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)

2. Page 2

3. Page 3

4. Page 4

5. Resource challenge
Page 5

6. Resource challenge
Page 6

7. Prosperity for everybody?
Page 7

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. CubeFactory
Page 9

10. Learning
environment
to
promote
sustainable
value
crea9on
in
areas
with
insufficient
infrastructure
Page 10

11. Page 11

12. CubeFactory
Page 12

13. Page 13

14. Page 14

15. Page 15

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. DIY
-­‐
Bicycle
Page 17

18. Living Standards
Population
Environmental Impacts
Time

19. Living Standards
Consump;on
Pa>erns
Population
Products
Environmental Impacts
Time
Processes

24. DIY
Cra?manship
Mass
produc;on
Autonomous
produc;on
Mass
produc;on

25. Thank
you
for
your
aHen9on
Page 25

26. Backup
Page 26

27. Contents
u Challenges
u Collaborative Research Centre 1026
u CubeFactory
u DIY - Bicycle
Page 27

28. Structure of the Collaborative Research Centre (CRC) 1026
Page 28

29. Global value creation
Source: [Seliger, 2010]
Page 29

30. 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

31. 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

32. Meeting the challenge
Page 32

33. 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

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. 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

47. 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

48. 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

49. 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

50. 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

51. 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

52. 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

53. 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

54. 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

55. 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