adixen s Green LabFab Feedback on environmental excellence EMM2012

Transcription

1 adixen s Green LabFab Feedback on environmental excellence EMM2012 Johann Parrochon Intermeca service provider for adixen Vacuum Products

2 adixen Vacuum Products and Pfeiffer Vacuum Pfeiffer Vacuum Industrial group, leading supplier of vacuum solutions Adixen Vacuum Products >560 employees in Annecy sales >220M Adixen products range Vacuum pumps 2010 dec 31, acquired vacuum technology unit of Alcatel-Lucent : adixen High industrial investments in Annecy Helium leak detectors Contamination equipments 2247 employees ww High level of innovation 2

3 Market segments 3

4 Solar = 10% total sales Total sales 4

5 Green LabFab Key challenges to next generation pumps for solar industry Higher dimensions / severe mechanical constraints / new materials Environmental excellence for a comprehensive approach Financials > 25 M perimeter 5.4 M fundings Time span :

6 Green LabFab : a R&D project R&D Design Pilot Line R&D INNOVATION Manufacturing processes Environmental excellence Volume Production 6

7 Green LabFab : a global project FACILITIES DESIGN MANUFACTURING ASSEMBLY «Green LabFab aims for enhanced industrial capabilities to supply the solar industry with highperformance vacuum solutions, while keeping the means of production at top environmental sustainability.» TRANSPORTS 7

8 Facilities : saving energy Idea : energy consumption dashboard on machining center : Helping users to decide Idle mode Schneider 5 Electric Puissance kw Puissance moyenne Installation on MC Result : 4.7kW All MC = 7% consommation du site Need global understanding on energy consumption 8

9 Facilities : saving energy Global approach Manual measurements on transformer stations Stations are dedicated to several types of activities Impact of activity on consumption Threshold to be improved Biggest consumers are identified first station to be instrumented in 2012 Studies on compressed air Charge losses at end of lines Idea : loop the lines on themselves 9

10 60 Hz powersupply compressor Miling center A P A S S I O N F O R P E R F E C T I O N Facilities : saving energy Cleaning tools Environment tools R&D Building conso moyenne en semaine Conso Weekend Future to come : Invest into equipment energy monitoring Supervision using a CTM (Centralized Technical Management) Collaborative program develop a versatile energy applicative framework sustained by service oriented middleware 10

11 Eco-design 2003 : adixen to start with ISO14001 environmental management 2010 : new focus on carbon footprint and eco-design 1 materials 2 electronics 3 manufacturing and tests Example of results on different products 11

12 Eco-design Software tool to designers 14 project leaders involved in the adoption of the software tool Main effort on reducing the amount of materials E.G. CAN network to be implemented to He Leak Detectors to reduce circuits 12

13 Manufacturing Roots multistage pumps Maglev hybrid turbo pumps shafts - lobes - stators turbine lobes stator Holweck stators casing 13

14 Manufacturing Challenges of solar Corrosive gases Light gases Important flows Solutions Resistant but expensive materials Repeatable and precise machining Higher tolerances Statistical Process Control on bores position (30µm) 14

15 Manufacturing Automated turning center unit Optimised space and material flow Adapted ergonomy for new dimensions Flexible, autonom & robust 15

16 Manufacturing Flexible Manufacturing System (mining unit) Optimised space and material flow Adapted ergonomy for new dimensions Flexible, autonom & robust 16

17 Manufacturing ducts New Cooling Lubricant Filtration Unit Variable process speed (energy saving) Temperature control 25 C in constant motion Environment module Selective sorting of chips Sorting / recycling 17

18 Manufacturing Targets Reduce painting amounts Reduce hot air flow Improve painting quality Robot-spray painting Size detection control drying IR power Robot-assisted handling 18

19 Assembly More bigger pumps more space more organisation lean manufacturing Improvement of kitting and logistics Easier acess to heavy parts Reduction of temporary stocks Walking distance for one pump assembly 400 m 60 m 19

20 % poids A P A S S I O N F O R P E R F E C T I O N Transport Internal procedure to favour sea freight rather than air freight But cyclical activity requires air freight Répartition des modes de transport - Exportations 100% 90% Adixen encourage employees to comute on public transports (agreement on lower fares) or bicycle and organize ride sharing. 80% 70% 60% 50% 40% 30% 20% 10% 0% T T T T Route Aérien Maritime 20

21 Conclusion FACILITIES Instrumentation on infrastructure for energy control ECO-DESIGN Flow/mass and energy : efficiency x2 MANUFACTURING SPC for NQ 30% down and intelligent energysaving equipements ASSEMBLY Lean for 400 down to 60 m walk TRANSPORTS Sea freight x5 within one year 21

22 Acknowledgments FUNDINGS : TECHNOLOGY & STRATEGY : ADIXEN : Yves FONTAINE / Alexandre GOURDOU / Sébastien JALMAIN / Elodie RATAJCZAK / Thierry PRADEL / Lionel FAVRE-FELIX / Serge PERREARD / Pascal OCHALEK / Hind BEAUJON / Magali DAVENET 22

23 Thank you for your attention! 23