Download - York University – Continuous Improvement Conference June 2015 Dr Richard Court – Centre for REMS
York University – Continuous Improvement ConferenceJune 2015
Dr Richard Court – Centre for REMS
Resource Efficiency of Processes – Lessons from Industry
Workshop OutlinePresentation and scene setting (10 minutes)Demonstration of modelling technique – improvements to an
industrial system (15 minutes)Examples of possible applications in a University setting (5
minutes)Discussion & interactive session (15 minutes)
Presentation & Scene SettingCentre for Resource Efficient Manufacturing Systems (REMS)
A collaboration between: CPI, IfM, Teesside UniversityThe REMS aim is:
To encourage the optimization of resource use in a way that improves manufacturing efficiency, reduces environmental impact, increases economic value and creates social benefit. To use modelling and systems analysis of whole supply chains to create knowledge and understanding of the way resources flow within and are consumed in manufacturing processes.
Title for today: Improving the resource efficiency of processes within universities –
lessons from industry that use representations and models of the flow of items (e.g. materials, items, people) through processes and systems
Problem DefinitionLinear economies, “take-make-use-dispose” and their growth,
have massively contributed to developing today’s society.
But, is it the most efficient use of resources?REMS research is directed at examining this resource use by
the overall system, and how to secure resources for the future.Is “circularisation” of resource flow more efficient?
Resources Raw Materials Manufacturing
UseLandfill
Reuse
RemanufactureRecycle
- Concepts discussed in: C. Campbell & R. Court, Steps towards a circular economy – what can we do?, eg magazine, 19 (5), 2014- Used by APSRG Remanufacturing report.
Possible types of dynamic “flow” modelling
Image from www.anylogic.com
Modelling the “flow”?The technique of Discrete Event Simulation (DES), focusses on a
“process-centric” view of the situation.Useful for scientists and engineers to model processes without
prohibitive levels of detail.A key point is that DES is a dynamic model – changes with time“Entities” travel through a process. Various “operations” dictate
the fate of each entity.REMS uses DES for its balance between:
Complexity – can be made more or less to suit situation & audienceReflecting reality – many aspects of life have this “flow”Comprehensibility – the results make sense – with hind sight
A Discrete Event Simulation (DES) software package – one example is AnyLogicWhy use computers and software?
Because it is hard to perform it as a spreadsheet calculation, or to set up a series of closed-form equations – except for very trivial examples.
Presentation of DES models developed by the Centre for REMS:An example from a real REMS case-study for industry – polymer
moulding for the automotive industry: Complex, but gives a flavour of what can be undertaken.
A simple worked example for this CIC workshop: Considers polymer production, manufacture and use of a “part” Compares the linear versus circular supply chains that can exist
Automotive – nylon supply chainStatic pictorial model
developed by REMSRaw materials
through to resin and user
Developed a dynamic model of these stages
“What if?” scenarios possible
Automotive – nylon case studyDES model – 4 stages - compounding, moulding, use, disposalCompany interested in: non-oil sources of material; recycled material;
“take back” parts schemes; etc. and company’s long-term strategy
Simple DES example – linear supply chainPolymer production and use of a partTonnes of material extracted, processed, produced, used over 5 years.Check the effect of:
i) production efficiency – 50% or 90% ii) constraint on either production or use phase of life
Linear supply chain - Results
Production efficiency – 50% or 90% - scaled reduction in tonnes extracted and to landfill
Constraint on use or production – large effect on amount of material needed…
Implications for policy makers on unrestricted consumption…? 0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Production 50% efficient -use constraint
Production 90% efficient -use constraint
Production 90% efficient -production constraint
Tonn
es o
f Mat
eria
l
Oil processed
Parts used
Landfill
Simple DES example – circular supply chainPolymer production and use, re-use and recycle of a partTonnes of material over 5 years.Check the effect of:
i) re-use vs recycle ratio on tonnes used and extracted ii) other variables constant, e.g. 90% production efficiency
Re-use
Recycle
Circular supply chain - ResultsFour scenarios compared:
Scenario Production Efficiency (%)
Landfill (%) Re-use (%) Recycle (%)
Linear 90 100 0 0
Circular 90 30 60 10
Circular 90 30 40 30
Circular 90 30 10 60
Circular supply chain - Results Linear – Circular. More
parts used; less oil processed…!
Re-use – Recycle. More recycling = fewer parts available for use… why?
Because production becomes the limiting factor.
Implications for policy makers on what to measure/control, GDP value and what is effective…?
0
2000
4000
6000
8000
10000
12000
Linear Circular Re-use 60%Recycle 10%
Circular Re-use 40%Recycle 30%
Circular Re-use 10%Recycle 60%
Tonn
es o
f Mat
eria
l
Oil processed
Parts used
Landfill
Applications in University Systems?Equipment for practical sessions.Materials for laboratories.Students progressing through modules / courses.Planning of events / conferences – visitor numbers and
required facilities / resources.Others…?
Discussion and Interaction
Departments / Facilities / Areas that attendees work in?“Flows” of entities in day-to-day activities?.Mapping of flows and processes - sketchDiscussion – good / bad aspects of DES technique?
Thank you
Centre for Resource Efficient Manufacturing Systems (REMS)
Dr Richard Court – [email protected]
https://twitter.com/Centre4REMS/