Factory modelling seeking energy reduction opportunities across building and production systems
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Factory modelling: seeking energy reduction opportunities across building and production systems. Dr Peter Ball Reader in Manufacturing Operations Manufacturing & Materials Department Cranfield University, UK +44 1234 750111, Ext 5657 [email protected]

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Factory modelling seeking energy reduction opportunities across building and production systems

Factory modelling: seeking energy reduction opportunities across building and production systems

Dr Peter Ball

Reader in Manufacturing Operations

Manufacturing & Materials Department

Cranfield University, UK

+44 1234 750111, Ext 5657

[email protected]

www.cranfield.ac.uk/sas/manufacturingsystems/


Fellow conspirators

Fellow conspirators!

  • 1Airbus Operations Ltd

  • 2Cambridge University

  • 3Cranfield University

  • 4De Montfort University

  • 5Integrated Environmental Solutions Ltd

  • 6Toyota Motor Europe

  • P.D.Ball3

  • M.Despeisse3

  • S.Evans2

  • R.M.Greenough4

  • S.B.Hope6

  • R.Kerrigan5

  • A.Levers1

  • P.Lunt1

  • V.Murray5

  • M.R.Oates4

  • R.Quincey5

  • L.Shao4

  • T.Waltniel6

  • A.J.Wright4


Tsb therm project

TSB THERM project

  • THrough-life Energy and Resource Modelling (THERM)

  • THERM seeks to integrate

  • ‘Sustainable Building Design’ tools and ‘Sustainable Manufacturing Process’ tools

  • to achieve an

  • ‘Integrated Sustainable Manufacturing’ system.

  • It is concerned with the creation of a new, innovative commercial modelling tool specifically for the manufacturing industry.

  • Funded by UK’s Technology Strategy Board (TSB)


Sustainable manufacturing activities

Sustainable manufacturing- activities

Manufacturing operations

Consume and dispose of significant amount of energy and other resources

A lot of work on energy reduction, other resource reduction and life cycle design

Typically managed separately to buildings and facilities

Buildings and facilities

Consume and dispose of significant amount of energy and other resources (20-40% space heating typical – M.Oates)

A lot of work on building design and operation

Typically managed separately to operations

Broad and yet narrow view of sustainable manufacturing!


Sustainable manufacturing analysis

Sustainable manufacturing- analysis

Manufacturing operations

Various well known approaches to improve ‘traditionally’

Waste hierarchy can guide improvements

Sophisticated tools for analysis (e.g. Arena, Simul8 & Witness)

Some extensions to include energy use

Rare to analyse with buildings or facilities

Buildings

Guided by codes (BREEAM, LEED)

Sophisticated tools for comfort and energy performance (e.g. IES VE)

Rare to analyse with manufacturing operations

Absence of integrated methods and tools


Project aim

Methodology

Software

Tactics & practices

Step 1

Step 2

Step 3

Tool

Model

Project aim

  • To develop commercially tool for factory energy reduction

  • Secondary work created an improvement methodology and a library of sustainable manufacturing practices


Material energy and waste flows

Material, energy and waste flows

Generalised view ...

... can be applied to production, facilities as well as buildings ...

Materials

Materials

Product

Product

Process

Manufacturing

Process 1

Building

Manufacturing operation & facilities

conceptually simple …

complex in practice …

need to understand…

time

location

quality

etc.

Energy

Energy

Waste

Waste xxxx

Materials

Product

Manufacturing

Process 2

Product

Materials

Energy

Waste yyyy

Waste

Energy

Materials

Service

Support

Process 3

Energy

Waste zzzz

... with the potential to identify and exploit re-use


The waste hierarchy

The waste hierarchy

Hierarchy has potential as basis for improvement methodology ...

Prevent

Reduce

Reuse

http://en.wikipedia.org/wiki/Waste_hierarchy

... which would be enhanced if good practice was available


Examples of practice tactics

Examples of practice & tactics

... to tactics of ‘how’ ...

Measurement

Follow the value and waste

From general collections of ‘what’ ...

Water

Conserve, grey, reuse

Facilities

Air, heating, tolerances

Lighting

Switch off, sensors, removal

Machines

Maintenance, hibernation

Despeisse, Ball, Evans, 2011

... aligns to improvement methods ...

People

Involvement, behaviours

Waste

Separation, purity, seeing it!

... which is enhanced with simulation software support

Prevent

Reduce

Reuse


A methodology for improvement

A methodology for improvement

Ball, Roberts, Dave, Pimenta. GCSM 2013

manual mapping

bespoke spreadsheets

energy simulation software


Architecture

Architecture


Therm modelling tool

THERM modelling tool

Factory building

Manufacturing

processes

Tactics

Dynamic data input

IES Ltd VE-Ware

Eliminate

Stop

Repair

Reduce

Pick up

Change

Output analysis

Attitudes

Modelling & simulation workflow


Example application drying tank model

Example application:Drying tank model

Simulation model

Conceptual model

Simulation results and analysis

Applying tactics to results:

A11 Align resource input profile with production schedule`

Despeisse, Oates, Ball (2013)


Impacts of energy efficiency action

Impacts of energy efficiency action

Ball, POMS 2012

switch off

hibernate

decommission

Prevent

manage technology

smooth flow

product velocity

Reduce

Reduces flexibility?

Operationally easier?

Design

Operational

harvest locally

harvest pan-factory

intensify capital

Reuse

Dispose

forced vent

passive vent

slower operations

highest

impact

actions

constraints

waste

hierarchy


On going work

On going work …

  • Refinement of IES VE-THERM simulation environment

  • Further research now beyond original collaborators

  • Understanding how to use the tool across functional boundaries

  • Plus how to cope with lack of data (or too much!)

www.therm-project.org

THrough-life Energy and Resource Modeling


Next centre for industrial sustainability

Next … Centre for industrial sustainability

A national Centre

  • Core EPSRC funding £5M over 5 years

  • 88 PhD students … developing future leaders

  • 4 universities, 20+ companies

  • www.industrialsustainability.org


Factory modelling seeking energy reduction opportunities across building and production systems1

Factory modelling: seeking energy reduction opportunities across building and production systems

Questions?

www.industrialsustainability.org

Dr Peter Ball

Reader in Manufacturing Operations

Manufacturing & Materials Department

Cranfield University, UK

+44 1234 750111, Ext 5657

[email protected]

www.cranfield.ac.uk/sas/manufacturingsystems/

www.therm-project.org


References

References

  • Ball, P.D. 2012. The impact of low energy production on scheduling and flow, Proceedings of the Production and Operations Management Society (POMS) international conference, Chicago, USA, April 2012.

  • Ball, P.D., Roberts, S., Davé, A. & Pimenta, H. 2013 Towards a factory eco-efficiency improvement methodology, Global Conference on Sustainable Manufacturing (GCSM), Berlin, Germany, September.

  • Despeisse, M., Ball, P.D. & Evans, S. 2011. Modelling and tactics for sustainable manufacturing: an improvement methodology, 9th Global Conference on Sustainable Manufacturing, 28-30 September 2011, Saint Petersburg, Russia. Republished in Sustainable Manufacturing: shaping global value creation, Ed: Seliger G., SpringerLink series 10152, 2012, pp9-16.

  • Despeisse, M., Oates, M.R. & Ball, P.D. 2013. Sustainable manufacturing tactics and cross-functional factory modelling, Journal Cleaner Production, Vol. 42, pp. 31-41. DOI: 10.1016/j.jclepro.2012.11.008.


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