GREEN MATERIALS. Frédéric Rabain. an SMM practice in the automotive industry. Materials Management Engineer

Transcription

1 GREEN MATERIALS an SMM practice in the automotive industry Frédéric Rabain Materials Management Engineer

2 ECODESIGN >> Sustainable Materials Management Manufacturing Reduce environmental impact at each step in the vehicle life cycle ISO Reducing energy use Engines Cut fuel consumption and CO 2 emissions Green materials Lower vehicle mass Materials Optimise the use of resources Lower vehicle mass Low particulate matter and CO 2 emissions Low fuel consumption; Hybrid engine Recyclability (85/95%) >> Reduce the impact of end-of-life vehicles

3 SCOPE 70% of metals 100% recycled 5% of fluids, 5% various 20% of polymers 150 to 250 kg of plastics OBJECTIVE: 20% green materials by 2011 (European production) OBJECTIVE: 30% green materials by 2015 (European production) Same Quality without Cost and Weight increase

4 DEFINITION: Green Materials Recycled materials 3 families of materials Waste Renewable resources Global warming Toxic emissions Materials from parts recovered at end of life Natural fibres Renewable resources Biomaterials Global warming Energy Used in blends with polymers to a rate of up to 80% Renewable resources Global warming Soil use Polymers produced using renewable resources

5 AMBITIOUS POLICY 3 families of materials for all vehicles 35% 30% 25% 20% 15% Design 07/08 10% 5% 6% 0% Vehicle development 3 years 7%

6 AMBITIOUS POLICY 3 families of materials for all vehicles 35% 30% 25% 20% 15% Objective 2011 = 20% Design 07/ % 5% 6% 0% Vehicle development 3 years 7% 2011

7 AMBITIOUS POLICY 3 families of materials for all vehicles 35% 30% 25% 20% 15% Objective EU 2015 = 30% Objective EU 2011 = 20% Design 07/ % 5% 6% 1 Vehicle development 3 years 7% TREND BEFORE GREEN MATERIALS PLAN 0%

8 AMBITIOUS POLICY 3 families of materials for all vehicles 35% 30% 25% 20% 15% 10% 5% Objective EU 2015 = 30% Objective EU 2011 = 20% 6% Design 07/08 1 Vehicle development 3 years 7% 2 Peugeot 508 New Citroën C4 TREND BEFORE GREEN MATERIALS PLAN 0% Natural Materials Biopolymers Recycled

9 AMBITIOUS POLICY Green Materials Plan Launch in Latin America: 20% in families of materials for all vehicles Biopolymers 35% 30% 25% Objective PSA EU 2015 = 30% 3 Natural Materials Recycled 20% 15% Objective PSA EU 2011 = 20% Design 07/ % 5% 6% 1 Vehicle development 3 years 7% TREND BEFORE GREEN MATERIALS PLAN 0%

10 GLOBAL MANAGEMENT Implement Include green materials in our guidelines Extend use to all current development projects Short term Innovate New materials and processes Extend to large body and impact parts Work closely with parts suppliers Medium term Step up research on automotive applications External partnerships, on bioplastics in particular Cooperative research projects Long term

11 CASE STUDY: the bumper For each vehicle sub-assembly, a green materials solution is identified and included in projects under way, depending on feasibility Three eligible areas: supports, absorber and spoiler Criteria: features, mass and cost price Applications: 750 g in supports and 1.1 kg in the spoiler Total: 1.85 kg of green materials in an 8 kg component New materials currently under review to reach 4 kg Mid term: 4 kg of recycled plastics, or 50% of bumper weight

12 ENVIRONMENTAL IMPACT Natural fibres: Hemp fibres vs glass fibres Data from lifecycle analysis in 2009 by EVEA agency for PSA, on a Peugeot 207 rearview mirror plate in PP/Hempfibre, in comparison with PP/fiberglass (ISO et 14044) - 5% reduction in weight - 25% non renewable resources use - 43% reduction in water consumption - 14% reduction in greenhouse gases

13 CONCLUSION Ambitious policy on materials in line with the Three R s principle on reducing environmental footprint Reduce Reuse Recycle Green materials plan is a part of PSA Peugeot Citroën sustainable developement approach

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15 MAIN CHALLENGES Availability of recycled materials Need to promote recycling channels in all countries Bio-based polymers: opportunity and risk Lower maturity of bio-processes / petrochemicals >> R&D Environmental questions to address: Competition with food production Soil use Need for complete LCA for each bio-process (fertilizers, transport, GMO )

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