Customizing the Enterprise Specific Manufacturing Processes

Environmental Product Lifecycle Management – Customizing the
Enterprise Specific Manufacturing Processes
Benjamin Kuhrke1, Eberhard Abele1, Stefan Feickert1, Frank-Dieter Clesle2
1
Technische Universität Darmstadt, Institute of Production Management, Technology and
Machine Tools, Germany
2
TechniData AG, Germany
The most recent EU Directives lay down new conditions toward the environmental responsibility of producers and their products. The requirements to the products’ lifecycles rise continuously. Methods and tools for Life Cycle Assessment (LCA) of products become more and
more important for the industry. Highly sophisticated tools, offering a wide range of environmental data and functionalities are already available. However, due to the high scientific level
of these tools, the applications are very complex. They result often in a lack of integration in
the daily practice. This paper describes the “Environmental Product Lifecycle Management”
approach which integrates the LCA in standard software systems like the mySAP Business
Suite. This will be realized by extending the SAP module Compliance for Products (CfP) of
TechniData AG. Nowadays the CfP manager provides many solutions concerning the material declaration (e.g. check of the fulfilment of certain material lists), RoHS Compliance and
many other material based questions. The product structure within the CfP Manager will be
extended by the processes of the product life cycle; material production, manufacturing, use
and disposal. The main focus of this paper lies on the manufacturing phase of the product
and in particular on the customization of the enterprise manufacturing processes. In this context, customization means to preset all environmental process information, needed for an
LCA. The aim is to enable the calculation of the environmental impact when manufacturing a
specific product within an LCA Compliance tool. After the customization, the user has to enter the product specific information only. In the background the tool combines the manufacturing specific information and the product specific information and calculates the energy and
material flows that are defined in advance.
Keywords: Product Lifecycle Management, Manufacturing, Life Cycle Assessment, SAP
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Transfer-Unit 55
Ökobilanzierung in SAP
Benjamin Kuhrke
Ökobilanz-Werkstatt 2006
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Background
Research Department:
Environmentally sound
products and processes
Institute for Productionmanagement,
Technology and Machine Tools
Technical University Darmstadt
Transfer-Unit 55
Optimised Processes, Methods and
Instruments for the Development of
Environmentally- Friendly Products
C1
C2
C3
C4
C5
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Overview
• motivation and approach
• status quo of the e-business solution
• underlying concept of the Lifecycle Assessment
within the e-business solution
• example to point out the concept with the focus on
the manufacturing processes
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Motivation and Approach of the Project
Motivation
Industry Challenges
Requirements from product
related environmental
protection:
legislation
customer requirements
environmental policy
Problems
• isolated application
• time consuming
• difficulties in interpreting
the results
Scientific Solutions
Life Cycle Assessment
methods
instruments
software solutions
Approach
use of environmental
information which is
already kept in the
enterprises
Life Cycle Assessment
with SAP CfP –
„Compliance for Products“
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Compliance for Products – CfP
AIAG
IMDS
Jeita - Compliance Connect Sheet
IEC and IPC are planned
Data Collection Tool - Technidata
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General Concept
Guidlines
Untersuchungs Ziel
„Goal
rahmenand Scope“
Computer
Lebenswegsbased
Inventory
Berechung der
Analysis
Materials from EH&S
Computer based
Impact
Charakterisierung
Assessment
Gewichtung /
Abwägung
Untersuchungs Scope
rahmen
Modelling
of the
Modellierung
des
Life
Cycle
Lebenswegs
Calculation der
of the
Berechung
Inventory Data
Sachbilanzdaten
Life Cycle Assessment ISO 14040
Disposer
Klassifizierung
Goal
Ziel
Interpretation
External
Supplier
Impact Assessment
Working plan from PP
BASIS
Definition
Sachbilanzdaten
the main challenge of the LCA-tool
development is the “automatic”
inventory analysis
Wirkungsabsch
ätzung
Impact Assessment
Bill of material from MM
Sachbilanz
Inventory
Analysis
Modellierung des
Presentation of results
Enterprise
Definition
Requirements
specification
Environmental Assessment within SAP
LCI
Information/Data
Classification
Klassifizierung
Charakterization
Charakterisierung
Gewichtung /
Weighting
Abwägung
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Concept for the Computer based
Life Cycle Inventory Analysis
Supplier
Bill of materials
from SAP MM/PP
IMDS, AIAG, IPC, own Tool
Product
A
Inventory Analysis
Product structure
in CfP
Inventory
Analysis
DB
A1
Material X, kg
Material Y, kg
Inventory
Analysis
DB
A2
Material X, kg
Information
B
Transportation
km, kg…
B1
Working plan
from SAP PP
Material X, kg
Inventory
Analysis
DB
Scenarios
Inventory
Analysis
DB
Production process A
Process, Time…
B2
Disposer
Production
DB
Material X, kg
Inventory Data
Materials from
SAP EH&S
Recycling Quote
Requirements
specification
Use Processes
Lifetime, Frequency of
Usage etc.
Scenarios
IA
DB
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Example: Electric Brush from Kärcher
battery operated (NiCd-Accumulator)
input power
1,6 W
operating time
20 minutes
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Gathering and Processing of the Transport Data
Switch cpl black
Plastro GmbH
Vendor
Distance
Means
= ton kilometer
1000 km
40 t Truck
0,00013 tkm
Transport data
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Customizing the Manufacturing Processes
Workflow of the application:
Goal: automatic calculation
of lifecycle inventory data
• •attribution
attribution
• •ecological
ecological
activity
activitytype
type
Working plan
from SAP PP
Other data
sources
Product structure
energy-,
energy-,material
material
consumption
consumptionand
and
emissions
emissions
Product
B
B1
Material X, kg
Production process A
process time…
Production
DB
process
processtime
time
other
otheractivity
activitytypes
types
Inventory
Analysis
DB
elementary
elementaryininand
andoutput
output
flows
flows
Goal: Modeling environmental process parameter to enable the automatic
Lifecycle Inventory of the Production Processes
Analyzing the
production
processes
Modeling the
product specific
material and
energy flows
Estimation of the
pre-process
chains
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Customizing the Manufacturing Processes
Analyzing the production processes
Selection of relevant production
processes
• added value -> no transport
• environmental impact
P
cost center X
cost center 1
P
P
M
defining of process boundaries
M
M
M
M
M
cost center
cost center 2
machine
peripherie
defining the system boundary
defining the structure of the process
(Process machine and periphery systems)
e.g. process
time
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defining the ecological activity types
to get product specific energy- and material
flows
Customizing the Manufacturing Processes
Modeling the product specific material and energy flows
energy demand:
ecological activity type = process time
Eprocess = Pworkplace ⋅ tprocess
Pworkplace = Pmachine + Pperiphery / machine
Pmachine = fcorrection ⋅ Pconnection
fcorrection with measurement or expert survey
Psystemj / machine =
Psystemj ⋅ Tsystem / year
N
∑T
i
i=1
Psystem/machine= pro rata Power of one system
Ti= machine operating time
M
Pperiphery / machine =
∑P
systemj / machine
j=1
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Customizing the Manufacturing Processes
Modeling the product specific material and energy flows
operational supplies and waste flows:
ecological activity types = process time, others
time depending
consumption
and waste
parameter value
Cp ( t ) = CPVp ⋅ tprocess
Wp ( t ) = WPVp ⋅ tprocess
1. Consumption per time is equivalent
CPVp =
Cp/year
N
∑T
i
i =1
2. Relation of consumption per time is known
same procedure
Cp/yearfor waste and
N parameters
emissions
CPVp,i =
x i−1 ⋅
∑(x
i =1
1
i −1
⋅ Ti )
3. yearly consumption per machine is known
CPVp,i =
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Cp,i/year
Tmachine
Cp,i/year= consumption
per machine
Customizing the Manufacturing Processes
e.g. machining process
energy demand:
Eprocess = Pworkplace ⋅ tprocess
Pworkplace = Pmachine + Pperiphery
Pmachine = fcorrection ⋅ Pconnection
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Energy measurement
45.000
connection power (43 kVA)
40.000
tool change
machine tool:
Power [VA]
35.000
modern 5 axis Pmeasured = 10,1 kW
machining center
rapid feed
30.000
material:
25.000
= 4 times less connection
actual power
power
Titanium Alloy
20.000
process time:
22 min 65 sec
15.000
correction factor can be
estimated with f = 0,25
10.000
measured base power (8,18 kVA)
5.000
0
0
200
400
600
800
1000
1200
1400
Zeit [sec]
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Customizing the Manufacturing Processes
e.g. machining process
energy demand:
Eprocess = Pworkplace ⋅ tprocess
Pworkplace = Pmachine + Pperiphery
Pmachine = fcorrection ⋅ Pconnection
Pmachine = 10,32 kW
Pperiphery =
171,8 kW ⋅ 4422 h/a
3840 h / a ⋅ 120
Pworkplace = 10,32 kW + 1,64 kW
operational supplies and
waste flows:
CPVlubricant =
31000 kg/a
(3840 ⋅ 60) min/ a ⋅ 120
CPVlubricant = 1,12 ⋅ 10−3 kg/min
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Manufacturing – Accu Brush
push button
Injection
Moulding
Example:
worst case
Production
push button
Process
power hydraulic pump
installed total power
standby power
injection moulding
PDM tree for production processes
55 kW
89 kW
40 kW
Injection Moulding
Process data
Process parameter
Energy parameter
Resources
Emissions
Waste
Machine data
Machine parameter
Energy parameter
Resources
Emissions
Waste
Auxiliary machine data
Machine parameter
Energy parameter
Resources
Production
Specification
Production
Specification
Emissions
Waste Exact Procuction Process Specification
Calculation Structure
push button
active proc...
0,026 kWh
89 kW
* 0,03 H / 100
0,026 kWh
Ressource
K50_28845140_1
push button injection
Quantity
Entity
100
piece
0,03
hour
Working Place
injection moulding
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Use Phase
Accu Brush
Power Charging
1,6 W
Power non Charging
0,2 W
Lifetime
4 years
Charging Time
8 hours
Operating Time per
charged Battery
20 min.
Scenario
Operating Time
per Lifetime
12 hours
Charging Time
per Lifetime
4 years
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Electric and Electronical Waste Treatment
Scenarios
Category
Volume
[l]
Smallest Appliances
Small Appliances
Medium Appliances
Large Appliances
Weight
[kg]
Example
Recycling
Disposal
<1
< 0,5
Mobile Phone, Watch
20 %
80 %
1…15
0,5….3
Telephone, Coffee Machine
50 %
50 %
>15…75
>3…15
Vacuum Cleaner, Microwave
75 %
25 %
> 75
> 15
TV, Air Conditioner
98 %
2%
Volume = 1,5 l50 % Disposal
Combustion
Weight = 1,98 kg
50 % Recycling
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Shredder
Disposer Disclosure
Recycling rates
Ferrous Metals
95%
Non Ferrous Metals
95%
Thermoplasts
PP, PS, ABS
35 %
Residual
0%
Electric and Electronical Waste Treatment
Example: Axis of the Wheel
Weight
Product Category
Recycling in %
Disposal in %
4g
Small Appliance
50 %
50 %
Recycled Fraction
Combusted Fraction
1,9 g
2,1 g
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Zusammenfassung der berücksichtigten Werte
• 100 % Material mit Idemat
• Lediglich 700 g Injection Moulding
• Alle Transporte von den Zulieferen
• Alle Nutzungsprozesse
• Entsorgung mit vorhandener Datenbasis
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Ergebnisse – nur eigene Produktion
100%
80%
60%
Produktnutzung
Transporte
Produktion
Entsorgung Akkubesen
Werkstoffe
40%
20%
0%
ec
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tic
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w
ar
oz
gl
ob
al
ab
io
tic
de
(G
W
pl
et
P1
0
io
n
0)
-20%
12
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Ergebnisse – alle Produktionsprozesse
100%
80%
60%
Produktnutzung
Transporte
Produktion
Entsorgung Akkubesen
Werkstoffe
40%
20%
0%
ye
rd
g
ne
la
ar
m
in
oz
o
gl
ob
al
w
ab
io
ti c
de
pl
et
io
n
(G
W
P
ep
10
le
0)
tio
n
fre
(O
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sh
D
P)
m
w
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ac
n
id
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ca
eu
tio
tr o
n
ph
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at
io
n
-20%
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3 Abschlussfragen
Ist die Abbildung der Produktionsprozesse ausreichend?
Welche Daten muss oder kann ich mindestens von
meinen Zulieferern bekommen?
Bestehen Alternativen zu dem
Datenaustausch mit den Zulieferern?
13