Meman toolbox Product/software New product 5-6 6-7 N/A Figeac Aero Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 AD Industrie Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 Stahl Judenburg Advanced specifications & materials data management Process Significantly improved process 5-6 6-7 <2 THOMA Optimization of business and information processes Process Significantly improved process 5-6 6-7 <2 Fagor Ederlan New hollow suspension part Product Significantly improved product 5-6 6-7 1-2 DiTec Extension of MES system Product/software Significantly improved software product 6-7 7-8 <1 Softec Extension of ERP system Product/software Significantly improved software 6-7 7-8 <1

Innovations created in MEMAN  17 exploitable results  Significant development in TRL  Short “time to market” after end

• f project.

Results

Exploitable results

Exploitable Results

Partner Name of innovation Type of innovation Characterization Current TRL End of project TRL Time to "market" (years after project)

Mecanic Vallée Predictive maintenance Service/consulting Consulting service 3-4 4-5 2-3 Technofi Ressource effciency diagnosis Service/consulting Consulting service 8-9 9 <1 Cetim Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Acciona Internal consulting service Service/consulting Consulting service 4-5 6-7 <2 Eiffo Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 6-7 <2 VMT Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Loramendi More efficient core making machines Product New product 4-6 6 <2 Insertec New furnace Product New product 3-4 6 <1 MSI Common data cloud interface Product/software New product 5-6 6-7 <1 TUBS Meman toolbox Product/software New product 5-6 6-7 N/A Figeac Aero Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 AD Industrie Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 Stahl Judenburg Advanced specifications & materials data management Process Significantly improved process 5-6 6-7 <2 THOMA Optimization of business and information processes Process Significantly improved process 5-6 6-7 <2 Fagor Ederlan New hollow suspension part Product Significantly improved product 5-6 6-7 1-2 DiTec Extension of MES system Product/software Significantly improved software product 6-7 7-8 <1 Softec Extension of ERP system Product/software Significantly improved software 6-7 7-8 <1

Innovations created in MEMAN  17 exploitable results  Significant development in TRL  Short “time to market” after end

• f project.

Results

Exploitable results

Products/Production processes  2 new products  4 significantly improved processes  1 significantly improved product  3 patents filed Results

Exploitable Results

Partner Name of innovation Type of innovation Characterization Current TRL End of project TRL Time to "market" (years after project)

Mecanic Vallée Predictive maintenance Service/consulting Consulting service 3-4 4-5 2-3 Technofi Ressource effciency diagnosis Service/consulting Consulting service 8-9 9 <1 Cetim Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Acciona Internal consulting service Service/consulting Consulting service 4-5 6-7 <2 Eiffo Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 6-7 <2 VMT Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Loramendi More efficient core making machines Product New product 4-6 6 <2 Insertec New furnace Product New product 3-4 6 <1 MSI Common data cloud interface Product/software New product 5-6 6-7 <1 TUBS Meman toolbox Product/software New product 5-6 6-7 N/A Figeac Aero Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 AD Industrie Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 Stahl Judenburg Advanced specifications & materials data management Process Significantly improved process 5-6 6-7 <2 THOMA Optimization of business and information processes Process Significantly improved process 5-6 6-7 <2 Fagor Ederlan New hollow suspension part Product Significantly improved product 5-6 6-7 1-2 DiTec Extension of MES system Product/software Significantly improved software product 6-7 7-8 <1 Softec Extension of ERP system Product/software Significantly improved software 6-7 7-8 <1

Innovations created in MEMAN  17 exploitable results  Significant development in TRL  Short “time to market” after end

• f project.

Results

Exploitable results

Products/Production processes  2 new products  4 significantly improved processes  1 significantly improved product  3 patents filed Results Software solutions  2 new software products, incl. the MEMAN toolbox.  2 significantly improved software products. Results

Exploitable Results & Exploitation Strategy

Partner Name of innovation Type of innovation Characterization Current TRL End of project TRL Time to "market" (years after project)

Mecanic Vallée Predictive maintenance Service/consulting Consulting service 3-4 4-5 2-3 Technofi Ressource effciency diagnosis Service/consulting Consulting service 8-9 9 <1 Cetim Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Acciona Internal consulting service Service/consulting Consulting service 4-5 6-7 <2 Eiffo Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 6-7 <2 VMT Consultancy based on the use of MEMAN toolbox Service/consulting Consulting service 5-6 7-8 <2 Loramendi More efficient core making machines Product New product 4-6 6 <2 Insertec New furnace Product New product 3-4 6 <1 MSI Common data cloud interface Product/software New product 5-6 6-7 <1 TUBS Meman toolbox Product/software New product 5-6 6-7 N/A Figeac Aero Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 AD Industrie Predictive maintenance Maintance process Significantly improved process 3-4 5-6 2-3 Stahl Judenburg Advanced specifications & materials data management Process Significantly improved process 5-6 6-7 <2 THOMA Optimization of business and information processes Process Significantly improved process 5-6 6-7 <2 Fagor Ederlan New hollow suspension part Product Significantly improved product 5-6 6-7 1-2 DiTec Extension of MES system Product/software Significantly improved software product 6-7 7-8 <1 Softec Extension of ERP system Product/software Significantly improved software 6-7 7-8 <1

Innovations created in MEMAN  17 exploitable results  Significant development in TRL  Short “time to market” after end

• f project.

Results

Exploitable results

Products/Production processes  2 new products  4 significantly improved processes  1 significantly improved product  3 patents filed Results Software solutions  2 new software products, incl. the MEMAN toolbox.  2 significantly improved software products. Results Consulting Services  6 new consulting services, within:  Resource efficiency  Predictive maintenance  Construction Results

Contact

MONDRAGON CORPORATION

Innovation & Technology department http://www.mondragon-corporation.com/

• Dipl. MSc Joseba BILBATUA

Responsible for Advanced Manufacturing and Raw Materials MONDRAGON Corporation Headquarter jbilbatua@mondragoncorporation.com

www.meman.eu

Thanks for your attention

INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR

Joseba Bilbatua

Primary MEMAN Coordinator Senior Manager International Projects MONDRAGON CORPORATION RESER 2017 September 8, 2017 – Bilbao