Abstract
Nowadays achieving sustainable development is a global concern. The issue of unsustainability can be related to population growth and excessive consumption of natural resources. To tackle these issues, several management tools and methodologies have been developed in the last years, to assess, analyse and improve the environmental and economic performance of production systems. This work presents an approach based value stream mapping in order to assess and improve energy efficiency, environmental performance and financial performance of a production system. The developed approach can be applied to any industry or production system, where all the unit processes involved are identified and the inputs/outputs of each unit system quantified and easily perceived. Key environmental performance indicators and the corresponding eco efficiency ratios arise as outcomes of this approach, in which a Multi Layer Stream Mapping (MSM) with visual management attributes is created
Growth, supply chain, new applications: inverter industry is about to redefine itself.
The inverter market is heavily application dependent. However, there are some cross-fertilization trends — companies with a good position within one inverter market segment are researching entry into other segments. Companies like Alstom, ABB, Ingeteam, Siemens, and General Electric already offer products in two or more inverter segments.
Some players have chosen vertical integration to optimize their internal cost structure to better target commodity-like markets, as well as to meet the severe cost requirements of the automotive industry. Other players have bet on horizontal integration to offer complete solutions to customers.
Growth, supply chain, new applications: inverter industry is about to redefine itself.
The inverter market is heavily application dependent. However, there are some cross-fertilization trends — companies with a good position within one inverter market segment are researching entry into other segments. Companies like Alstom, ABB, Ingeteam, Siemens, and General Electric already offer products in two or more inverter segments.
Some players have chosen vertical integration to optimize their internal cost structure to better target commodity-like markets, as well as to meet the severe cost requirements of the automotive industry. Other players have bet on horizontal integration to offer complete solutions to customers.
Using Multi-layer Stream Mapping to assess the overall efficiency and waste o...António J. Baptista
Multi-layer Stream Mapping (MSM) is a new methodology used to assess the efficiency of unit processes within any given production system, and also for the evaluation of its overall performance. The MSM® has an intrinsic connection with the lean tool Value Stream Mapping, but introduces disruptive modifications, since it seeks a straightforward analysis for evaluating the value added and non-value added (waste) components of a given process and its integration amongst the production sequence. The method assesses if resource variables and process variables are used/optimized to their full potential (strictly between 0% and 100%). The costs related with misuses/inefficiency situations are also quantified and integrated in a simplified form. A real case study applying the MSM® method is presented regarding a Medium Density Fiberboard (MDF) finishing line. Operations as “sanding”, “trimming” and “packaging stages” are addressed. For this study all the resources and materials consumed in each unit process where considered. The overall efficiency of the finishing line was assessed and improvements actions were evaluated.
Life cycle assessment and simulation enablers of sustainable product designeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Life cycle assessment of construction materials using eio lcaeSAT Journals
Abstract
As per the growing demands of wireless communication there is enormous new technologies participating to make sophisticated environment for an end user. In a recent survey of International Telecommunication Union (ITU) it was found that the number of mobile phone subscribers has exceeds seven billion subscriptions at the end of 2014 using more than 10 to 15 internet utility apps which is more than the entire population of planet. To serve this increasing number and size of wireless communication system the German physicist – Harald Haas proposed a “Li–Fi technology” which he calls “Data through illumination” or “D-Light”. Li-Fi is a new approach of VLC which has much more similar working of a OFC communication system providing data rates of ten’s of Gbps. In this technology data is interpreted by the LED’s ON/OFF concepts.
This paper gives a brief focus on Li-Fi technology, it’s working principal, some misconceptions about Li-Fi and related researches like Nobel Prize winning Blue Light emitting diode, Optoelectronic integrated circuit (OEIC) receiver, etc.
Keywords: Li- Fi, VLC, Visible light communication, photo detector, optoelectronic integrated circuit, OEIC receiver, AP.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
An Optimization-LCA of a Prestressed Concrete Precast Bridge► Victor Yepes
The construction sector is one of the most active sectors, with a high economic,
environmental and social impact. For this reason, the sustainable design of structures and buildings
is a trend that must be followed. Bridges are one of the most important structures in the construction
sector, as their construction and maintenance are crucial to achieve and retain the best transport
between different places. Nowadays, the choice of bridge design depends on the initial economic
criterion but other criteria should be considered to assess the environmental and social aspects.
Furthermore, for a correct choice, the influence of these criteria during the bridge life-cycle must
be taken into account. This study aims to analyse the life-cycle environmental impact of efficient
structures from the economic point of view. Life-cycle assessment process is used to obtain all the
environmental information about bridges. In this paper, a prestressed concrete precast bridge is
cost-optimized and afterwards, the life-cycle assessment is carried out to achieve the environmental
information about the bridge.
A software algorithm/package for control loop configuration and eco-efficiencyISA Interchange
Software is a powerful tool to help us analyze industrial information and control processes. In this paper, we will show our recently development of a software algorithm/package which can help us select the more eco-efficient control configuration. Nowadays, the eco-efficiency of all industrial processes/plants has become more and more important; engineers need to find a way to integrate control loop configuration and measurements of eco-efficiency. The exergy eco-efficiency factor; a new measure of eco-efficiency for control loop configuration has been developed. This software algorithm/package will combine a commercial simulator, VMGSim, and Excel together to calculate the exergy eco-efficiency factor.
Decentralised PI controller design based on dynamic interaction decoupling in...IJECEIAES
An enhanced method for design of decenralised proportional integral (PI) controllers to control various variables of flotation columns is proposed. These columns are multivariable processes characterised by multiple interacting manipulated and controlled variables. The control of more than one variable is not an easy problem to solve as a change in a specific manipulated variable affects more than one controlled variable. Paper proposes an improved method for design of decentralized PI controllers through the introduction of decoupling of the interconnected model of the process. Decoupling the system model has proven to be an effective strategy to reduce the influence of the interactions in the closed-loop control and consistently to keep the system stable. The mathematical derivations and the algorithm of the design procedure are described in detail. The behaviour and performance of the closed-loop systems without and with the application of the decoupling method was investigated and compared through simulations in MATLAB/Simulink. The results show that the decouplers - based closedloop system has better performance than the closed-loop system without decouplers. The highest improvement (2 to 50 times) is in the steady-state error and 1.2 to 7 times in the settling and rising time. Controllers can easily be implemented.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
Design-for-X (DfX) approaches are of great importance to support sustainable development of new products, since the goal of DfX practices is to improve life cycle cost, life cycle environmental performance, increase design flexibility, manufacturing efficiency, etc. Therefore DfX supports a better decision-making process whenever a new complex product is being developed. In this work the new Lean Design-for-X (LDfX) approach is presented embracing the principles of Lean Product Development and Modular Design, for a systematic applicability by design engineers and product managers, assessing the effectiveness and efficiency of a given product design. An LDfX index metric, ranging between 0-100%, and original scorecard were created for consistent decision support for the comparison of different design concepts or products, integrating different “X” domains. The approach was applied in a real design study of a machine tool (press-brake), integrating Ecodesign principles, Design for Structural Optimization and Modular Design.
XVI SIMPÓSIO LUSO-ALEMÃO DE ENERGIA
„EFICIÊNCIA ENERGÉTICA, INCLUINDO ENERGIAS RENOVÁVEIS, NA INDÚSTRIA”
4 de julho de 2017 às 9h00 - 17h30 / SANA Malhoa Hotel em Lisboa
A Relevância da Eficiência Energética no Âmbito da Indústria 4.0
António Baptista, - INEGI-Instituto de Engenharia Mecânica e Gestão Industrial
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Using Multi-layer Stream Mapping to assess the overall efficiency and waste o...António J. Baptista
Multi-layer Stream Mapping (MSM) is a new methodology used to assess the efficiency of unit processes within any given production system, and also for the evaluation of its overall performance. The MSM® has an intrinsic connection with the lean tool Value Stream Mapping, but introduces disruptive modifications, since it seeks a straightforward analysis for evaluating the value added and non-value added (waste) components of a given process and its integration amongst the production sequence. The method assesses if resource variables and process variables are used/optimized to their full potential (strictly between 0% and 100%). The costs related with misuses/inefficiency situations are also quantified and integrated in a simplified form. A real case study applying the MSM® method is presented regarding a Medium Density Fiberboard (MDF) finishing line. Operations as “sanding”, “trimming” and “packaging stages” are addressed. For this study all the resources and materials consumed in each unit process where considered. The overall efficiency of the finishing line was assessed and improvements actions were evaluated.
Life cycle assessment and simulation enablers of sustainable product designeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Life cycle assessment of construction materials using eio lcaeSAT Journals
Abstract
As per the growing demands of wireless communication there is enormous new technologies participating to make sophisticated environment for an end user. In a recent survey of International Telecommunication Union (ITU) it was found that the number of mobile phone subscribers has exceeds seven billion subscriptions at the end of 2014 using more than 10 to 15 internet utility apps which is more than the entire population of planet. To serve this increasing number and size of wireless communication system the German physicist – Harald Haas proposed a “Li–Fi technology” which he calls “Data through illumination” or “D-Light”. Li-Fi is a new approach of VLC which has much more similar working of a OFC communication system providing data rates of ten’s of Gbps. In this technology data is interpreted by the LED’s ON/OFF concepts.
This paper gives a brief focus on Li-Fi technology, it’s working principal, some misconceptions about Li-Fi and related researches like Nobel Prize winning Blue Light emitting diode, Optoelectronic integrated circuit (OEIC) receiver, etc.
Keywords: Li- Fi, VLC, Visible light communication, photo detector, optoelectronic integrated circuit, OEIC receiver, AP.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
An Optimization-LCA of a Prestressed Concrete Precast Bridge► Victor Yepes
The construction sector is one of the most active sectors, with a high economic,
environmental and social impact. For this reason, the sustainable design of structures and buildings
is a trend that must be followed. Bridges are one of the most important structures in the construction
sector, as their construction and maintenance are crucial to achieve and retain the best transport
between different places. Nowadays, the choice of bridge design depends on the initial economic
criterion but other criteria should be considered to assess the environmental and social aspects.
Furthermore, for a correct choice, the influence of these criteria during the bridge life-cycle must
be taken into account. This study aims to analyse the life-cycle environmental impact of efficient
structures from the economic point of view. Life-cycle assessment process is used to obtain all the
environmental information about bridges. In this paper, a prestressed concrete precast bridge is
cost-optimized and afterwards, the life-cycle assessment is carried out to achieve the environmental
information about the bridge.
A software algorithm/package for control loop configuration and eco-efficiencyISA Interchange
Software is a powerful tool to help us analyze industrial information and control processes. In this paper, we will show our recently development of a software algorithm/package which can help us select the more eco-efficient control configuration. Nowadays, the eco-efficiency of all industrial processes/plants has become more and more important; engineers need to find a way to integrate control loop configuration and measurements of eco-efficiency. The exergy eco-efficiency factor; a new measure of eco-efficiency for control loop configuration has been developed. This software algorithm/package will combine a commercial simulator, VMGSim, and Excel together to calculate the exergy eco-efficiency factor.
Decentralised PI controller design based on dynamic interaction decoupling in...IJECEIAES
An enhanced method for design of decenralised proportional integral (PI) controllers to control various variables of flotation columns is proposed. These columns are multivariable processes characterised by multiple interacting manipulated and controlled variables. The control of more than one variable is not an easy problem to solve as a change in a specific manipulated variable affects more than one controlled variable. Paper proposes an improved method for design of decentralized PI controllers through the introduction of decoupling of the interconnected model of the process. Decoupling the system model has proven to be an effective strategy to reduce the influence of the interactions in the closed-loop control and consistently to keep the system stable. The mathematical derivations and the algorithm of the design procedure are described in detail. The behaviour and performance of the closed-loop systems without and with the application of the decoupling method was investigated and compared through simulations in MATLAB/Simulink. The results show that the decouplers - based closedloop system has better performance than the closed-loop system without decouplers. The highest improvement (2 to 50 times) is in the steady-state error and 1.2 to 7 times in the settling and rising time. Controllers can easily be implemented.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
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Design-for-X (DfX) approaches are of great importance to support sustainable development of new products, since the goal of DfX practices is to improve life cycle cost, life cycle environmental performance, increase design flexibility, manufacturing efficiency, etc. Therefore DfX supports a better decision-making process whenever a new complex product is being developed. In this work the new Lean Design-for-X (LDfX) approach is presented embracing the principles of Lean Product Development and Modular Design, for a systematic applicability by design engineers and product managers, assessing the effectiveness and efficiency of a given product design. An LDfX index metric, ranging between 0-100%, and original scorecard were created for consistent decision support for the comparison of different design concepts or products, integrating different “X” domains. The approach was applied in a real design study of a machine tool (press-brake), integrating Ecodesign principles, Design for Structural Optimization and Modular Design.
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„EFICIÊNCIA ENERGÉTICA, INCLUINDO ENERGIAS RENOVÁVEIS, NA INDÚSTRIA”
4 de julho de 2017 às 9h00 - 17h30 / SANA Malhoa Hotel em Lisboa
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LCE 2016 BERLIN - ecoPROSYS Presentation by A.J. BaptistaAntónio J. Baptista
Abstract
Assessing eco-efficiency performance of a production system is of great importance, since such assessment enables one to make an informed decision concerning economic and environmental performance of elementary systems within industrial productions systems. The framework presented in this paper is based on the eco-efficiency principles and four cornerstones i) Data inventory, ii) Environmental performance evaluation, iii) Environmental impact assessment and iv) Cost models/Value data. The Eco-Efficiency Integrated Methodology for Production Systems (ecoPROSYS) approach relies on the use of a systematized and organized set of indicators easy to understand/analyse promoting continuous improvement and a more efficient use of resources and energy. The goal is to assess eco-efficiency performance in order to support decision and enable the maximization of product/processes value creation and minimization of environmental burdens. The methodology was applied to a Medium Density Fibreboard (MDF) finishing line. The results of the study intent to validate the applicability of ecoPROSYS. The caste study showed that the cutting and the feeding table have superior eco-efficiency performance while packing and sanding have lower eco-efficiency performance. The presented framework is a powerful tool that can be used to identify and quantify key variables, assess alternative scenarios, evaluate environmental aspects, environmental influence and assess unit processes and overall eco-efficiency performance.
The described methods and tools were developed in order to assess the overall efficiency of a project, or group of projects, based in lean principles and in the novel framework MSM –Multi-layer Stream Mapping. The approach is proving to be a very powerful tool towards an easy and intuitive interpretation of KPI metrics of aggregated efficiency in project management. Since the number of KPI is not restricted, and should be set accordingly to the management rules of each organization, it can also be of great usefulness to handle the common trade-offs that exist in project management so that the project manager can see the consequences of a decision that puts more emphasis on one aspect of management, possibly neglecting other aspects. The proposed approach facilitates ways to compare groups of projects, as for portfolio management or multi-project management. In this type of analysis the approach present by itself a new kind of simple dashboard evaluation that can be both used by top-management, middle management, and also by the collaborators.
The other methods and tools, related to team management such as the described skill/intrinsic motivation matrix and radar charts are proving to be, not only popular within the project teams, but are also effective and positive to improve team motivation, identifying skill needs for project execution, decision support for training events and even to discover hidden talents.
A novel approach for product lifecycle management of mechatronic equipment in...António J. Baptista
The need for increased complexity of mechatronics equipment and products, along with intense worldwide competition, induce companies to increase their performance all along the life cycle of their products. Thus, it becomes essential to manage product information with increased effectiveness and efficiency. Different types of Product Lifecycle Management (PLM) tools can be found in the market, nevertheless, these solutions tend to be complex, costly, and inflexible for Small and Medium Enterprises (SME). To overcome this issue, a new methodological approach named PLM4all we developed together with a supporting “product lifecycle management toolbox”. PLM4all is easily customizable and oriented to the needs of SME. It is focused on the critical product lifecycle phases, processes, activities and tasks. Furthermore, it embraces lean thinking principles, thus focusing effort on the critical value-generating activities, i.e., integrating just the essential processes, thus discarding full CAD, ERP, PDM systems integration, which tend to be very cumbersome for SME. PLM4all toolbox includes IT components to manage the product lifecycle activities and a set of stubs connectors between the different ERP and CAD systems that ensure information consistency and integrity. The software-based platform also provides methodological contents (recommendations, best practices, etc.) and templates to support the implementation of the product’s life cycle key phases.
Ingenium 144 - Multi-Layer Stream Mapping (MSM), Revista Ordem Engenheiros António J. Baptista
Artigo (1página) sobre a inovadora ferramenta MSM (by INEGI) publicado na revista INGENIUM da Ordem dos Engenheiros, o qual foi apresentado no Congresso XX.
O Multi-Layer Stream Mapping (MSM) foi desenvolvido pelo INEGI, assume-se como uma inovadora metodologia Lean para a avaliação da eficiência total de sistemas e poder induzir um espírito de melhoria contínua mais intuitivo e visualizando mais facilmente valor / desperdício. O MSM tem como base inspiradora o conceito e ferramenta Lean Value Stream Mapping (VSM), explorando as virtudes de avaliar sistematicamente o binómio valor-desperdício, em múltiplas variáveis e camadas, mas de modo integrado, com vista à avaliação agregada da eficiência de sistemas (produtivos ou de serviços).
Lean Management Methods in Product Development – A Case Study António J. Baptista
Lean Management Methods in Product Development – A Case Study
Advances in Sustainable and Competitive Manufacturing Systems
Lecture Notes in Mechanical Engineering 2013, pp 1385-1399.
23rd International Conference on Flexible Automation & Intelligent Manufacturing (FAIM 2013)
http://link.springer.com/chapter/10.1007%2F978-3-319-00557-7_112
Daniel Soares 1, João Bastos 2,3, Diana Gavazzo 1, João Paulo Pereira 1 and A.J. Baptista 1
1 INEGI – Instituto de Engenharia Mecânica e Gestão Industrial Faculdade de Engenharia da Universidade do Porto Porto, Portugal
2 INESC TEC Faculdade de Engenharia da Universidade do Porto Porto, Portugal
3 ISEP Instituto Superior de Engenharia do Instituto Politécnico do Porto Porto, Portugal
ABSTRACT
The current reality of intense competition has forced many companies to increase their performance and competitive advantages by pursuing innovation and improving and streamlining internal methods of designing products and processes. With shortening of product life cycle, in order for companies to survive, the need for a continuous stream of multiple innovations over time has arisen. However, the resources consumed by companies, whilst developing a product or process, are increasingly high, even in integrated approaches, and often the finished product or process arrives too late to provide the company with an edge over its competitors. Due to the large impact Lean philosophy has had in recent decades, within the manufacturing area, through the increase of efficiency and generation of continuous improvement, more companies have progressively applied Lean methods in their units of product and process development. This paper seeks to present a reference model for Lean implementation in the areas of product and process development in order to support companies in their path to streamline and make their innovative processes more efficient. The proposed reference model includes a concrete case study example that helps to explain the main concepts behind the proposed approach.
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Incremental Volumetric Remapping Method - Analysis and Error EvaluationAntónio J. Baptista
Incremental Volumetric Remapping Method: Analysis and Error Evaluation
A.J. Baptista 1, J.L. Alves 2, M.C. Oliveira 1, D.M. Rodrigues 1, L.F. Menezes 1
1 CEMUC, University of Coimbra, Pólo II, Rua Luís Reis Santos, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
2 Department of Mechanical Engineering, University of Minho, Campus de Azurém, 4800-058 Guimarães, Portugal
Abstract. In this paper the error associated with the remapping problem is analyzed. A range of numerical results that assess the performance of three different remapping strategies, applied to FE meshes that typically are used in sheet metal forming simulation, are evaluated. One of the selected strategies is the previously presented Incremental Volumetric Remapping method (IVR), which was implemented in the in-house code DD3TRIM. The IVR method fundaments consists on the premise that state variables in all points associated to a Gauss volume of a given element are equal to the state variable quantities placed in the correspondent Gauss point. Hence, given a typical remapping procedure between a donor and a target mesh, the variables to be associated to a target Gauss volume (and point) are determined by a weighted average. The weight function is the Gauss volume percentage of each donor element that is located inside the target Gauss volume. The calculus of the intersecting volumes between the donor and target Gauss volumes is attained incrementally, for each target Gauss volume, by means of a discrete approach. The other two remapping strategies selected are based in the interpolation/extrapolation of variables by using the finite element shape functions or moving least square interpolants. The performance of the three different remapping strategies is address with two tests. The first remapping test was taken from a literature work. The test consists in remapping successively a rotating symmetrical mesh, throughout N increments, in an angular span of 90º. The second remapping error evaluation test consists of remapping an irregular element shape target mesh from a given regular element shape donor mesh and proceed with the inverse operation. In this second test the computation effort is also measured. The results showed that the error level associated to IVR can be very low and with a stable evolution along the number of remapping procedures when compared with the other two methods. Besides, the method proved to be very robust even in critical remapping situations such as poor geometrical definition of the mesh domain boundaries.
Keywords: Remapping, Mesh Transfer Operator, Numerical Simulation, Deep-Drawing, Error Evaluation, Incremental Volumetric Remapping.
Numerical Simulation of Multi-Step Deep-Drawing Processes-Trimming 3D Solid F...António J. Baptista
Numerical Simulation of Multi-Step Deep-Drawing Processes: Trimming 3D Solid Finite Element Meshes
A.J. Baptista, J.L. Alves, M.C. Oliveira, D.M. Rodrigues, L.F. Menezes
The implemented strategy of DD3TRIM consists firstly, to evaluate the elements that are to be eliminate/keep with the trimming and then adjust the remaining affected elements of the boundary to the desired trim geometry. This adjustment is done by node stretching technique for two different projection schemes with optimization of the final element shape at the boundary. Additionally, a splitting option is also introduced which allows, for instance, to open rings or other closed meshes. The implemented solutions were tested in the simulation of a multi-step deep-drawing benchmark test that consists on cutting a ring specimen from a drawn cup and then splitting it longitudinally along a radial plan. The process consists in a sequence of drawn, spring-back, trimming, splitting and final springback. All this steps were simulated with the DD3 family codes (DD3IMP, DD3OSS and DD3TRIM). In this example application problem, both algorithms (trimming and splitting) have show good reliability to treat the meshes during the multi-stage processes.
http://www.ctresources.info/ccp/paper.html?id=3713
António Baptista - A.J. Baptista PhD value and compensation António J. Baptista
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FIA officials brutally tortured innocent and snatched 200 Bitcoins of worth 4...
MSM - Multi-Layer Stream Mapping as a Combined Approach for Industrial Processes Eco-efficiency Assessment
1. 1PRODU[T]ECH
AUTOMOBILE AND TRANSPORT
AERONAUTICS, SPACE AND DEFENCE
HEALTH
SEA ECONOMY
ENERGY
EQUIPMENT AND DURABLE GOODS
SERVICES
ENVIRONMENT
Multi-Layer Stream Mapping as a Combined
Approach for Industrial Processes
Eco-efficiency Assessment
E.J. Lourenço1, A.J. Baptista1, J.P. Pereira1, and Celia Dias-Ferreira2
1 INEGI - Institute of Mechanical Engineering and Industrial Management,
Campus FEUP, Universidade do Porto, Porto, PORTUGAL
2 CERNAS - Research Center for Natural Resources, Environment and Society,
Campus da Escola Superior Agrária, Coimbra, PORTUGAL
Singapore 17-19 April 2013
2. 2PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
CIRP – LCE 2013 Singapore, 17-19 April 2013
CONTENTS
1. Introduction
2. Value Stream Mapping: The root for the concept
3. The Multi-layer Stream Mapping Description
4. Strengths of the MSM concept and applicability
5. Application Example
6. Conclusions and Future Work
3. 3PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Eco-efficiency
Last decades economic growth and industrialization lead to major environmental impacts
In the 90’s the World Business Council for Sustainable Development (WBCSD) defined the term
eco-efficiency, which combines ecological and economical efficiency
WBCSD developed a framework to assesses eco-efficiency in order to promote sustainable
development. The main goals are: maximize value creation (more goods/services) and minimize
environmental burdens (less resource consumption and waste creation)
Eco-efficiency measures the relationship between economic growth and environmental
pressure, and is generally expressed by the ratio between economic value and environmental
influence, represented by.
Eco-efficiency
Product or service value
Environmental Influence
4. 4PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Eco-efficiency
Eco-efficiency as a management philosophy towards sustainability can be a very useful tool to
assess environmental and economic performance and enhance the global performance of a
company or even of a production system
The framework developed by WBCSD can be used by any business to assess and measure
progress towards economic and environmental sustainability.
However, this framework lacks a simple and discrete approach in order to analyze and assess
unit processes that are part of a production system
5. 5PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Objectives
Develop a multi-variable combined use of the Value Stream Mapping (VSM) Lean Tool and
demonstrate its suitability to assess environmental and energy performance of unit
processes and production systems in a fast and flexible manner. This by mapping the unit
processes inputs and outputs and assessing their efficiency.
Demonstrate the importance of presenting environmental issues and eco-efficiency
performance in a simple manner through visual management maps and layouts, in order to
simplify top/middle management understanding of the Key Environmental Performance
Indicators (KEPI’s) and their suitability for decision making and overall awareness.
Create an approach that solves the existing eco-efficiency tools and methods that are not
always directly applicable to every product and/or production system, and often addressed
as “isolated stage analysis”.
Create a very easily understandable assessment (for all level collaborators) based in fast
visual management attributes in most methods and tools used for eco-efficiency
assessments.
6. 6PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
2. Value Stream Mapping: The root for the concept
CIRP – LCE 2013 Singapore, 17-19 April 2013
Value Added vs NON Value Added
A value stream mapping consists basically in the collection of all actions (actions that add
value and actions that do not add value) that are required to bring a product or a group of
products through the main flow, starting with the customer and ending with the raw-
material (upstream).
The primary goal of this tool is to identify all types of waste in the value stream flow and
processes in order to take actions to try and eliminate these, by analyzing the Value Stream
Map.
Example of a common VSM of a Metalworking Industry
Transport
WTS
(input)
Cleaning
WTS
Coating bolt
holes
(manually)
Mixing paint
(pneumatic
mixer)
Applying
primer coat
Drying
primary
coat
Coating
Inspection
2 2 2 2 2 2 2
VA 0,75 h 0,50 h 0,50 h 1,50 h 3,00 h 0,50 h PT 6,75 h
NVA LT 7,89 h
0,38 h 0,03 h 0,20 h 0,15 h 0,15 h 0,06 h WT 1,14 h
86%0,70 h0,53 h1,13 h0,17 h
- 66% 94% 71% 89%
Production
Time (hours)
0,56 h3,15 h1,65 h
0,17 h
91% 95%
7. 7PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
2. Value Stream Mapping: The root for the concept
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM framework combines Value Stream Layers evaluated by the waste elimination /
value creation mindset, identifying the variable part that adds value from the one that does
not add value, with detailed unit process inventory and visual management attributes
The VSM root transforms, in the MSM concept, the understanding of eco-efficiency into
something easily quantifiable, simpler, concise and directly applicable to any production
system, in a process sequence or even in compartmented units
To assess the environmental, financial and global performance of a production system (by the
composition analysis of its subparts), and identifying and quantifying the inefficiencies or
misuses, the MSM concept starts from the classic bathtub curve of Value Stream Mapping
The combined use of Value Stream Layers of a Value Stream Map emerges in order to “see
beyond” the global environmental and financial performance of a production system in a
simpler manner and enable the understanding of the eco-efficiency assessments, and at the
same time simplify the identification and quantification of specific inefficiency situations
8. 8PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM consists in replicating part of the approach used for Value Stream Mapping,
but allowing the addition of multiple layers (stream flows for each process variable) that
embrace environmental and economic aspects, or other variable, to assess eco-efficiency
VSM
MSM
ØTPi
=
PTPi
LTPi
[%]
ØEPi
=
PEPi
TEPi
[%]
ØCPi
=
PCPi
TCPi
[%]
ØXPi
=
PXPi
TXPi
[%]
9. 9PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The values located below of the MSM line are those which do not add value to the product,
i.e. representing the waste/misuses of time, money or resources
The values that are presented above the MSM line (Process Stages) are those that add value
to the product, thus representing the “useful consumption” of stream flow that can be
analyzed in order to assess, evaluate and quantify production efficiency and eco-efficiency
ØTP1
ØTPi
ØTP2
ØEP1
ØEPi
ØEP2
ØCP1
ØCPi
ØCP2
ØXP1
ØXPi
ØXP2
10. 10PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM approach considers dimensionless ratios (actual variable divided by the maximum
of the same variable, on the same process step), so the higher the result for the ratio, the
better the performance of the energy, mass or time flow or other key variable of a
process or system
The process variables, must be assigned consistently to be maximized. The analysis of
variables with the MSM is almost unlimited, for instance, the following environmental aspects
can take place as assessing variables:
Electrical energy
Raw Material
Fuel
CO2 Emissions reduction
Waste elimination
Toxic materials reduction
Beside environmental aspects, other specific cost flows can be added, i.e. cost flow lines to
assess the costs of energy consumption only, or raw material only, thus allowing to assess
specific eco-efficiency indicators (since product value and environmental influence are specific)
For a faster assess of the efficiency quantity, it was added visual management attributes by
relating a very common key of 4 colors (red, orange, yellow, green) in the positive direction of
efficiency, from 0% to 100%
11. 11PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM global efficiency dashboard (illustrative data)
Process Stream Analysis
Multi-LayerStreamMapping
Process Efficiency 100 - 90%
Process Efficiency 89 - 70%
Process Efficiency 69 - 40%
Process Efficiency <40%
12. 12PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM Strengths
The MSM approach can assess, quantify and analyze environmental aspects (energy
consumption, emissions, raw material consumption etc.), economic aspects and productions
aspects one by one for each unit process. On the other hand the global performance can be
assessed and quantified.
One key feature of the MSM approach consists in considering dimensionless ratios, so the
higher the result for the ratio, the better the performance. This feature allows the comparison
of efficiency performance of distinct variables, and combine an integrated quantification of the
overall efficiency, for instance by weighted average or product (by column or row)
The outcome and results are a diagrammatical and intuitive representation of managerial
concepts, and can be very practical and useful for:
Top management decision support
Defining priorities
Identifying inefficiencies in an easy manner
Identifying Key Environmental Performance Indicators (KEPI)
Assessing eco-efficiency performance
Identifying improvement actions needs
Informing all level of collaborators of the efficiency of the production cell or unit
13. 13PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM Strengths
This approach can also be used for process re-engineering evaluation (multi-scenarios analysis),
since in some cases the unit processes, or even the whole production system of a factory, have
good operational results, but the efficiency is not as high as it could be.
Therefore, using this approach to start point for scrutinize “where”, “how”, and “how much” can
a unit process and/or a production system improve its financial, environmental and performance
aspects, is of great importance for decision-making
It’s simplicity is one great advantage, since it allow a very fast and visual assess of multi-variable
efficiency and its integration (for instance by heighted average), simultaneously for top
management or even workers.
14. 14PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists
… and …… and …… and …… and …
LLLL1111 (line 1) = M(line 1) = M(line 1) = M(line 1) = M11111111 (machine 11) +(machine 11) +(machine 11) +(machine 11) + MMMM1i1i1i1i (machine(machine(machine(machine 1i) +…1i) +…1i) +…1i) +…
LLLL2222 (line(line(line(line 2)2)2)2) ==== MMMM21212121 (machine(machine(machine(machine 21212121) +) +) +) + MMMM2i2i2i2i (machine 2i(machine 2i(machine 2i(machine 2i) +…) +…) +…) +…
MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)
ProcessesProcessesProcessesProcesses
LinesLinesLinesLines
15. 15PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Combine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layouts
P3
60%
L1
61%
L2
62%
L3
57%
16. 16PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Integrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layouts
P3
60%
L1 L2
L3
61% 62%
57%
P2
60%
P1
90%
P4
75%
Company
71%
Lines
Plant
17. 17PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Other MSM applicationsOther MSM applicationsOther MSM applicationsOther MSM applications Wine Vineyard FarmWine Vineyard FarmWine Vineyard FarmWine Vineyard Farm
Other examples:Other examples:Other examples:Other examples:
HospitalsHospitalsHospitalsHospitals
BuildingsBuildingsBuildingsBuildings
Office units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)
Transport companiesTransport companiesTransport companiesTransport companies
etc…etc…etc…etc…
BedBedBedBed 2222
BedBedBedBed 3333
BedBedBedBed 1111
18. 18PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicators
The visual management attributes integration and its mathematical simplicity, based on the
well-known VSM lean tool, the MSM can be viewed as a promoter for the importance of
assessing, evaluating and quantifying environmental aspects of an industrial process or plant,
in order to improve global industrial performance
19. 19PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
5. Application Example
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM simplified diagramMSM simplified diagramMSM simplified diagramMSM simplified diagram
20. 20PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
6. Conclusions and Future Work
CIRP – LCE 2013 Singapore, 17-19 April 2013
Develop a mathematical approach for optimization system purposes
Study the application of the results for Life Cycle Engineering decision support, assessing
process/resource usage efficiency vs. process/resource usage eco-efficiency
Study its application in multi-product analysis
Develop data base with environmental impact (single score contribution – Pt) for major/most
common materials and energy types/flows
ConclusionsConclusionsConclusionsConclusions
Future WorkFuture WorkFuture WorkFuture Work
MSM concept, based on the lean tool VSM, brings new perspective on how eco-efficiency
assessments results can be quantified by a discreet method for a process sequence or a individual
system
It integrates strong visual management attributes and is mathematically simple (very easy to use
for all kind of stakeholders)
Very versatile and wide range concept that can be applied for multi-variable and multiple
economic activities (project management, logistics, economics, services, health care, etc.)
21. 21PRODU[T]ECH
Thank You
Multi-Layer Stream Mapping as a Combined Approach for
Industrial Processes Eco-efficiency Assessment
E.J. Lourenço, A.J. Baptista, J.P. Pereira, and Celia Dias-Ferreira
Corresponding author: abaptista@inegi.up.pt
INEGI - Institute of Mechanical Engineering and Industrial Management,
Campus FEUP, Universidade do Porto, Porto, PORTUGAL