Bernd muschard sa 12.40_sustainable manufactoring-shaping global value creation_sustainable manufactoring

CRC 1026 Sustainable Manufacturing – Shaping Global Value Creation Funded by German Research Foundation (DFG)

Collaborative Research Centre 1026 Sustainable Manufacturing – Shaping Global Value Creation

MaketechX – 09. November 2013 Dr.-Ing. Jérémy Bonvoisin, Dipl.-Ing. Bernd Muschard

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Resource challenge

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Resource challenge

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Prosperity for everybody?

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Quality of life and consumption of resources

Page 8 Source: [Seliger, 2010]

Early  Industrialised  countries  

Maintaining  th

e  qu

ality  of  life  while  

redu

cing  th

e  resource  con

sump9

on  

Improving  quality  of  life  with  a  

responsible  consump9on  of  resources  

Emerging  countries  

Responsible  consump9on  of  resources  

Acceptable  living  standard  

Irresponsible  development  path:  Wealth  for  all  people  

relying  on  present  technologies  

Quality  of  life  

Consum

p;on

 of  resou

rces  

Acceptable  living  standard  with  responsible  

consump9on  of  resources  

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CubeFactory  

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

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CubeFactory

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Recycling

Designing

Manufacturing

Use B6, C5, PA: CubeFactory Learnstrument

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Non-renewable resources ABS: recyclable plastic derived from local waste Local  needs  

Manufacturing

Renewable resources PLA: biodegradable plastic derived from starch

Manufacturing: Open Source 3D printer as sustainable machine tool to create values and as an instrument for learning

Energy storage: Lithium iron phosphate (LiFePO4) battery with high power density

Energy supply: Off-grid power supply by detachable high-efficient solar panels (200W/m2)

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

Learning environment to promote sustainable value creation in areas of insufficient infrastructure.

u  Enables user to create sustainable values u  Teaches a closed loop material cycle u  Contains all necessary infrastructure for

production u  Manufacturing, energy and material supply,

knowledge

Solar power

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DIY  -­‐  Bicycle  

Population

Living Standards

Environmental Impacts

Time  

Population

Living Standards

Environmental Impacts

Time  

Consump;on  Pa>erns  

Processes  Products  

Cra?manship  

Autonomous  produc;on  

Mass  produc;on  

Mass  produc;on  

DIY  

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Thank  you  for  your  aHen9on  

Backup

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u  Challenges

u  Collaborative Research Centre 1026

u  CubeFactory

u  DIY - Bicycle

Contents

Structure of the Collaborative Research Centre (CRC) 1026

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Global value creation

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Source: [Seliger, 2010]

Increasing the teaching and learning productivity

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Governmental  Organisa;ons  Big  Enterprizes  NGOs  

Na;ons  Unions  Industries  

Educa;onal  Ins;tu;ons  Schools  SMEs  

boHom-­‐up  approach  

Educa;onal    Ins;tu;on  

Governmental  Organisa;ons  

Non-­‐Gonvernmental  Organisa;ons  

Enterprizes  

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Depth and breadth of CRC 1026

Combining  the  breadth  of  systemic  reference  with  the  depth  of  produc9on  technology  to  enable  for  sustainable  value  crea9on  

Collabora9ve  Research  Centre  1026  

Meeting the challenge

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Sustainable manufacturing community

I want a product

I design products

I design VCNs

I design workplaces

101011001  

1010110011010110101      101100110

1011010  

+

+ +

Legend: VCN: Value creation network  

Sustainable    manufacturing    community  cloud  

I configure VCNs

I run a factory

I do research for the

CRC 1026

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Project Area A: Strategy development

Mul9-­‐Criteria  System  Dynamics  Op9misa9on  

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Sustainability  Indicators  

Microeconomic  /  Macroeconomic  Assessments  

Technology  Pathways  

Wide  Range  of  Possible  Scenarios  

Mathema9cal  Models  and  

Solu9ons  

Life  Cycle  Aspects  

Technology  Assessment  and  

Global  Consequences  

Selected  Scenarios  as  tools  for  evalua;on  

Models  

Parameter  

Tools  

Effects   Knowledge  flow  

A2

A3 & A4

A5 & A6

A1

Research   Create  Projects  

Project Area B: Production technology solutions

Virtual  Product  Crea9on  

Resource  Efficient  Produc9on  Technologies  

Integra9on  Shop  

Lightweight  &  Accuracy  Improved  Machine  Tool  Structures  

Value  crea9on  networks  

Microsystem  technology,  

adadaptronic  enhanced  structures  

Industrial  informa9on  technology  

Turning,  cleaning,  welding  

Demonstrator  

Processes  

So?ware  tools  

Flexible  machine  tools  

Knowledge  flow  

B1

B2 & B3

B4 & B5

B6

Research   Create  Projects  

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Project Area C: Principles, methods and tools for qualification

Learnstruments,  Human  Oriented  Automa9on  

Strategic  Interac9on  and  Incen9ves  for  Sustainable  Economic  Ac9vity  

Experimental  economics  and  

macroeconomics  

Educa9on  methods  

Quality  science,  integrated  

sustainabilty  repor9ng  

Strategies  for  connected  economies  

Models  

Learnstuments  for  individuals  

So?ware-­‐tool  for  sustainable  management  

C1 & C2

C3

Research   Create  Projects  

C4 & C5

Mul9-­‐Perspec9ve  Modeling,  Intellectual  Capital  and  Knowledge  Management  

Effects  

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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

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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

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C5 Learnstruments in value creation modules – Challenge

Combined Learning and Working Environment

Development and Selection of Learning Methods and Tools

Design and Application of Industrial Artifacts

Learnstrument Development in Design for Mediation Approach

Learning Environment Working Environment

Learner Learning  Material  Learning  Task  

Worker Equipment Work  Task  

User Learnstruments Tasks

u  Goal: Increase in Teaching and Learning Productivity for Sustainable Manufacturing through application of Learnstruments

u  Approach: Learning and user centered design in combined learning and working environment

User Centered Tool Development Competence

Portfolio  

Learning Centered Task Development Learning Cycle

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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  

Combina9on  with  learning    

materials  program  

Technology  iden9fica9on  

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C5 Learnstruments in value creation modules – Results 2012

User Centered Tool Development Competence Portfolio

Portfolio Strategy: Increase error tolerance for untrained and unqualified users

Learning Centered Task Development Learning Cycle

Cycle Strategy Learnstruments cover all aspects of the perception and processing continua for highest teaching productivity

Processing Continuum Pe

rcep

tion

Con

tinuu

m

Innovation and Transformation,  

Active „experímenting“

Skills,  Active Experimentation

„Doing“

Systemic Knowledge,  Abstract

Conceptualisation, „Thinking“

Awareness,  Reflective

Observation, „Watching“

Motivation,  Concrete

Experience, „Feeling“

Kno

wle

dge

Skills

qualified

untrained

unqualified

qualified

trained

unqualified

trained untrained

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Population

Time

Use productivity of resources

Living Standards

Population

Resource Consumption

Resources Consumption

Living Standard

Ecologic Constraints

Population

Living Standards

Living  Standards

Resources Consumption Time  

Social challenge of use productivity of resources

Source: [Seliger, 2005]

Limit  popula;on  growth  by  increasing    living  standards  

Higher  living  standards  conflict  with  ecological  limits  due  to  an  increased  consump;on  of  resources  

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  are  sustainable    only  when  the  per  capita  resources  consump;on  decreases  

Time

Time

Ecologic Constraints

Time  

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Challenge of resource efficiency and energy conversion

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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]  

Environmental challenge of consumption of renewable resources

Population [Mio.]

Ecological Footprint

[global ha/cap]

Biological Capacity

[global ha/cap]

Ecological Deficit (-) or Reserve (+) [global ha/

cap]

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

Germany 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 -3,6

Russia 142.8 4.4 6.6 +2.2

USA 315.8 7.2 9.6 - 3.3

u  12,8 billion ha divided by 7.112 billion people: The planet‘s bio-capacity is 1.8 global ha/cap.

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]

1961

Global Ecological Footprint

Eco

logi

cal F

ootp

rint (

Num

ber o

f Ear

ths)

CO2 Share of the Global Ecological Footprint

0

2  

1970 1980 1990 2000 2008

Biological Capacity

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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

A1 Pathways for sustainable technology development – Approach

Systems

System elements

Mobility Energy Production

Functions

Specific Criteria

General Criteria

Substitution Combination

System creation

Technology pool Surrounding field scenarios

Assessment

or

Functions

Syst

ems

Con

ditio

ns

System elements

Syst

em

elem

ents

Area of human living

Sustainability dimension

Development level

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 u  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

Mobility Scenarios 2030

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

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A6 System Dynamics Optimization – Approach

u  Core Product: Software package „System Dynamics SCIP“

u  Branch-and-bound approach to control problems: u  Division of the problem

into subproblems u  Solution of linearized

subproblems using Simplex Method

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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  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

Product Design Alternatives

Optimised Product Design

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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)

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B1 Virtual product creation in sustainable value creation networks – Results 2012

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  Process u  Interview partner in

industry identified to analyse Product Development Processes (PDP) and discover potentials

u  Collection of public PDPs

u  Decision Support u  First terminology as a

basis for the ontology

u  Analysis of ontology tools

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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

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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

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B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Results 2012

0.00

µm 2.29 1.15

5.17 (a)

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

(c)

7.26

0.00

µm 3.23 1.61

(b)

4.88

0.00

µm 2.17 1.09 Deflection simulation results (a) regular cube,

(b) lightweight cube (c) honeycomb

Regular cube

Light-weight cube

Hexagon-comb

Weight - 22.5 kg

+ 19.5 kg

++ 18.8 kg

Welding - + -

Machinability + ++ -

Stiffness + - ++

Fill damping material

+ - +

Table to assess design concepts

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

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