Factory modelling: seeking energy reduction opportunities across building and production systems

1. Factory modelling: seeking energy reduction opportunities across building and production systems Dr Peter Ball Reader in Manufacturing Operations Manufacturing & Materials Department Cranfield University, UK +44 1234 750111, Ext 5657 p.d.ball@cranfield.ac.uk www.cranfield.ac.uk/sas/manufacturingsystems/

2. Fellow conspirators! • 1Airbus Operations Ltd • 2Cambridge University • 3Cranfield University • 4De Montfort University • 5Integrated Environmental Solutions Ltd • 6Toyota Motor Europe • P.D.Ball3 • M.Despeisse3 • S.Evans2 • R.M.Greenough4 • S.B.Hope6 • R.Kerrigan5 • A.Levers1 • P.Lunt1 • V.Murray5 • M.R.Oates4 • R.Quincey5 • L.Shao4 • T.Waltniel6 • A.J.Wright4

3. TSB THERM project • THrough-life Energy and Resource Modelling (THERM) • THERM seeks to integrate • ‘Sustainable Building Design’ tools and ‘Sustainable Manufacturing Process’ tools • to achieve an • ‘Integrated Sustainable Manufacturing’ system. • It is concerned with the creation of a new, innovative commercial modelling tool specifically for the manufacturing industry. • Funded by UK’s Technology Strategy Board (TSB)

4. Sustainable manufacturing- activities Manufacturing operations Consume and dispose of significant amount of energy and other resources A lot of work on energy reduction, other resource reduction and life cycle design Typically managed separately to buildings and facilities Buildings and facilities Consume and dispose of significant amount of energy and other resources (20-40% space heating typical – M.Oates) A lot of work on building design and operation Typically managed separately to operations Broad and yet narrow view of sustainable manufacturing!

5. Sustainable manufacturing- analysis Manufacturing operations Various well known approaches to improve ‘traditionally’ Waste hierarchy can guide improvements Sophisticated tools for analysis (e.g. Arena, Simul8 & Witness) Some extensions to include energy use Rare to analyse with buildings or facilities Buildings Guided by codes (BREEAM, LEED) Sophisticated tools for comfort and energy performance (e.g. IES VE) Rare to analyse with manufacturing operations Absence of integrated methods and tools

6. Methodology Software Tactics & practices Step 1 Step 2 Step 3 Tool Model Project aim • To develop commercially tool for factory energy reduction • Secondary work created an improvement methodology and a library of sustainable manufacturing practices

7. Material, energy and waste flows Generalised view ... ... can be applied to production, facilities as well as buildings ... Materials Materials Product Product Process Manufacturing Process 1 Building Manufacturing operation & facilities conceptually simple … complex in practice … need to understand… time location quality etc. Energy Energy Waste Waste xxxx Materials Product Manufacturing Process 2 Product Materials Energy Waste yyyy Waste Energy Materials Service Support Process 3 Energy Waste zzzz ... with the potential to identify and exploit re-use

8. The waste hierarchy Hierarchy has potential as basis for improvement methodology ... Prevent Reduce Reuse http://en.wikipedia.org/wiki/Waste_hierarchy ... which would be enhanced if good practice was available

9. Examples of practice & tactics ... to tactics of ‘how’ ... Measurement Follow the value and waste From general collections of ‘what’ ... Water Conserve, grey, reuse Facilities Air, heating, tolerances Lighting Switch off, sensors, removal Machines Maintenance, hibernation Despeisse, Ball, Evans, 2011 ... aligns to improvement methods ... People Involvement, behaviours Waste Separation, purity, seeing it! ... which is enhanced with simulation software support Prevent Reduce Reuse

10. A methodology for improvement Ball, Roberts, Dave, Pimenta. GCSM 2013 manual mapping bespoke spreadsheets energy simulation software

11. Architecture

12. THERM modelling tool Factory building Manufacturing processes Tactics Dynamic data input IES Ltd VE-Ware Eliminate Stop Repair Reduce Pick up Change Output analysis Attitudes Modelling & simulation workflow

13. Example application:Drying tank model Simulation model Conceptual model Simulation results and analysis Applying tactics to results: A11 Align resource input profile with production schedule` Despeisse, Oates, Ball (2013)

14. Impacts of energy efficiency action Ball, POMS 2012 switch off hibernate decommission Prevent manage technology smooth flow product velocity Reduce Reduces flexibility? Operationally easier? Design Operational harvest locally harvest pan-factory intensify capital Reuse Dispose forced vent passive vent slower operations highest impact actions constraints waste hierarchy

15. On going work … • Refinement of IES VE-THERM simulation environment • Further research now beyond original collaborators • Understanding how to use the tool across functional boundaries • Plus how to cope with lack of data (or too much!) www.therm-project.org THrough-life Energy and Resource Modeling

16. Next … Centre for industrial sustainability A national Centre • Core EPSRC funding £5M over 5 years • 88 PhD students … developing future leaders • 4 universities, 20+ companies • www.industrialsustainability.org

17. Factory modelling: seeking energy reduction opportunities across building and production systems Questions? www.industrialsustainability.org Dr Peter Ball Reader in Manufacturing Operations Manufacturing & Materials Department Cranfield University, UK +44 1234 750111, Ext 5657 p.d.ball@cranfield.ac.uk www.cranfield.ac.uk/sas/manufacturingsystems/ www.therm-project.org

18. References • Ball, P.D. 2012. The impact of low energy production on scheduling and flow, Proceedings of the Production and Operations Management Society (POMS) international conference, Chicago, USA, April 2012. • Ball, P.D., Roberts, S., Davé, A. & Pimenta, H. 2013 Towards a factory eco-efficiency improvement methodology, Global Conference on Sustainable Manufacturing (GCSM), Berlin, Germany, September. • Despeisse, M., Ball, P.D. & Evans, S. 2011. Modelling and tactics for sustainable manufacturing: an improvement methodology, 9th Global Conference on Sustainable Manufacturing, 28-30 September 2011, Saint Petersburg, Russia. Republished in Sustainable Manufacturing: shaping global value creation, Ed: Seliger G., SpringerLink series 10152, 2012, pp9-16. • Despeisse, M., Oates, M.R. & Ball, P.D. 2013. Sustainable manufacturing tactics and cross-functional factory modelling, Journal Cleaner Production, Vol. 42, pp. 31-41. DOI: 10.1016/j.jclepro.2012.11.008.