Bernd muschard sa 12.40_sustainable manufactoring-shaping global value creation_sustainable manufactoring


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Bernd muschard sa 12.40_sustainable manufactoring-shaping global value creation_sustainable manufactoring

  1. 1. Collaborative Research Centre 1026 Sustainable Manufacturing – Shaping Global Value Creation MaketechX – 09. November 2013 Dr.-Ing. Jérémy Bonvoisin, Dipl.-Ing. Bernd Muschard CRC 1026 Sustainable Manufacturing – Shaping Global Value Creation Funded by German Research Foundation (DFG)
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  5. 5. Resource challenge Page 5
  6. 6. Resource challenge Page 6
  7. 7. Prosperity for everybody? Page 7
  8. 8. Emerging   countries   Responsible  consump9on  of  resources   Improving  quality  of  life  with  a   es   responsible  consump9on  of  resourc Quality  of  life   Acceptable  living   standard  with   responsible   consump9on  of   resources   Consump;on  of  resources   Irresponsible  development   path:  Wealth  for  all  people   relying  on  present  technologies   Acceptable  living  standard   Early   Industrialised   countries   Maintaining  the  quality  of  life  while   reducing  the  resource  consump9on   Quality of life and consumption of resources Source: [Seliger, 2010] Page 8
  9. 9. CubeFactory   Page 9
  10. 10. Learning  environment  to  promote  sustainable  value  crea9on  in   areas  with  insufficient  infrastructure   Page 10
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  12. 12. CubeFactory Page 12
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  16. 16. B6, C5, PA: CubeFactory Learnstrument Use Solar power Learning environment to promote sustainable value creation in areas of insufficient infrastructure. u  u  u  Enables user to create sustainable values Teaches a closed loop material cycle Contains all necessary infrastructure for production u  Manufacturing, energy and material supply, knowledge Manufacturing: Open Source 3D printer as sustainable machine tool to create values and as an instrument for learning Energy supply: Off-grid power supply by detachable high-efficient solar panels (200W/m2) Energy storage: Lithium iron phosphate (LiFePO4) battery with high power density Recycling Manufacturing Manufacturing Renewable resources PLA: biodegradable plastic derived from starch Designing Local  needs   Non-renewable resources ABS: recyclable plastic derived from local waste Material supply: Plastic recycler for local available materials to supply 3D printer filament Knowledge transfer: Intuitive learn and control environment to teach sustainable value creation Page 16
  17. 17. DIY  -­‐  Bicycle   Page 17
  18. 18. Living Standards Population Environmental Impacts Time  
  19. 19. Living Standards Consump;on   Pa>erns   Population Products   Environmental Impacts Time   Processes  
  20. 20. DIY   Cra?manship   Mass  produc;on   Autonomous   produc;on   Mass  produc;on  
  21. 21. Thank  you  for  your  aHen9on   Page 25
  22. 22. Backup Page 26
  23. 23. Contents u  Challenges u  Collaborative Research Centre 1026 u  CubeFactory u  DIY - Bicycle Page 27
  24. 24. Structure of the Collaborative Research Centre (CRC) 1026 Page 28
  25. 25. Global value creation Source: [Seliger, 2010] Page 29
  26. 26. Increasing the teaching and learning productivity boHom-­‐up  approach   Na;ons   Unions   Industries   Governmental  Organisa;ons   Big  Enterprizes   NGOs   Governmental   Organisa;ons   Enterprizes   Educa;onal     Ins;tu;on   Non-­‐Gonvernmental   Organisa;ons   Educa;onal  Ins;tu;ons   Schools   SMEs   Page 30
  27. 27. Depth and breadth of CRC 1026 Collabora9ve  Research  Centre  1026   Combining  the  breadth  of  systemic   reference  with  the  depth  of  produc9on   technology  to  enable  for  sustainable  value   crea9on   Page 31
  28. 28. Meeting the challenge Page 32
  29. 29. Sustainable manufacturing community I run a factory I design workplaces I design products I want a product 101011001 101011010 1   1001   10101 I do research for the CRC 1026 Sustainable     manufacturing     community  cloud   00  1011   11 01 1011 0 0   I design VCNs + + I configure VCNs + Legend: VCN: Value creation network   Page 33
  30. 30. Project Area A: Strategy development Projects   A2 Research   Life  Cycle  Aspects   Create   Parameter   Sustainability  Indicators   A3 & A4 Microeconomic  /  Macroeconomic  Assessments   A5 & A6 Technology   Assessment  and   Global   Consequences   Mathema9cal   Models  and   Solu9ons   Models   Tools   Mul9-­‐Criteria  System  Dynamics  Op9misa9on   A1 Wide  Range  of   Possible  Scenarios   Selected  Scenarios   as  tools  for  evalua;on   Technology  Pathways   Effects   Knowledge  flow   Page 34
  31. 31. Project Area B: Production technology solutions Projects   Research   Create   B1 Industrial   informa9on   technology   So?ware   tools   Virtual  Product  Crea9on   B2 & B3 Turning,  cleaning,   welding   Processes   Resource  Efficient  Produc9on  Technologies   B4 & B5 Lightweight  &  Accuracy  Improved   Machine  Tool  Structures   B6 Microsystem   technology,   adadaptronic   enhanced   structures   Value  crea9on   networks   Flexible   machine   tools   Demonstrator   Integra9on  Shop   Knowledge  flow   Page 35
  32. 32. Project Area C: Principles, methods and tools for qualification Projects   C4 & C5 Research   Educa9on   methods   Create   Learnstuments  for   individuals   Learnstruments,  Human  Oriented  Automa9on   C1 & C2 Mul9-­‐Perspec9ve  Modeling,  Intellectual   Capital  and  Knowledge  Management   C3 Strategic  Interac9on  and  Incen9ves  for   Sustainable  Economic  Ac9vity   Quality  science,   integrated   sustainabilty   repor9ng   Experimental   economics  and   macroeconomics   Models   So?ware-­‐tool  for   sustainable   management   Strategies  for  connected   economies   Effects   Page 36
  33. 33. C4 Methods for Human Oriented Automation – Approach u  Technology u  Markerless Motion capturing in industrial environment u  Automatic in-process worker ergonomics analysis using industrial standard (EAWS) u  Applications u  visual guidance for ergonomic qualification u  automated support during physical work Page 37
  34. 34. C4 Methods for Human Oriented Automation – Results 2012 u  Conception of „Human centric workplace“ for worker qualification u  Stereo camera algorithms u  Automatic ergonomics analysis using Microsoft Kinect 3D camera Page 38
  35. 35. C5 Learnstruments in value creation modules – Challenge u  Goal: Increase in Teaching and Learning Productivity for Sustainable Manufacturing through application of Learnstruments Learnstrument Development in Design for Mediation Approach Development and Selection of Learning Methods and Tools Learning Environment Learner Learning  Material   Learning  Task   Combined Learning and Working Environment Design and Application of Industrial Artifacts Working Environment Worker Equipment Work  Task   User Learnstruments Tasks User Centered Tool Development Competence Portfolio   Learning Centered Task Development Learning Cycle u  Approach: Learning and user centered design in combined learning and working environment Page 39
  36. 36. C5 Learnstruments in value creation modules – Approach Learnstruments  are  objects  which   automa;cally  demonstrate  their   func;onality  to  the  learner.  They   consist  of  aspects  of  cogni&ve   s&mula&on  and  emo&onal  associa&on   with  new  and  exis;ng  ICT  and  design   approaches  for  produc&ve  media&on.     Adapta9on  of   func;onality   and  interfaces   Technology   iden9fica9on   Combina9on   with  learning     materials  program   Page 40
  37. 37. C5 Learnstruments in value creation modules – Results 2012 Innovation and Transformation,   Active „experímenting“ Processing Skills,  Active Experimentation „Doing“ Perception Continuum Motivation,   Concrete Experience, „Feeling“ Continuum Awareness,   Reflective Observation, „Watching“ Systemic Knowledge,  Abstract Conceptualisation, „Thinking“ Cycle Strategy Learnstruments cover all aspects of the perception and processing continua for highest teaching productivity User Centered Tool Development Competence Portfolio Knowledge Learning Centered Task Development Learning Cycle qualified qualified untrained trained unqualified unqualified untrained trained Skills Portfolio Strategy: Increase error tolerance for untrained and unqualified users Page 41
  38. 38. Social challenge of use productivity of resources Limit  popula;on  growth   by  increasing    living   standards   Population Living Standards Population Time Higher  living  standards   are  sustainable    only   when  the  per  capita   resources  consump;on   decreases   Time Ecologic Constraints Living Standard Resources Consumption Time Ecologic Constraints Living  Standards Resources Consumption Time   An  increase  of  the  use-­‐ produc;vity  will  allow   for  the  desired  increase   of  the  living  standards     within  the  planets   ecological  limits   Higher  living  standards   conflict  with  ecological   limits  due  to  an   increased  consump;on   of  resources   Living Standards Use productivity of resources Population Resource Consumption Time   Source: [Seliger, 2005] Page 42
  39. 39. Challenge of resource efficiency and energy conversion u  Keeping non-renewables in product and material life cycles without disposal u  Substituting non- renewables by renewables u  Consuming renewables only to the extent that they can be regained 100% global annual primary energy resources correspond to about 500 EJ [Exajoule = 1018 Joule] or 140 PWh [Petawatt hours = 1015 Watt hours] Source: [VDI, 2010; Cullen, 2010; Seliger, 2010]   Page 43
  40. 40. Environmental challenge of consumption of renewable resources World 7.112 2.4 1.8 -0,9 Brazil 198.4 2.9 9.6 +6.7 China 1.353.6 2.1 0.9 -1,2 82.0 4.6 2.0 -2,6 India 1.258.4 0.9 0.5 -0,4 Japan 126.4 4.2 0.6 Russia 142.8 4.4 6.6 -3,6 +2.2 USA 315.8 7.2 9.6 - 3.3 Germany u  12,8 billion ha divided by 7.112 billion people: The planet‘s bio-capacity is 1.8 global ha/cap. 2   Ecological Footprint (Number of Earths) Ecological Ecological Biological Deficit (-) or Population Footprint Capacity Reserve (+) [Mio.] [global ha/ [global ha/ [global ha/ cap] cap] cap] Biological Capacity Global Ecological Footprint CO2 Share of the Global Ecological Footprint 0 1961 1970 1980 1990 2000 2008 u  Global bio-capacity of 1,8 global ha/cap equals an ecological deficit of 50 % or 1.5 earths. Source: [WWF 2012; World Bank, 2013] Page 44
  41. 41. A1 Pathways for sustainable technology development – Challenge u  Challenge u  Different requirements for different development levels u  Rapid technology development u  Lack of orientation in knowledge landscape u  Limited interdisciplinary knowledge u  Goal u  Robust technology pathways for different levels of development u  Exploit technological potentials for useful applications u  Connect technological concepts
  42. 42. A1 Pathways for sustainable technology development – Approach Technology pool Surrounding field scenarios Sustainability dimension Mobility Energy Production Functions Systems System elements Area of human living Functions Substitution Combination or Assessment System elements Specific Criteria General Criteria Conditions System creation System elements Systems Development level
  43. 43. A1 Pathways for sustainable technology development – Results 2012 u  Surrounding field scenarios u  Energy scenarios for developing countries u  Production scenarios for developing countries u  Mobility scenarios for emerging and industrialised countries u  Public transportation in Sao Paulo u  Bicycle mobility in Berlin u  Three pathways identified Technology oriented u  with existing system implemented in LEG2O machine tool u  with system element implemented in hydrogen based mobility u  Problem oriented implemented in decentralised energy supply in developing countries and cocoa mass production in developing countries u  Mobility Scenarios 2030
  44. 44. A2 Sustainability Indicator Development – Challenge u  Integration of the three dimension of sustainability u  social, environmental, & economic u  Creation of indicators for the manufacturing community u  usable at a brought field of different applications Sustainable indicators Manufacturing network Knowledge & stakeholder Porous knowledge Page 48
  45. 45. A6 System Dynamics Optimization – Approach u  Core Product: Software package „System Dynamics SCIP“ u  Branch-and-bound approach to control problems: Division of the problem into subproblems u  Solution of linearized subproblems using Simplex Method u  Page 49
  46. 46. B1 Virtual product creation in sustainable value creation networks – Challenge u  Engineering Challenges u  An engineer must consider each lifecycle phase when designing a product u  Product Design Alternatives He / she must be supported with information related to the sustainability of the product u  An approach is necessary defining u  when (process) u  how (methods) and u  by which information (decision support) the engineer can be supported in designing sustainable products Optimised Product Design Page 50
  47. 47. B1 Virtual product creation in sustainable value creation networks – Approach u  Development Process u  Analyse, modify and complement development process for creating sustainable products u  Methodology u  Analyse, combine and, if needed, modify methods for sustainable product development u  Decision Support u  Identify and combine information/knowledge u  Develop ontology for combining information u  Implement Methodology database u  Decision assistant (software) Page 51
  48. 48. B1 Virtual product creation in sustainable value creation networks – Results 2012 u  Process u  Interview partner in industry identified to analyse Product Development Processes (PDP) and discover potentials u  Collection of public PDPs u  Methodology (Database) u  Collection of Methods (110, appr. 50 sustainability related) u  Classification of Methods u  Overview on database Options u  First approach for defining goals for combining methods u  Decision Support u  First terminology as a basis for the ontology u  Analysis of ontology tools Page 52
  49. 49. B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Challenge u  Motivation u  Development of an innovative concept for machine tool frames capable of adapting to continuously varying production tasks, - requirements and - locations u  Provision of advanced functionalities of the single modules, e.g. identification, communication and distributed sensing as key requirements for hardware concept u  Challenge u  Fusion of microsystem technology (MST) based systems with machine tool (MT) components u  Alignment of use times of MST and MT components considering effects of aging, failure and innovation cycles u  Sustainability aspect u  Reconfigurable machine tool structures, allowing for a more intensive, effective use of equipment u  Flexibility and mobility of production systems through moderate module sizes u  Exchange, upgrade or repair depending on technical condition and market demands u  Implementation of EcoDesign strategies for electronics development Page 53
  50. 50. B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Approach u  Concept u  Replacement of conventional monolithic frames by lightweight, accuracy optimized and reusable frame modules u  Active and passive modules to compensate thermally and mechanically induced or structural deformations u  Microsystem technologies to provide enhanced functionalities u  Value creation u  Flexibility with respect to application scenario u  Cost reduction along with environmental improvements through more intensive and/ or prolonged use times of equipment u  New perspectives with respect to mobility, scalability and mutability of production systems Page 54
  51. 51. B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Results 2012 u  Microsystem technology concept u  Prototypical sensor system setup for first evaluation of measurement concepts and energy saving potentials u  Provision of data from distributed sensor nodes via central PC, using webserver as interface for MST/MT u  Investigation of environmental impacts of wireless sensors using indicators for toxicity and resource scarcity u  Machine tool concept u  Modules must be easy to manufacture and guarantee a repeatable and easy assembly u  Low module weight ! transportability u  Thermal, static and dynamic properties similar to monolithic frame properties u  Side length of 200.0 mm and plate thickness of 10.0 mm u  Honeycomb structure is favorable design (a) 5.17 µm 2.29 1.15 0.00 (b) Table to assess design concepts Regular cube Hexagoncomb (c) 4.88 µm 2.17 1.09 0.00 - + ++ 22.5 kg 19.5 kg 18.8 kg Welding - + - Machinability + ++ - Stiffness 7.26 µm 3.23 1.61 0.00 Weight Lightweight cube + - ++ Fill damping material + - + Deflection simulation results (a) regular cube, (b) lightweight cube (c) honeycomb Page 55