cardeal eco efficiency in the aerospace industry (2) · objectives • methodologies and tools for...
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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
Mass Production
Introduction
With the fast increase in number of planned satellite launches, the need for mass production is becoming more evident.
Introduction
INDUSTRIAL LEADER
CORE PARTNERS
R&D Leader
Key Partners
PASSARO
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
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
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
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
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
Efficiency: MSM Results
Methodologies and tools
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
Integrated DMU (Digital Mock Up)3D environment
Integration with LCA framework
Data
Core Partner PASSARO
AssemblyProcesses
&Resources
PPRProductProcessResource
Case Study
KPIs
Integrated DMU 3D environment
Partner INEGI+ISQ
Integration with LCA framework
AssemblyProcesses
&Resources
PPRProductProcessResource
Case Study
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
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
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
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
