Rolf Steinhilper

Produktrecycling im Maschinenbau

Inhaltsubersicht: Abkurzungen und Formelzeichen.- Aufgabenstellung und Ziele.- Stand der Erkenntnisse.- Produktrecycling.- Entwicklung automatisierter Technologien und Einrichtungen fur Demontage- und Sortiervorgange beim Produktrecycling.- Erarbeitung von Regeln und Massnahmen zur konstruktiven Begunstigung des Produktrecycling.- Entwicklung eines rechnergestutzten Verfahrens zur kostenorientierten Mengenflussoptimierung in Austauscherzeugnisfertigungen.- Erarbeitung von Entscheidungskriterien und Planungsinstrumentarien zum Produktrecycling.- Zusammenfassung und Ausblick.- Schrifttumsverzeichnis.- Anhang.

Management des Produktlebenslaufs

Unternehmen in nachhaltig orientierten Gesellschaften konnen sich nicht mehr nur auf den okonomischen Erfolg beschranken, sondern mussen ebenso die okologischen und sozialen Folgen unternehmerischen Handelns einbeziehen. Als Ausgangspunkt dieser Entwicklung gilt die Konferenz der Vereinten Nationen im Jahr 1992 in Rio de Janeiro. Seither gewinnt eine an den Erfordernissen von Okologie, Okonomie und sozialen Standards ausgerichtete Unternehmenspolitik zunehmend an Bedeutung. Ziel ist das „nachhaltige Unternehmen“. Mit Blick auf Teilprozesse bei der Entwicklung, der Herstellung, der Nutzung und der Entsorgung von Produkten werden lediglich Suboptima bei Wertschopfungsprozessen erreicht. Ziel muss es sein, das Gesamtoptimum anzustreben. Dazu mussen kunftig alle Akteure im Zusammenhang mit der Entwicklung, der Herstellung, dem Gebrauch und der Entsorgung eines Produktes – also alle Lebenslaufpartner – zusammenarbeiten. Life Cycle Management (LCM) soll den Unternehmen ermoglichen, technische Produkte und Anlagen zukunftig uber deren gesamten Lebenslauf zu managen, um sowohl negative Umweltwirkungen von Produkten zu minimieren als auch die Wirtschaftlichkeit zu optimieren.

RFID Integrated Adaption of Manufacturing Execution Systems for Energy Efficient Production

An emerging challenge for manufacturing companies is to increase the energy efficiency of their manufacturing systems in order to reduce both energy costs and overall environmental impact. Modern manufacturing execution systems must cope with the new requirements of sustainable manufacturing in addition to the conventional focus on production management. This approach shows how the digital network of manufacturing execution systems can be used to eliminate non-value adding energy consumption in the manufacturing system. Therefore, an integrated use of workstation-related information from production schedules as well as the availability of product, operator and manufacturing equipment was developed. In particular, the advantages of the radio frequency identification technology is considered, as a decentralized information source for the manufacturing execution system for product and operator induced idle and stand-by times of production machinery.

Increasing energy efficiency by remanufacturing and reengineering

Traditionally, manufacturing companies are mainly optimising their process efficiency with lean management approaches like reducing the seven wastes. In times of rising energy and material costs due to limited primary energy and raw material availability, small and medium-sized companies (SMEs) in particular are facing the challenge to increase their energy efficiency. Analyzing the manufacturing costs of SMEs during the European research project “Methods for Efficiency” (M4E) clearly revealed that a reduction of energy costs is possible as soon as the machinery and the factory infrastructure of these companies are specifically set-up or reengineered for the purpose of energy efficiency. Hence, to enable SMEs to gain transparency in terms of the energy consumption of both their machinery and auxiliary production equipment, a proceeding was developed for assessing their energy efficiency in detail. First component-wise power measurements of the pneumatic systems, lighting and various machinery in different operation modes such as ramp-up, idle or production mode were conducted. Based on these gathered data guidelines are developed to increase the energy efficiency of manufacturing processes which use yet existing machinery and systems. This affects the energy-efficient operation as well as reengineering and remanufacturing of equipment.

New Technologies for Remanufacturing of Automotive Systems Communicating via CAN Bus

The present paper summarizes the recent methodologies, technologies, results and opportunities in the field of analyzing and extending the life cycle of automotive systems by remanufacturing that have been developed within the European research project “CAN REMAN”, conducted by Bayreuth University in cooperation with two other universities and eight industrial partners. The aim of this project is to develop appropriate and affordable testing and diagnostics technologies that enable small and medium sized enterprises (SME) to remanufacture mechatronic vehicle components.

Managing Complexity in Remanufacturing Focusing on Production Organisation

Due to individual requirements of economic actors, remanufacturing companies face the challenge of an increasing variety as well as the associated complexity. Therefore, a successful complexity management, created upon detailed knowledge of drivers and effects, is necessary. To close the lack of knowledge, the main complexity drivers and effects within the production organisation of remanufacturing companies are identified. Furthermore, common optimisation methods to manage this drivers and effects are assessed and the best ranked methods are shown within this paper. For the complexity effects, which occur the most and with a low number of available optimisation methods, new methods are presented.

Total Cost and Environmental Impact of Ownership : TCEIO

Kurzfassung Steigende Kundenansprüche und kürzer werdende Produktlebenszyklen stellen hohe Anforderungen an die Fertigungsverfahren. Die Auswahl und Bewertung von Fertigungsverfahren und der zugehörigen Maschinen erfolgt in produzierenden Unternehmen bislang überwiegend nach wirtschaftlichen Aspekten. Verstärktes Umweltbewusstsein sowie eine zunehmend strengere Umweltgesetzgebung führen aber dazu, dass auch die ökologischen Aspekte bei der Auswahl in den Fokus rücken. Doch in der Praxis fehlt es noch an einem Investitionsbewertungsverfahren, das beide Aspekte berücksichtigt. Deshalb beschreibt dieser Artikel mit dem TCEIO-Ansatz (Total Cost and Environmental Impact of Ownership) eine praxisorientierte ökonomisch-ökologische Bewertungsmethode, die beiden Aspekten Rechnung trägt.

Development of a Procedure for Energy Efficiency Evaluation and Improvement of Production Machinery

A major and growing challenge for manufacturing companies is to increase the energy efficiency of their production machinery in order to reduce both their energy costs and their overall environmental impact. Established approaches either focus on optimizing the base line energy consumption of auxiliary production infrastructure, or directly target the optimization of value creating processes like special machine tools. In practice, heterogeneous machinery in operation requires a procedure to prioritize which machine should be improved first. Hence a decision support procedure based on multiple criteria was developed and implemented during a use case. This system combines machine data, production process information and the evaluation of expert knowledge and energy consumption measurements.

Economically optimal non-destructive and destructive sampling inspection by attributes within the production

To avoid that defective units reach downstream production stages and cause a considerable amount of costs, quality control steps must be implemented. However, quality control steps cause further costs. Implemented sampling inspections are an opportunity to check the quality of lots within the production. In order to keep the costs to a minimum, the production planning must determine sample plans which incur the lowest costs. Due to the high number of different parameters and possible sample plans, this determination is extremely complicated. In order to deal with this issue, a tool to determine the economically optimal sample plan for destructive and nondestructive sampling inspection by attributes was developed. This paper describes the development of the tool as well as the procedure of the tool. The development is based on various sampling inspection related key figures and the international standard ISO 2859.

Analyzing the active power of variable frequency drives in manufacturing plants

In multi-axis machining centers the individual operating loads of axis and spindle drives are often unknown. Especially in serial production, drive systems are oversized including electric motors, frequency inverters and shaft drives. But also in special plant engineering, where multiple drive systems are connected to one intermediate circuit, the individual operating loads cannot be assessed. Subsequently, performance, operating points and energy efficiency are suboptimal. Economic disadvantages, such as the necessity of higher investments and increased operational costs, are associated. Therefore an approach to active power measurement behind the frequency inverter to separate the power consumption profiles of spindle and axis drives is necessary. In this paper two systems for an active power measurement for variable frequency drives are discussed. One of them has been developed by the authors themselves with the advantage of lower cost compared to commercially available systems. The systems were analyzed for performance, accuracy, installation effort and costs. The investigated active power measurement systems provide basic data for an optimal dimensioning of drive systems for industrial equipment manufacturers.