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 – r.court@tees.ac.uk

https://twitter.com/Centre4REMS/