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Eco-efficiency in the aerospace industry
Gonçalo Cardeal (IST)
Innovation Takes Off
2018 International Workshop for Global Sustainability. October 23, The Research Triangle Region of North Carolina
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Mass Production
Introduction
With the fast increase in number of planned satellite launches, the need for mass production is becoming more evident.
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Introduction
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INDUSTRIAL LEADER
CORE PARTNERS
R&D Leader
Key Partners
PASSARO
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Objectives
• Methodologies and tools for eco-efficient design or re-adaptation of production facilities based on co-evolving product-process-production systems.
• Improve resources utilization, increase productivity, energy efficiency and reduction of waste in the factories.
• Simulation tools for assessing both environmental and economic costs linked with the use of renewable materials and energy resources, as well as technologies to guide decision making.
Concept
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Multidimensional Design Assessment Model
Multidimensional Design Assessment Model
Domains of Process Design
Eco-efficiencyCostsResource Efficiency
Operational Performance
Economical Dimension
Environmental Dimension
Non-value addedValue added
Integration
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Eco-efficiencyProduct/Service Value
Environmental Influence=
7 Principles
Reduce the material intensity
Reduce energy intensity
Enhance recyclability
Reduce dispersion of toxic substances
Increase service intensity
Extend product durability
Maximize use of renewable resources
Eco-efficiency: Goal and Scope
Eco-efficiency core measurements suggest a paradigm: DOING MORE WITH LESS.
Methodologies and tools
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Eco-efficiency: EcoPROSYS
Life Cycle Impact Assessment
Scope & Data Collection
Cost & Value Assessment
Environmental Performance Evaluation
KEPI Eco-efficiencyIndicators
Cost & Value Data
Environmental Profile
Eco-efficiencyRatios Value Profile
Con
tinuo
us Im
prov
emen
t
Indicators
Profile
Methodologies and tools
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Efficiency: Multi-Layer Stream Mapping (MSM)
Value Stream Mapping (VSM) with application of Lean PrinciplesPillar 1: Assess Value Addition versus not adding value
Evaluating Variables (KPI) via efficiency ratios
Pillar 2: Systematic evaluate variables through efficiency
ratios
Calculate overall efficiency of processes/systems (bottom-up analysisPillar 4: Aggregate efficiency of unit processes (columns) and the variables (lines)
Visual ManagementPillar 3: Apply simple methodologies of Visual Management
Methodologies and tools
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Efficiency: MSM Results
Methodologies and tools
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Integrated efficiency framework
OF
FLIN
E (
“Gre
enfield
”, “
In S
itu
”) a
nd
ON
LIN
E (
Monitoring)
Assesm
ents
LEAN THINKING &
Manufacturing
PDCA, VSM, etc.
Resource,
Operations, Flow
Efficiency
Environmental
LCA, EPA
Eco-Efficiency
Economical
Value,
Cost, LCC
EFFICIENCY FRAMEWORK
http://maestri-spire.eu
Methodologies and tools
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Integrated DMU (Digital Mock Up)3D environment
Integration with LCA framework
Data
Core Partner PASSARO
AssemblyProcesses
&Resources
PPRProductProcessResource
Case Study
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KPIs
Integrated DMU 3D environment
Partner INEGI+ISQ
Integration with LCA framework
AssemblyProcesses
&Resources
PPRProductProcessResource
Case Study
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Data input
Build process
Phase/station
Operation
Task
JigTool
kW consumptionTime of use
Consumablesurface of use
lengthweight
Number of holes, nuts, screws, stickers, etc.
Operator#
Time
VA NVA
Results
Resource
Costs
Environmental dimension (Pt)
Operational Performance
Eco-efficiency[Total; VA; NVA]Efficiency
Economical dimension
VA NVA VA NVA VA NVA
Case Study
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Resource Efficiency
Eco-efficiency
Operacional Performance
Costs
Effi1 % Effi2 % Effi3 % Effi %
EE1 % EE2 % EE3 %
Per1 % Per2 % Per3 %
C1 % C2 % C3 %
AS1 % AS2 % AS3 % GlobalPerformance
EE %
Per %
C %
LDfX domains – AssemblyProcess design
Effi1 %
EE1 %
Per1 %
C1 %
Define the “ratios” and Functional and
Hierarchical perspective RAW DATA
0 – Operational KPIs
1 – Tactical KPIs
2 – Strategic KPIs
Board/top management
Middle management
workers
0 – Machine/Equipment
1 - Section
2 – Line/Product
3 – Department
4 – Company
5 – Group
“Equipment effi”
Case Study
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3D virtual process design
Measure time and resource consumption
Assess efficiency, eco-efficiency & costs
Assembly process in real world
Real world Assess efficiency, eco-efficiency & costs
Analyse Virtual vs. Real world results
Available Assembly means per Asub
Fine tune Virtual assessment (β)
Case Study - Workflow
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Next Steps
• Develop and integrate the digital mock up,
• Test the methodology with simulated data in a virtual scenario,
• Compare the results with a real case scenario,
• Expand the methodology to other assembly lines,
Conclusion