Green Manufacturing Efficiency of Products and Processes Innovative Manufacturing of Resource-efficient Products

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1 Green Manufacturing Efficiency of Products and Processes Innovative Manufacturing of Resource-efficient Products Hans-Jörg Bullinger Fraunhofer-Gesellschaft

2 The Profile of Fraunhofer 60 Institutes more than 18,000 employees about 1,65 billion research budget 7 Groups: Information and Communication Technology Life Sciences Microelectronics Light & Surfaces Production Materials and Components MATERIALS Defense and Security

3 180 OIL Import price ind dex (2000=100)) Import price in ndex (2000=100 0) Motivation for the introduction of a resource-efficient manufacturing ELECTRICITY STEEL Year Bildquelle: 2007 Source: Destatis, Deutsche BP, E.ON, Statistisches Landesamt BW, ThyssenKrupp Year Price e index (2000=1 100) Producerr price index (20 000=100) Year WATER Year

4 Energy and tool costs in a cylinder head production Costs s / % Costs for electrical energy Tool costs Source: Volkswagen

5 Influencing factors on the industrial production Business objectives Profit Sustainability Competitiveness Market Globalisation Increase in consumption of resources Environment Scarcity of resources Increase of disposal costs Environmental damage Politics and society Consumer awareness Social responsibility Change in political objectives Industrial production Legislation and jurisdiction Prescription and tightening of critical values Legal restraints Consequences of the law

6 Resource-efficient production the production chain as a focus Energy Tools Supplies Semi-finished part/ material Forming Milling Annealing Grinding Assembly Component/ product Support processes Residual materials Emissions Scrap chips, effluent, sludge heat, noise, vapours, exhalation, vibrations Source: IWT Bremen, Kutz + Schulz, ThyssenKrupp

7 Resource saving by process modification and substitution in bevel gear manufacturing Forging Forging Soft turning, drilling, tapping with cooling lubricant Soft turning, Soft turning drilling, tapping with cooling with cooling lubricant lubricant Conventional process chain Gear cutting with lubrication Gear cutting Gear Dry gear cutting with cutting dry lubrication Grinding Case hardening with cooling lubricant Grinding Case hardening Hard withturning cooling lubricant Gear lapping 3. Optimisation 2. Optimisation step step 1. Optimisation step 3. Gear lapping Screwing Screwing Welding Wet machining: Cutting material: HSS Coating: TiN Elimination Dry machining: New process parameters: lubrication/ year Cutting material: VHM Feed f ca l Coating: TiAlN Cutting speed v c Source: BMW Screwing of crown wheel : - Process drilling and tapping - central cooling lubricant system Elimination cooling lubricant system, consumption/ year Energy: 1,15 Mio. kw/h Medium: 1052 m³ Filter fleece: ca. 45 t Welding of crown wheel : - Process Elimination i of drilling and tapping - Elimination of a central cooling lubricant system

8 Resource saving by reconditioning instead of recycling Serial reconditioning of starters and generators Starter and generators Back in Box Distributor pump Disassembling + Cleaning Replacement of wear parts Fuel injection/ignition Assembly + Final check Exchange product Fuel-injector-mount combination Annual savings compared to production of new components: MWh energy = 88% savings compared to new production kg kg kg kg kg kg Copper Aluminium Steel CO CO 2 SO 2 Source: Bosch

9 Energy and tool costs in a cylinder head production Costs Energy ,2% Cost ts / % ,5% 57,3% Costs for electrical energy Tool costs Cooling lubricant Cleaning Machining Source: Volkswagen

10 Demand driven thinking: Green automobile production Green Carbody Technologies Green Powertrain Technologies Resource efficiency in the process chain coated body Tool making Goal Press plant Body manufact. Coat Press plant: - Reject (< 2 %) - Utilization of material (> 75 %) Body manufacturing: Innovation-Alliance Planning Tool making Press plant Body manufacturing Coating - Energy consumption (um 20 %) - Stand-by-losses (um 50 %) From the Motor to the Wheel Goal Adadaptive Formhonstrategy CO 2 -Emissions 20 % - Efficiency 5 % (through friction power minimization) - Light construction Cam shaft: 50 % weight Con rod: 20 % weight Crank shaft: 25 % weight Lead projects Low energy motor Light construction transaxle Electric-Traction Fraunhofer IWU, I, IPA, 62 companies

11 Resource saving by adapted lubrication injection Shoe injector Air diverter Cooling lubricant Grinding Schleifscheibe disc Needle injector Source: Grindaix

12 Effects of lubrification and coatings on the tool wear behaviour in drilling of Inconel 718 Emulsion Synthetic ester without additives wear land VB / µm Width of flank uncoated TiAlN/WC/C ml-tialn/γ-al 2 O 3 nl-tin/tialn Number of holes TiAlN/WC/C nl-tin/tialn ml-tialn/γ-al 2 O Number of holes Material: Inconel 718 Process: centre drilling Drill depth: l = 17 mm Cutting parameter : v c = 20 m/min f = 0,09 mm Drill: substrate: HW-K20 d = 6,8 mm Cooling lubricants: Emulsion 6% Synthetic ester without additives ml: multilayer, nl: nanolaminate

13 Three steps towards implementation of a resource-efficient production Material flow Working plans ERP System Use of Supplies Energy consumption Location-based Department-based Process-based Identification of resource-intensive processes Generation of environment- and resource-ratios Efficiency analysis of the resource-intensive processes Each action is process specific

14 Data acquisition and generation of ratios by the tool Resource Cost Accounting RCA 1. Analysis of the current state of the business process 2. Formulation of potentials and aims 3. Generation of necessary structures for data acquisition 4. Generation of RCA: Input Output calculation 5. Ratio generation: Evaluations and reports 6. Implementation in the decision process 7. Deriving and controlling actions Source: Effizienz-Agentur NRW Benefits for the company and the environment: Transfer of relevant information in an integrated t controlling Identification of cost drivers Generation of optimization approaches Adding value Expansion of existing operational planning and cost calculation with the aim to increase the resource productivity

15 Energy consumption in manufacturing and life cycle Production Products service life Small lever Energy demand in production Large effects Energy consumption in service life Manufacturing alternative 2 Manufacturing alternative 1 Energy consumption in product life cycle: E ges1 >> E ges2

16 Resource savings by surface design Functionality of riblets Shark skin with riblets Ma Large-eddy simulation (LES) Vortex Turbulent vortexes are kept away from the surface so that wall friction is reduced Riblets can theoretically reduce the wand friction and also wall resistance up to 10% Sawtooth riblets Source: Boeing, DB, MTU, Rolls Royce

17 Innovative process for the production of riblet structures on compressor blades Functionality of riblets Shark skin with riblets Ma Large-eddy simulation (LES) Vortex Turbulent vortexes are kept away from the surface so that wall friction is reduced Riblets can theoretically reduce the wand friction and also wall resistance up to 10% Sawtooth riblets Basic raw material (TI6Al) Massive forming Investment casting ECM Shot Milling peening Milling blade root dove tail turbine blade Rolling riblet Source: Leistritz Turbomaschinen Technik, MTU, ThyssenKrupp

18 Assessment of resource consumption with Environmental Product Lifecycle Management e ct structure Produc Source: IEC Machine enclosure Manufacturing Labour costs Cost element

19 Assessment of a tool changer in machine tools X-Module Y-Module Z-Module Head Tool changer Coolant system Machine enclosure Hydraulic/ pneumatic Packaging Sum 11140,7 9116,7 3427, ,0 814,8 2417,1 113,8 3137,0 479, ,3 Life cycle phase Activity Inputs/Outputs Amount Unit Eco-Indicator Eco-Points % Raw material manufact. Material C kg 0,086 30,1 3,7 Logistics Transport (3000km) 1 Truck (24t) 1050 tkm 0,024 25,2 3,1 Manufacturing Energy consumption Electricity 224 kwh 0,026 5,8 0,7 Use and maintenance Energy consumption Electricity kwh 0, ,8 91,9 Disposal Material C kg 0,014 4,9 0,6 Sum 814,8 100

20 Summary: Targets for resource-efficient production Resource scarcity Increased global demand Increase in resource prices Selective use of resources in product life cycle Resource-efficient production Source: Airbus, Stahlwille Resource intensive manufacturing for resource savings in service life Minimal use of resources in the entire product life cycle

21 Green