Car Body Painting Paint Shops Put to the Test

Transcription

1 Car Body Painting 2010 Paint Shops Put to the Test Plant Assessment as a Systematic Approach for more Efficiency and Sustainability in use of Energy and Resources Dr. Hans Schumacher, Dürr Systems Bad Nauheim, 03./04. November 2010

2 Agenda Paint shops Installed base Plant Assessment: 1 st step for improving existing plants Examples -2-

3 Agenda Paint shops Installed base Plant Assessment: 1 st step for improving existing plants Examples -3-

4 Car Manufacturing Age structure of paint shops Age Structure of Paint Shops Failure Function "Bathtub Curve" 60% 50% 40% 30% 20% Average age > 30 years years years 0-10 years Failure Rate Time 10% 0% Europe Russia North America South America Asia- Pacific South Africa Total (1) Early Failure Period (2) Intrinsic Failure Period (3) Wear out Failure Period 60 % of all paint shops are older than 20 years -4-

5 Car Manufacturing Developments in the last 30 years: Product Design Diversity Corrosion protection Emissions Safety 30 years Price Performance Efficiency Individuality Quality -5-

6 Car Manufacturing Developments in the last 30 years: Energy & Environment Costs CO 2 Regulations Renewable Energy Natural Gas Sustainability 30 years E-mobility Efficiency Global Warming Shortage of Resources -6-

7 Car Manufacturing Developments in the last 30 years: Paint process Waterborne Materials Compact Processes Footprint TA-uft Energy 100% Bell Application CO 2 30 years Sustainability Efficiency Quality CPU Substrate Materials Automation Availability -7-

8 Agenda Paint shops Installed base Plant Assessment: 1 st step for improving existing plants Examples -8-

9 Plant Assessment vs. New Paint Shop New Paint Shop Invest Plant Assessment Time -9-

10 CPU: Influencing Factors & Saving Potentials Effects (Example: Top Coat) - 10% material usage CPU Reduction: 8,50 Saving potential: /a Material 44% Investment 19% - 20% energy consumpt. CPU Reduction: 4 Saving potential: /a Maintenance 3% Staff 24% Energy 10% + 5% first run increase CPU Reduction: 9 Saving potential: /a CPU % uptime increase CPU Reduction: 6 Saving potential: /a Europe, CPU (Example: Top Coat), Capacity U/a, Medium-class vehicle (90m²) -10-

11 Plant Assessment: Entry for CPU Reduction First run TE Colour Change Material 44% Investment 19% ifetime Equipment update Maintenance 3% Staff 24% Energy 10% Uptime First run Equipment update Uptime First run Europe, Total CPU (example) = 195, Capacity U/a, Medium-class vehicle (90m²) -11-

12 Plant Assessment: Elements & Approach Teamwork for new ideas Shows worldwide best practice Expertise Know How Customer Gives overview in new technologies Covers all type of processes Informs about green paint shops Guarantees systematical approach Generates more potentials Ensures quicker results Improvement plan -12-

13 Plant Assessment Teamwork and expertise ensure quicker results Evaluation of customer targets (workshop) Handover Plant documentation On site Assessment Check single items Analysis of Assessment findings Conclusion of potentials/proposals Presentation Assessment Management Report Customer Customer Check documents as built Evaluate, define targets Kick off Assessment on site Ort Brief information Evaluate findings Assessment Report Final presentation Time line in workdays Complete Assessment in 20 days -13-

14 Plant Assessment Professional full range guaranteed Specialists for Assessment Process Application Booth HVAC Oven Conveying Control Systems SCADA Energy Management Interfaces / Building Environment Selected targets Cost per unit Energy consumption ongevity Quality 1 st run egal conformity Environment H 2 O, CO 2 Availability Flexibility A E B PT EC D UBS - Sealing C Primer Top coat Audit, Spot repair Additional findings, proposals and conclusion regarding Replacement Repair Modification to fulfill, to improve to meet customers targets -14-

15 Plant Assessment Worksheet: Systematically recorded findings ocation Situation Proposal, measure improvement evel to achieve targets -15-

16 Plant Assessment Detailed results: Findings summarized and grouped to subjects Detailed results work sheets OVEN Page numbering Measure: Target Detailed results work Page sheets No. BOOTH Section Component Brief description ongevity Quality 1st Energy Picture no. Page numbering Measure: Target Detailed results work sheets ENERGY / ENVIROMENT Page No. Section Component Brief description ongevity Quality 1st Energy Picture no. Page numbering Measure: Target Detailed results work Page sheets No. Section CONTROS Component Brief description ongevity Quality 1st Energy Picture no. Page numbering Measure: Target Detailed Detailed results results work Page work sheets No. sheets Section PROCESS CONVEYOR Component APPICATION Brief description ongevity Quality 1st Energy Picture no. Page numbering Measure: Target Blatt Nummerierung Measure Targets Page No. Section Component Brief description ongevity Quality 1st Energy Picture no. lfd. N Page No. Section Component Brief description 2020 Run Rate savings ongevity Quality Energy Picture No. Chapter lfd. N Chapter Chapter Chapter lfd. Data sheet Paint shop Chapter lfd. Data sheet Paint shop lfd. Page no. Chapter lfd. Page no. lfd. Data sheet Paint shop lfd. Data sheet lfd. Paint Page no. shop lfd. N lfd. N lfd. N lfd. N lfd. Data sheet lfd. Paint Page shop no. Data Sheet lfd. Page Paint no. shop Page No. replace replace repair repair modify replace modify Urgent measure repair replace Urgent measure detailed study modify replace repair detailed study Urgent measure repair modify detailed study modify Urgent measure 2020 Replace Urgent detailed measure study Repair detailed study Modify 2020 Run Rate 2020 Urgent measure Detailed Study Run Rate savings Run Rate savings 1st Run 2020 Run Rate Rate savings savings eerschlittenspeicher ST 290 Schlittenstapl Ersatz erforderlich, alterungsbedingt X X X 1-3 Tragarm Füllerschleifen Heber Ebene 00, HubHubschlitten ager defekt X X X Wassertrockner ängsgurt Wassertro Technik klären X X X NAD (Nahtabdichtung)WerkermitfahrbänderGurte austauschen X X X 1-3 Werkermit Füllerschleife Heber 51 / 41 Ersatz von Verschleißteilen X X X Fertigstellung Quergurtförderer Umbau Quergurtförderer X X X 1-4 Quergurt F VBH- KT Verbindende FT VBHErsatz erforderlich, alterungsbedingt X X X VBH VBH Antriebsstation Kettentausch u. Zahnräder X X X D 3 Antriebsstation SPK-FReinigung notwendig X X X D 3 Klarlack Spritzkabine FT KlarlaVerschleiß an Ketten u. Zahnrädern X X X D 3 Klarlack Spritzkabinen Ersatz von Verschleißteilen X X KT Trockner Trockner FT Reparartur zwingend erforderlich, sofort X X X KT Trockner Trockner FT Rollenbaackaufbau auf Tragrollen X X X Heber Schleusen Heißbereichsheber Überprüfung Verbindungselemente X X X D Trockner Trockner FT einseitige Abnutzung Führungsleisten X X X Fertigstellung Rollenbahn ArbeitsplArbeitssicherheitsaspekte X X X Trockner Heißbereichsheber Karossenverschmutzung X X X X VBH VerriegelungsprüfungNachrüstung Skid-Klammerung X X X X VBH VBH- Kette Kettentausch u. Zahnräder X X X VBH VBH PendelübergabeAblaufoptimierung Übergabe X X X Fördertechnik VBH 05 VBH Pendel Pendeltausch X X X Rollenbahn Ar KT KT Pendel Pendeltausch X X X KT Fördertechnik KT Antriebsstationen KT Kettenräder tauschen X X X D 2 HT Heber Entkopplung Heber / Trocknergehäuse X X X Gurtheber Gurtheber Zustandsuntersuchung X X X X X X Definition of measures for replacement, repair and modification Evaluate potentials for each measure according to the customer s targets savings -16-

17 Plant Assessment Management summary (example): Urgent measures per target classified egal conformity ongevity VOC Emission Reduction Opt. #1, #2, (#3) H Example Recirculation of the Flash-off Air Emergency Routes across Conveyors Program Changes of Control System M Exposed Rollers on the Chain Conveyors BC Robots H Elevators don't follow latest Safety Rules Different Brands/Generations of controls in use TopCoat 1+2 BC Bells M Control Systems Primer* ) egend: Control Systems TopCoat M HT Problems on machines orange = ongevity Spare Parts Availability for Télemécanique TSX evel Controls Paint-Mix Control System M yellow = egal conformity M Substitution of Pneumo- Pumps for BC Substitution of E-Pumps for UNI and CC M M Replacement of the Prime Oven Incinerators Replacement of Corroded Filter Frames M investment level = low (< 0.5 Mio EUR) M = medium ( Mio EUR) H = high (> 3.0 Mio EUR) Repair of Corroded Floors ASH Primer Robots ** ) H ASAP, < 2 yrs. 2-5 yrs yrs. > 10 yrs. time *) or replace with primer robots **) depending on availability of components -17-

18 Plant Assessment Management summary: High potentials reducing CPU per target classified Quality CPU ROI = short < 1 yr ROI = short Recirculation < 1 yr of the Flash-off Air Recirculation of Clearcoat the Spray Flash-off Booth Air Down Draft Reduction ROI = medium 1 3 yrs. ROI = medium Hot Air Seals 1 on 3 yrs. the Topcoat Ovens M Hot Air Seals on the Energy Saving Topcoat Potential Ovens Spraybooth Abatement Clearcoat Spray Booth Energy Saving Potential Spraybooth Operating Down Draft Reduction Skid Spraybooth cover Abatement Booth Window Removal Spraybooth of the Operating Black Out Window ine ROI = long > 3 yrs. ROI = long Visualization > Appl. 3 yrs. / Equipm. / Conveyor M Visualization Appl. / Process Equipm. & Conv. / Conveyor Controls Process & Conv. Program Changes of Controls -M Control System Humidifier Water Program Changes of Skid cover Spray Booth M Primer Robots H Management System Control System M M -M Example Removal of the Black Out ine Humidifier Water BC Robots H M TopCoat 1+2 Primer Management System BC Robots Bells M H egend: BC Robots H TopCoat 1+2 BC Bells M Energy Savings investment level Maintenance M egend: = low (< 0.5 Mio EUR) M = medium ( Mio EUR) Plant Energy Availability Savings M H = high investment (> 3.0 Mio level EUR) Application Maintenance M M = low (< 0.5 Mio EUR) M = medium ( Mio EUR) Plant Availability M H = high (> 3.0 Mio EUR) Application M -18-

19 Plant Assessment Result overview Complete list of findings to single items and main conclusions grouped to Process Application Energy Management Environment Conveyors Controls Management summary selected to URGENT Actions: Focus on legal conformity, lifetime, uptime POTENTIA Actions: Focus on modifications reducing CPU Change controls Refurbish supply air Modify conveyor Change, adapt exhaust air Change process tank Replace PVC piping -19-

20 Agenda Paint shops Installed base Plant Assessment: 1 st step for improving existing plants Examples -20-

21 Examples (1) Repair of Chain Conveyor Target Safeguarding of running production Measures Exchange of chain guidings Budget ow Result Avoiding of investment ifetime extended until

22 Examples (2) Burner Replacement Target Measures Reduction of process temperature Attainment of emissions values Installation of new burner Budget ow Result Reduction of temperature by approx. 20 C Reduction of Energy consumption by approx. 5 8% -22-

23 Examples (3) Fill Stop Sensor for BC-ESTA Target Reduction of paint losses during prepainting Measures Installation of 18 sensors, commissioning Budget ow Result savings/a per zone -23-

24 Examples (4) Upgrade EcoBell2 M to EcoBell2 HX for Bumper Painting Target More flexibility for a wide colour palette Measures Budget Installation of a prop-valve for a second shaping air, exchange of atomizer housing with an integrated shaping air ring, new bearing unit, bell cup Modification of four BC robots and one CC robot ow Result 15% higher TE Difficult colours now applicable Brush width before upgrade: mm Brush width after upgrade: mm EcoBell2 HX -24-

25 Examples (5) Exchange of Colour Changer System in 9 BC-Robots Target Reduction of paint losses during prepainting Measures Installation of a colour change system with significant reduced colour change loss Budget Medium Result savings/a per zone Shorter colour change time EcoCC -25-

26 Examples (6) Exchange of Canister Type Atomizer to EcoBell ICC in Primer Zone Target Measures Reduction of complexity and maintenance costs Increase of process time Exchange of atomizer, installation of the multi-pump paint dosing system, installation of regulators for shaping air and turbine speed, installation of HT controller and cascade Budget Medium Result Approx. 6 sec (14%) more process time Significant reduced maintenance costs EcoBell2 ICC -26-

27 Examples (7) Automation of CC Interior Application Target Reduction of overspray losses Measures Installation of 4 robots and 4 opener in the manual zone Budget High Result savings/a per zone Quality improvement -27-

28 Conclusion Efficiency and Sustainability in use of Energy and Resources: Also required for existing paint shops Plant assessment enables a cost efficient implementation -28-