evaluation of cost structures of additive manufacturing processes
TRANSCRIPT
The 7th CIRP IPSS Conference
21-22 May 2015
Saint-Etienne, France
by
Malte Schröder, Björn Falk & Robert Schmitt Presenting Author: Malte Schröder
RWTH Aachen University, Laboratory for Machine Tools and Production Engineering Aachen, Germany
Evaluation of Cost Structures of Additive Manufacturing Processes
Using a New Business Model
Research idea
Extension of PSS trough an integration of business process support
In the case of additive manufacturing technologies
2
Maintenance
Materials
Machine setting
…
Machine focus
Maintenance
Materials
Process optimization
…
Business process focus
Cost calculation
Investment assessment
Process optimization
…
Problem statement
3
No fundus of experiences for new technologies/ different products
A lot of defects and nonconformities
Process models are not precise enough to make serious process forecasts
…
Need for an appropriate process model for cost calculations
Optimization of production costs
Assessment of investments in the hole additive manufacturing process
Management decision support
Complex geometries
Lightweight construction
Wide range of materials
High material utilization
…
“Additive manufacturing technologies are enabler for
individualized products” “Complex calculations”
Approach
4
Requirement definition
Planning phase (rough
model)
Development phase
(detailed model)
Configuration and validation
phase
Sensitivity analysis
cost-benefit analysis of
quality related investments
Expert interviews, literature review
Realistic presetting Safeguarding iterations
Findings: The additive manufacturing process
5
A A A
A A A
A A A
A A A
Analysis of all applicable individual activities
A A A
A A A
A
Intercommunicating activities are combined into logical sub-processes
A A A A A A
Summary of the sub processes to meaningful main process steps
2
3
1
A A A
A A A
A A A
A A A
Analysis of all applicable individual activities
A A A
A A A
A
Intercommunicating activities are combined into logical sub-processes
A A A A A A
Summary of the sub processes to meaningful main process steps
2
3
1
A A A
A A A
A A A
A A A
Post-processing
Machine preparation
Material processing
Desing & Planning
Configuration
Slicing
Scaling
Start/ execution
Start/ execution Scaling
Slicing
Configuration
Manufactu-ring
Quality check
Sales/ distribution
8 Main process steps were identified in the additive manufacturing process
Intercommunicating activities are
combined into logical sub-processes
2
Summary of the sub processes to
meaningful main process steps
3
Analysis of all applicable individual
activities
1
Po
st-
pro
cess
ing
Mac
hin
e p
rep
arat
ion
Mat
eri
al
pro
cess
ing
Man
ufa
ctu
-ri
ng
Qu
alit
y ch
eck
Sale
s/
dis
trib
uti
on
De
sin
g &
P
lan
nin
g
Findings: Cost calculation of each process step
6
A A A
A A A
A A A
A A A
Analysis of all applicable individual activities
A A A
A A A
A
Intercommunicating activities are combined into logical sub-processes
A A A A A A
Summary of the sub processes to meaningful main process steps
2
3
1
A A A
A A A
A A A
A A A
Analysis of all applicable individual activities
A A A
A A A
A
Intercommunicating activities are combined into logical sub-processes
A A A A A A
Summary of the sub processes to meaningful main process steps
2
3
1
A A A
A A A
A A A
A A A
All 8 process steps were calculated based on the companies data
Konstruktion & Planung 24,64%
Material 4,34%
Maschineneinrichtung 1,42%
Fertigung 18,21%
Post-Processing 25,65%
Verwaltung & Vertrieb 1,23%
Qualitätsmerkmale 24,51%
Konstruktion & Planung 300,18 €
Material 52,92 €
Maschineneinrichtung 17,33 €
Fertigung 221,79 €
Post-Processing 312,50 €
Verwaltung & Vertrieb 15,00 €
Qualitätsmerkmale 298,56 €
Gesamt 1.218,27 € - €
50,00 €
100,00 €
150,00 €
200,00 €
250,00 €
300,00 €
350,00 €
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Eingabemaske öffnen
relative values [%]
absolute values [%]
What's happening in the background?
7
Data Input: Order information
8
Dreiseitiges Prisma (umgeben von Hüllkörper)
Drucken nur dünner Wandstärken
Drucken eines Vollkörpers (ganze Flächen)
General job-information have to be given
Different sub masks can be edited:
– The machine has to be selected
– Material has to be selected
– Quality related parameter have to be set
– Process Information are deposited
1
2
3
4
Example: Calculation of the manufacturing time
9
𝑁𝑚𝑎𝑥2𝐷 = 𝑅𝑑 𝐵𝑅𝑥 − 20
𝐻𝐾𝑥 + 𝑆𝑥∗ 𝑅𝑑
𝐵𝑅𝑦 − 20
𝐻𝐾𝑦 + 𝑆𝑦
𝑁𝑚𝑎𝑥3𝐷 = 𝑅𝑑 𝐵𝑅𝑥 − 20
𝐻𝐾𝑥 + 𝑆𝑥∗ 𝑅𝑑
𝐵𝑅𝑦 − 20
𝐻𝐾𝑦 + 𝑆𝑦∗ 𝑅𝑑
𝐵𝑅𝑧 − 20
𝐻𝐾𝑧 + 𝑆𝑧
𝑡𝑀𝑎𝑠𝑐ℎ𝑖𝑛𝑒 = 𝑍𝑆 + 𝑍𝑊 ∗ 𝑀𝐴𝑋𝑁𝐴𝑞
𝑁𝑚𝑎𝑥; 1 + 𝑁𝐷𝑟𝑢𝑐𝑘𝑒 ∗ 𝑍𝑉
Sensitivity analysis
10
Big part
Small part
100 1 1000
45 mm (1:110)
276 mm (1:18)
-3% -2% -1% 0% 1% 2% 3%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
actual example:
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
quantity
Sensitivity of unit costs during variation of input variables about +/- 10%
Sensitivity of unit costs during variation of input variables about +/- 10%
Findings: Sensitivity analysis
11
Ranking kleine Stückzahlen große Stückzahlen
1. AK Maschine (-7,39%) AK Maschine (-8,03%)
2. LT (-6,33%) LT (-6,88%)
3. t W (-6,20%) t W (-6,74%)
4. V füllgrad (-5,12%) V füllgrad (-6,11%)
5. ss max (-4,08%) ss max (-4,43)
Ranking kleine Stückzahlen große Stückzahlen
1. AK Maschine (-2,90%) t PP (-9,62%)
2. t W (-2,43%) AK Maschine (-0,24%)
3. T ende (-1,39) t W (-0,21%)
4. T start (-1,04%) V füllgrad (-0,21%)
5. a (-0,87) LT (-0,19%)
Post-Processing in case of a high quantity of small parts
-3% -2% -1% 0% 1% 2% 3%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
1 Stück
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
100 Stück
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
1000 Stück
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
1 Stück
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
100 Stück
-10%-8%-6%-4%-2%0% 2% 4% 6% 8%10%
LT
Vfüllgrad
Aq
tPP
tW
mr
Cm
AKMaschine
a
BRx
d
ssmax
hr
Tpredelay
Tpostdelay
Tstart
Tende
twb
1000 Stück
Small parts
Big parts
Main cost-influencing factors:
investment costs & workload of the machine
economies of scale only with small parts
Summary and Outlook
12
Konstruktion & Planung 24,64%
Material 4,34%
Maschineneinrichtung 1,42%
Fertigung 18,21%
Post-Processing 25,65%
Verwaltung & Vertrieb 1,23%
Qualitätsmerkmale 24,51%
Konstruktion & Planung 300,18 €
Material 52,92 €
Maschineneinrichtung 17,33 €
Fertigung 221,79 €
Post-Processing 312,50 €
Verwaltung & Vertrieb 15,00 €
Qualitätsmerkmale 298,56 €
Gesamt 1.218,27 € - €
50,00 €
100,00 €
150,00 €
200,00 €
250,00 €
300,00 €
350,00 €
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Eingabemaske öffnen
Summary:
• Extension of PSS trough an integration of business process support
• Cost model additive manufacturing technologies
• Development and configuration of the model with companies support and feedback
• Sensitivity analysis
Outlook
• Further development of the software
• Integration of the process model in the product portfolio of the machine provider