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IAP Workshop. Think twice: Economic benefits of sustainable factories. Tarek Aguizy, Kevin Chen, Stephanie Dalquist, Carsten Finkeldey Christof Irle, Gerald Rothenhöfer, Christoffer Seubert, Kushan Surana. Think twice: economic benefits of sustainable factories. Agenda. Problem definition

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Iap workshop l.jpg

IAP Workshop

Think twice:

Economic benefits of sustainable factories

Tarek Aguizy, Kevin Chen, Stephanie Dalquist, Carsten Finkeldey

Christof Irle, Gerald Rothenhöfer, Christoffer Seubert, Kushan Surana


Agenda l.jpg

Think twice:

economic benefits of sustainable factories

Agenda

  • Problem definition

  • Trend analysis

  • Technology directions

  • Focus on „3-D printing“

  • Summary


Our view of a sustainable factory l.jpg

A sustainable factory is prepared for the future

Think twice:

economic benefits of sustainable factories

Our view of a sustainable factory

Business dimension

  • A sustainable factory ...

  • ... is flexible

  • ... withstands competition

  • ... has the necessary resources (machines, humans, nature)

  • ... meets quality, cost and time requirements

  • ... operates within laws

  • ... is profitable

Technological dimension


Trend analysis l.jpg

Flexibility

Automation

Time

Organisation

Environmentaltrends

- electronic produc-

tion control systems

- new tools

(modular robots)

- shorter develop-

ment times

- shorter order times

- shorter production

times

- flexible workers

- skilled workers

- industry collabora-

tion

- mass customization

- solitary manu-

facturing

- modular cars

- Fuel efficiency

- emissions

- energy costs

- recycling

- legal rules and

restrictions

How to manufacture cars more flexibly

in less time at lower costs ?

Think twice:

economic benefits of sustainable factories

Trend analysis

Environment

Car industry / car factory


Solutions l.jpg

Flexible Tooling

Tooling that can change specifications or enables ultra-rapid changeover

E.g. magnetic field induced polymorphic dies

Interchangeable robot hands

Multi-functional tools

Aggregated assemblies

Plastic or composite-based molding technology for complex modules

E.g. Injection molded composite cars

Fewer, more complex parts

Fewer plant segments

Lower weight

Speed/cost

Recycling benefit

Think twice:

economic benefits of sustainable factories

Solutions


Solutions6 l.jpg

Distributed assembly

Smaller localized assembly plants that source from a larger network of module suppliers

E.g. factories in surging markets with high tariffs (E.g. Argentina, Egypt)

Lower labor costs

Representation in countries forming new markets

Assembly quicker and closer to customer

Self-aware machinery

Integrated heuristic diagnostics, control, and maintenance

E.g. automation of Process Control Systems found in MB supervisory centre

Shorter reaction time during breakdowns

Transparent factory

Quality control

Maintenance-type supervision

WIP-Inventory control

Think twice:

economic benefits of sustainable factories

Solutions


Solutions7 l.jpg

Outsourcing

Increased use of suppliers, move towards concentration of design and innovation core

E.g. split enterprise

Decreased cost

(Perceived) quality

External assembly

External manufacture of non-critical parts

Decreased environmental standards

Knowledge Organization

Improved Information flow leading to efficient use of expertise

E.g. corporate database of expertise

Worker input

Informational redundancy

Think twice:

economic benefits of sustainable factories

Solutions


3 d printing today l.jpg

Think twice:

economic benefits of sustainable factories

3-D Printing Today

  • Current technology

    • precise to 0.005 inches

    • only small parts can be made, no larger than a few inches

    • starches, polymers, metals all can be used

    • slow

  • Current applications

    • rapid prototyping

    • rapid tooling

    • toys, novelties


How is 3 d printing sustainable l.jpg

Think twice:

economic benefits of sustainable factories

How is 3-D printing sustainable?

  • Increases flexibility in development and production

  • Reduces development time and cost

  • Environmentally friendly, as scrap material is reduced

  • Need innovation for sustainable production

  • Not evolutionary, but revolutionary


Effect on pre production l.jpg

Think twice:

economic benefits of sustainable factories

Effect on Pre-Production

  • Production process starts directly from electronic model

  • Less effort to design parts of low complexity, reduction of development time and cost

  • Design cost for tooling eliminated

  • Link between order and production

    • Possibility to combine CAX and ERP

    • Integration of customer order, product data and production planning


Impact on production l.jpg

Think twice:

economic benefits of sustainable factories

Impact on Production

  • Freedom of complexity

    • component assemblies reduced to single parts

    • reduces cost of joining processes, changes in tooling

    • fewer factory segments, stimulates formation of production cells

  • Production sequence flexibility

    • possible to produce small body frame directly after producing a large frame using a single machine

    • more responsive to changes in demand

  • Possible variation in materials

    • Physical Particle Deposition currently used to form alloys during the printing process

    • possible to make one part that contains several different alloys


Issues to overcome l.jpg

Think twice:

economic benefits of sustainable factories

Issues to Overcome

  • Rate of production

  • Scale of parts produced

  • More usable materials must be developed

  • Management must accept major structural / logistical change in production


Summary l.jpg

Think twice:

economic benefits of sustainable factories

Summary

  • Need for automobile manufacturing facilities to be sustainable in the face of upcoming trends

  • Study focused on 3-D printing, a new and innovative method to manufacture cars more flexibly with high automation, in less time and lower cost

  • 3-D research increases production speed, material diversity and cost effectiveness

  • Other promising solutions need further investigation


Acknowledgments l.jpg

Think twice:

economic benefits of sustainable factories

Acknowledgments

  • MIT Germany Program

  • DaimlerChrysler

  • Siemens

  • Dr. Karsten Loehr


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