Unlock the value of product sustainability. (Software) Solutions and Options (not only) for fiberreinforced and textile based composites

Transcription

1 Unlock the value of product sustainability (Software) Solutions and Options (not only) for fiberreinforced and textile based composites

2 Global locations PE Offices in: Berlin Bhilai Boston Boulder Chicago Copenhagen Guelph Hamburg Istanbul Johannesburg Kuala Lumpur London Lyon Mumbai Melbourne Ottawa Paoli/Philadelphia Perth Ravenna San Francisco Seattle Sheffield Stuttgart Tokyo Vienna Wellington Zurich

3 Key sustainability drivers Legislation & Regulations Investors Corporate Values Modern Global Enterprise NGOs Consumer Preferences Sustainability Rankings & Dow Index Media & Analysts Competitive Pressure 3

4 Product sustainability advantage GaBi transforms data on products and processes into insights and enables companies to implement the most profitable and high impact sustainability initiatives. Reduces operational cost Reduces business risk Improves positioning of companies and products Improves energy & resource efficiency Improves brand preference Grows & protects revenues 4

5 Sustainability Performance now a board level priority 73% of executives say sustainability is a priority on their CEO s global agenda* Cost Reduction Optimise material energy and resource use across the value chain Competitive Advantage Enhance brand and reputation Appeal to employees, customers and investors Risk Management Compliance with regulation Mitigate risk from materials and process of concern Gain visibility into the supply chain Increase Revenue Customer preference for sustainability labeled goods Build new sustainable product portfolios *Source: The business of sustainability, McKinsey,

6 Corporate Value Chain Sustainability business scope Energy/ Carbon Water/ Resources Sustainability Impact Emissions/ Waste Labour/ H&S Profit/ Brand Social/ Ethics Enterprise Building & Infrastructure Transport & Logistics Supply chain Process Product 6

7 Sustainability aspects of fiber-reinforced composites Resource availability and scarcity and complexity of supply chain Influence on design, materials and secondary effects (e.g. simpler construction, due to smarter or lighter solution with same performance) Complexity and energy demand of production technology Potential (fuel or energy) savings in use (e.g. light weight / smart design) Endurance or life-time improvement Reduction of maintenance demands Design for disassembly <-> recyclability <-> use of recycled content Efforts of mechanical/chemical/energetic recycling Complete life-cycle must be considered and managed to evaluate options Simple answers tend to be simply wrong 7

8 Adequate multi-criterion decisions needed handle complexity differentiate your innovation consistent decision data access beyond own process Product Sustainability easy reporting Software fast results use existing own data Communicate results to customers 8

9 Adequate background data + own technology data 9

10 Different fibers, different impacts, different potentials 10

11 Multimaterial concepts and scenarios on system level Different materials have different technical properties Cost & weight reduction should be balanced 11

12 Fuel saving Primary & Secondary Weight Reduction Longer transmission Initial Design 1200 kg Weight reduction in body 1000 kg 1000 kg 950 kg Secondary Weight Reduction - brakes - chassis - tyres & suspension etc Smaller engine, powertrain 920 kg Equal performance 12

13 Lightweight Design - Production Phase! Lightweight materials typically have higher production phase burdens Material Mass Weight saving Al 3,4 kg 48% Mg 2,2 kg 67% PP/GF 2,4 kg 64% PA/GF 2,9 kg 56% Steel 6,5 kg 13

14 Lightweight Design Use Phase Extraction Transport Transport Refinery Fuel station Reduced upstream processes of fuel provisioning (10-15%) Reduced Fuel consumption Use 14

15 Lightweight Design - EoL Phase Car Disassembly & crushing Cube Shredding Shreds Waste Credits Remelting of Metals Separation Energy is required for EoL treatment Design decides on how much material is recovered Credits for metal content recovered from EoL -> reduces LC burdens 15

16 Mileage [km] Lightweight Design - Realisation of Benefits A very light weight material does not necessarily mean better environmental performance Complete life-cycle must be considered to evaluate an option Curves of Break-Even Points in Global Warming Potential (GWP) Al_0% Pl_0% Break-even of lightweight materials depend on actual weight savings Recycling can drastically reduce the break-even point Mg_E_0% Mg_T_0% Al_100% Pl_100% Mg_E_100% Mg_T_100% 0 0% 10% 20% 30% 40% 50% Weight savings [%] 16

17 Lightweight Design - Costs and Benefits Design Reference Lightweight M A > M B Production Use (FRV) Overall Part Level B Vehicle Level Iterative process Multimaterial concept for different parts Assess overall benefits & costs Realisation and capitalisation of benefits from secondary reductions (excl. recycling) Best use of Lightweight Concept 17

18 Life Cycle Thinking A lens to assess your business & supply chain sustainability Raw Materials Materials Manufacture Products Manufacture Transportation & Manufacture Use Recycling Final Disposal 18

19 Business Value GaBi builds business value long term Long-term company success Value Chain optimization Sustainable Product Portfolio Management Continuous operational optimization Product Communication & Verification Process & Resource Efficiency Verifiable BOM / BOP & Compliance Eco-design & sustainable product Innovation Rapid Prototyping (Generic LCA) Overview / Orientation Material Comparison Screening Maturity of LCA usage 19

20 GaBi addresses real business sustainability requirements Product & Process Sustainability Performance, Eco Footprinting Life Cycle Assessment, Product Eco Footprints, modelling and simulation of any system in relation to environment, cost and social aspects Design for Environment and Compliance Design for Compliance, Disassembly, Environment and Recycling, Integration into BOM Systems Sustainability Communications Communication of results, Eco-Design, Environmental Product Declarations (EPDs) CAD and PLM Integration CAD and PLM/ERP integrated or embedded GaBi calculation and content provision engine 20

21 GaBi Software Suite For: Integration GaBi with PLM/ERP For: LCA practitioners For: Non-LCA experts who need expert answers For: Instant scenario analysis Design for x [compliance, recycling, etc.] Professional LCA modeling software Intuitive, interactive decision-guidance tool powered by GaBi Software and Databases GaBi DfX GaBi 6 GaBi Envision Comparable, robust and up to date industry LCI Data underlies expert LCAs GaBi Databases 12 Chemicals, Energy, Precious and Non-Precious Metals, Plastics, End of Life, Manufacturing, Electronics, Renewables,, and external databases like USLCI, ecoinvent 21

22 Case study Challenge Beginning (1992): To conduct the first LCA of a car Today: analyse the environmental impacts of every car for product development, communication and compliance Solution Using GaBi DfX, VW can now easily conduct complex LCAs Business value VW now optimises environmental impact and cost of cars during product development. Over the years, GaBi Software has become a core tool for product- and process-related environmental activities at Volkswagen. Dr. Stephan Krinke, Head of Product and Environment, Volkswagen AG. 22

23 Case study Image: Bombardier Challenge LCA tool supporting their Design for Environment approach. Solution GaBi DfX for LCA of complex products The suite of tools that GaBi offers has proved invaluable to Bombardier s daily work in Design for Environment. The GaBi DfX tool in particular is extremely useful for dealing with complex product structures like our trains. Aleksandar Kolev, Design for Environment Engineer, Passenger Division Bombardier Transportation Business value faster LCA production of, saving time and money Integration in daily DfE work 23

24 Case study Zumtobel is first in its industry with a system to produce verified* EPDs for all of its 10,000 products. *according to ECO scheme Bill of Materials from ERP GaBi DfX GaBi Databases Customised datasets Other databases Product LCA Automatic verified ISO EPD Image: Zumtobel 24

25 Case study Challenge Incorporate sustainability in their products and business processes Solution Use of GaBi software in-house to track and improve its products life cycle performance Business value Understand and improve products environmental footprints EPDs for all its carpet products globally for verified communication and reporting Product optimization and innovation Risk Management in the supply chain»our use of LCA with GaBi has evolved to a proactive assessment of alternatives during the development process, making it a critical tool in helping us achieve our Mission Zero goals.«connie Hensler, Director Corporate LCA Programs, Interface, Inc 25

26 Case study Image: Timberland Challenge In 2009, Timberland set out to halve their carbon emissions by 2015 Solutions Establish a simple measure of environmental impact Realised 90% of its impacts are related to the product Created Green Index to make better products Business value Leading green brand in the outdoor industry Help consumers make purchasing decisions 26

27 Case study Challenge Meet customer demand for environmental information of products Process and feedstock optimization Solution GaBi Software and Databases for life cycle assessment of products and processes Calculation of Wacker-specific LCI data Image: Wacker Polymers Business value Internal and external communication of environmental footprint of their products Time and cost savings through more efficient processes Having access to the latest industry data is a critical success factor for the application of LCA in order to create solutions for our business. GaBi Databases deliver consistent, first-class content for our LCA work. Dr. Marcus Pfaadt, Manager Product Stewardship, Wacker Polymers

28 Case study Challenge Reduce CO 2 emissions in in-house production Solutions Launch of corporate-wide Climate Program New key performance indicator, the Climate Footprint Assess production systems, raw materials and energy used in production and supply chain GaBi Software and data (chemical products, transport, electricity) for analysis and interpretation Business value Decision support on production processes, investments and technology projects 28

29 Case study Images: Puma Challenge Analyze the environmental performance of the various footwear-packaging options Solution Puma s Clever Little Bag replaces the cardboard shoebox with a re-usable shoe bag. (Video) Innovation through Eco-Design Business value Brand enhancement Significant reduction of waste and CO 2 emissions. Annual Savings: 8,500 tons of paper 1 million liters of water 10,000 tons of CO 2 20 million MJ electricity 29

30 Case study Challenge Develop globally-accepted, peer-reviewed method for creation of LCA data Solution Development of global web based system to collect data from all member companies Benefits Benchmark, track performance and report 30

31 Case study Challenge Communicate the benefits of steel Image: Tata Steel Solution Use GaBi Software to build product models covering environmental impacts Interactive reports for EPD creation Business value Marketing tool for product differentiation and to support customers with data on the sustainability of steel Decision making in product development Identification of hot spots in the steel value chain to effectively reduce impacts and resource consumption»life Cycle Assessment helps us to fully understand the benefits across the life cycle and assists us in communicating these to our stakeholders.«allan Griffin, Knowledge Group Leader Sustainability, Tata Steel 31

32 Thank You 32