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INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR

INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR. Joseba Bilbatua MEMAN Coordinator Senior Manager International Projects MONDRAGON CORPORATION FoF for Automotive Workshop February 28, 2018 – Brussels. 1. Introduction. Agenda. 2. Background. 3.

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INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR

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  1. INTEGRAL MATERIAL AND ENERGY FLOW MANAGEMENT IN MANUFACTURING METAL MECHANIC SECTOR Joseba Bilbatua MEMAN Coordinator Senior ManagerInternational Projects MONDRAGON CORPORATION FoF for Automotive Workshop February 28, 2018 – Brussels

  2. 1 Introduction Agenda 2 Background 3 Concept & Implementation 4 ExemplaryApplication 5 Conclusions & Outlook

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

  4. Imagineyouaretheproductionmanagerof a producingfactory, whichisembbedded in a valuechainwithtwootherfactories. You Introduction

  5. Youareverymotivatedtoreduceresourcedemands. Introduction Wehavecommitedto save MONEY andtheENVIRONMENT!

  6. Youconvinceyour CEO aboutyournewidea. • We change our raw material supplier! Introduction The new material islesscostly.

  7. Meanwhile, at thefactoryofyourindustrialcustomer… We’ll miss our sustainability targets… Introduction KPI We need to order more raw parts! We have lots of defective parts now!

  8. Haveyoutaken a gooddecision? Who benefitsandwho loses? ? ? Introduction ? ? • Methodsandtoolsareneededto… • Identifyinterdependencies& targetconflicts • Avoidproblemshiftings • Find hiddenresourcesavingpotentials MEMAN is developing a toolbox to enhance resource and energy efficiency for single factories and entire value chains alike

  9. 1 Introduction Agenda 2 Background 3 Concept & Implementation 4 ExemplaryApplication 5 Conclusions & Outlook

  10. Focus ofmethodsregardinglifecyclephases Cradleto grave Raw Material Production Product Use End of Life Gate togate Background MEFA EVSM Simulation LCA Manufacturing

  11. Selected methodstoanalyseresourceefficiency & sustainabilityofproductionsystems: Background • MEFA (Material & Energy Flow Analysis): Analysis of material & energyinput/outputbalances • LCA (Life Cycle Assessment): Analysis of environmental impacts due toresourceconsumptions & emissions • EVSM (Energy Value Stream Management): Analysis ofmanifoldwastagesalongthevaluestream • Factory Simulation: Analysis ofdynamicconsumptionpatterns Complementarymethods  Combine themtoallowfor a holisticassessmentoffactories & valuechains

  12. 1 Introduction Agenda 2 Background 3 Concept & Implementation 4 ExemplaryApplication 5 Conclusions & Outlook

  13. Project „MEMAN“: Design andapplytoolboxtorevealresourcesavingpotentials in valuechainsof European metalmechanicindustry. Concept & Implementation - Project Background & Approach • www.meman.eu • Fundedby 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

  14. Product:Piston rod, Steel (42CrMo4), used in caterpillars & cranes Product:Structural aerospae components (Aluminium, Titanium) Exemplary Application – Configuration of Value Chain (Use cases) Image Source: http://www.figeac-aero.com/ MachiningCluster Image Source: http://www.directindustry.de/ Surface FinishingCluster Product:Control arm for automotive (Aluminium), Casting Cluster

  15. Project „MEMAN“: Design andapplytoolboxtorevealresourcesavingpotentials in valuechainsof European metalmechanicindustry. Concept & Implementation - Project Background & Approach • www.meman.eu Local Factory Data Decision-making Toolbox • calculatessavingpotentials • identifiesinterdependencies & targetconflicts Global ImprovementRecommendations

  16. Decision-making Toolbox 3 applicationpaths • User perspective: 3 paths applied independently or combined (depending on targets & data availability) Concept & Implementation – Toolbox Concept

  17. Decision-making Toolbox 3 applicationpaths • User perspective: 3 paths applied independently or combined (depending on targets & data availability) • Fed withconsistentdata Concept & Implementation – Toolbox Concept

  18. 3 applicationpaths • User perspective: 3 paths applied independently or combined (depending on targets & data availability) • Fed withconsistentdata • Resultsconsolidatedfordecisionsupport Concept & Implementation – Toolbox Concept

  19. EVSM* Quick hotspotidentification Concept & Implementation – ApplicationPaths • Capacities / Bottlenecks (static) • Product Quality • EnergyDemands • Costs Results * EnergyValue Stream Management

  20. EVSM* Quick hotspotidentification Concept & Implementation – ApplicationPaths • Capacities / Bottlenecks (static) • Product Quality • EnergyDemands • Costs Results * EnergyValue Stream Management

  21. Concept & Implementation – Application Paths Factory Simulation Dynamic systembehaviourunderstanding • Demand profiles • Inventories • Machineutilisation • Lead Times Results Factory Load Profile Lead Times per Batch Machine Load Profiles MachineQueing Times Energy per Batch

  22. Concept & Implementation – Application Paths Factory Simulation Dynamic systembehaviourunderstanding • Demand profiles • Inventories • Machineutilisation • Lead Times Results Factory Load Profile Lead Times per Batch Machine Load Profiles MachineQueing Times Energy per Batch

  23. MEFA* & LCA** Environmental impactassessment Concept & Implementation – ApplicationPaths • Carbon Footprint • Toxicity • Eutrophication • … Results * Material & Energy Flow Analysis ** Life Cycle Assessment

  24. MEFA* & LCA** Environmental impactassessment Concept & Implementation – ApplicationPaths • Carbon Footprint • Toxicity • Eutrophication • … Results * Material & Energy Flow Analysis ** Life Cycle Assessment

  25. Value Chain Module KPI Monitor Overviewfor all calculations Concept & Implementation – ApplicationPaths

  26. Value Chain Module KPI Monitor Overviewfor all calculations Concept & Implementation – ApplicationPaths

  27. KPI Monitor Overviewfor all calculations Concept & Implementation – ApplicationPaths

  28. 1 Introduction Agenda 2 Background 3 Concept & Implementation 4 ExemplaryApplication 5 Conclusions & Outlook

  29. Product:Piston rod, Steel (42CrMo4), used in caterpillars & cranes Product:Structural aerospae components (Aluminium), Exemplary Application – Configuration of Value Chain (Use cases) Image Source: http://www.directindustry.de/ Image Source: http://www.figeac-aero.com/ Product:Control arm for automotive (Aluminium),

  30. Exemplary Application – Base Scenario • Product: Control Arm , Aluminium, used in automotive applications

  31. Exemplary Application – Base Scenario • Product: Control Arm , Aluminium, used in automotive applications

  32. Exemplary Application – Base Scenario • Product: Control Arm , Aluminium, used in automotive applications Inputs Outputs Raw Aluminium Finished Products Energies Emissions Water Auxiliaries Workforce Waste Main Processes: Melting ovens Chips recycling Sand recycling Vacuum casting Tooling Sand core making

  33. Exemplary Application – Alternative Scenarios • Base scenario • Improved scenario* + 7,6 % *Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

  34. Exemplary Application – Alternative Scenarios • Base scenario • Improved scenario* + 7,6 % - 9,8 % *Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

  35. Exemplary Application – Alternative Scenarios • Base scenario • Improved scenario* + 7,6 % - 9,8 % - 1,4 % *Aluminium price increase by 10 % & quality rates of 7 processes increased by 1 %

  36. 1 Introduction Agenda 2 Background 3 Concept & Implementation 4 ExemplaryApplication 5 Conclusions & Outlook

  37. Conclusions • Complementarymethodscombined in oneenvironment • Holisticevaluationoffactoriesandvaluechains • High degreeoftransparency • Target conflictscanbeovercomewithnewbusinessmodels • Decisionsupport on strategicalandtacticallevelconsidering e.g.… • Material changes/substitution • Input-/Output quantitychanges • Processparameterchanges • Productionschedulechanges • Limitations & developmentpotentials • High dataacquisitioneffort • Expertsneededtoverifyresults • Multi productconsideration • Detailedmodelingoftechnicalbuildingservices • Publication: „Toolbox for Increasing Resource Efficiency in the European Metal Mechanic Sector” • Availablewith open access: http://www.sciencedirect.com/science/article/pii/S2212827116314160

  38. Contact • MONDRAGON CORPORATION • Innovation & Technology department • http://www.mondragon-corporation.com/ Thanks for your attention www.meman.eu • Dipl. MSc Joseba BILBATUA • Responsible for Advanced Manufacturing and Raw Materials • MONDRAGON Corporation Headquarter • jbilbatua@mondragoncorporation.com

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