Martin Bornschlegl

A new approach to integrate value stream analysis into a continuous energy efficiency improvement process

Due to increasing energy costs and the demand to lower CO2 emissions in the production, companies try to integrate a continuous energy efficiency improvement process. By implementing the energy value stream analysis, an optimized improvement process can be established which leads to a more efficient production. This approach shows a practically optimized method. It enables a holistic analysis of the energy productivity and helps to identify and to realize sustainable solutions. Furthermore this structured improvement process leads to a higher transparency of energy consumers.

Holistic Approach to Reducing CO2 Emissions Along the Energy-Chain (E-Chain)

Due to the increasing awareness to reduce CO2 emissions, it is important that car producers (OEM) get transparency about their energy consumption. Especially the production emission is becoming a focus topic in the next years. Hence, it should be started to minimize the energy consumption in a sustainable way. Therefore, this chapter presents a new approach to design a sustainable Energy Chain, which considers all elements beginning from the energy supplier to the end customer. Additionally the energy consumption is assessed, whether it is value-adding or not. This helps to find the levers to reduce energy consumption without reducing the level of quality and quantity. For the implementation of the Energy Chain a suitable software architecture is necessary. This chapter shows possible software modules for energy planning.

Determination of the prospective energy consumption of manufacturing technologies with methods-energy measurement (MEM)

The reduction of energy costs of manufacturing technologies is both an important and current objective for factory operators. But mostly, this idea to reduce the energy consumption is being implemented after the manufacturing technologies are installed. However, it would be more advantageous if efforts were made to save energy during the early planning process. To achieve an estimation of the energy consumption in this early planning stage, a new suitable forecast method is required. Therefore, this paper shows how the prospective energy consumption can be determined by using Methods-Energy Measurement (MEM). Based on the needs of production planners, future challenges and requirements for MEM are listed. Further-more, the concept of basic energy elements and their value determination techniques are introduced, and different possibilities are outlined and assessed. For an easier determination of the energy demands of a complex production cell or manufacturing equipment, standard equipment patterns will be designed. This template supports both planners and decision-makers to create reliable and standardized Resource Performance Indicators (RPI). Subsequently, the architecture of the MEM-calculation model is presented. This approach enables a holistic estimation of the energy consumption of manufacturing technologies and leads to higher levels of transparency. Furthermore, MEM contributes to identify and realize sustainable solutions in advance and as a result, increases the profitability of a factory.

Energieprognose mittels Methods-Energy Measurement: Berücksichtigung des Energiebedarfs in der frühen Planungsphase durch komponentenbasierte Energieplanung

Kurzfassung Eine frühzeitige Berücksichtigung des Energieverbrauchs im Planungsprozess ist sowohl ökologisch als auch ökonomisch sinnvoll. Dazu sind allerdings aussagekräftige Daten nötig, welche zu diesem Zeitpunkt oftmals noch nicht bereit stehen. Aus diesem Grund wurde der Methods-Energy Measurement-Ansatz konzipiert, damit eine ganzheitliche energetische Betrachtung der Fertigungsanlage über ihren Lebenszyklus im Planungsprozess erfolgen kann.

Lebenszykluskosten in der Digitalen Fabrik

Kurzfassung Die stetig steigende Komplexität der Anlagenstruktur im Karosseriebau sowie kürzer werdende Planungsphasen stellen eine große Herausforderung an die Planungsabteilung der Automobilhersteller dar. Bei der Ausschreibung von Produktionsanlagen spielen, neben den Anschaffungskosten, die Folgekosten eine immer wichtigere Rolle. Da wesentliche Produkt- und Produktionsfaktoren in der Regel mit Simulationsmodellen vorab untersucht werden, kann durch die Ergänzung um Lebenszykluskosten die Vergabeentscheidung unterstützt werden. Dieser Beitrag stellt ein Konzept zur Unterstützung der Bewertung von unterschiedlichen Lieferanten während der Planungsphase vor.

A model to assess the sustainability of manufacturing equipment using the example of a reusable frequency converter housing

This model shows how manufacturing equipment can be assessed according to its global warming potential. A model to evaluate, compare and therefore to enable a more sustainable production is shown. With the use of this model automotive production planners can improve the transparency for sustainable solutions. In addition, the example of a reusable frequency converter housing for conveyor technologies is presented. The main focus within the assessment is on raw material, product cycles and their ecologic and economic effects on the assessment results. It is shown that the end of life phase has a great influence on the overall carbon footprint of manufacturing equipment. Furthermore, ecologic and economic saving potentials suggest to establish new business models integrating the exploitation of used equipment.

Der modulare Lebenszykluskosten-Baukasten

Kurzfassung Durch den permanenten Kostendruck fokussieren sich Unternehmen zunehmend auf Folgekosten der Produktion. Gerade in einer komplexen Produktionsumgebung der Automobilindustrie spielt die Kostenbeherrschung entlang des Lebenszyklus eine wichtige Rolle. Die Berechnung der Lebenszykluskosten stellt dabei eine große Herausforderung dar, da aktuelle Normen hierzu nur unzureichend Methoden beschreiben. Der folgende Ansatz des modularen Lebenszykluskosten-Baukastens stellt eine Strukturierung von Methoden zur Kostenbewertung vor.

Energy Planning of Manufacturing Systems with Methods-Energy Measurement (MEM) and Multi-Domain Simulation Approach

Energy costs play a decisive role in the operation costs of automotive production companies. Therefore, energy planning in an early conception and planning stage becomes an important topic. This is because the early conception and planning stage has the greatest potential to influence the energy consumption of manufacturing technologies since about 70-80 % of the energy costs are committed during this stage. However, lifetime cost and specifically energy consumption are currently not a determining factor at this stage. The reason is that the prediction of energy costs for complex manufacturing systems are challenging. Previous research approaches in the area of energy planning are limited to detailed planned production. A standardized approach to determine the energy consumption rates at an early stage does not exist. In this context, the EffiPLAS project has therefore proposed to solve this challenge. The aim of this project is to develop a Methods-Energy Measurement approach with elementary energy elements to support the planning process at an early stage, and to develop a modular simulation model for calculating the energy consumption of industrial robots, which complements the energy prediction. In this paper, the basic concept of elementary energy units and their value determination techniques is presented, and the simulation model is outlined. The developed approach will help to predict the prospective energy consumption of complex production equipment so that energy costs can be accounted for in an improved manner within a life-cycle costing comparative analyses.