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This tutorial includes: Models to navigate through and to follow the built up Case Studies

Process Oriented Analysis For Design and Optimization of Industrial Production Systems. This tutorial includes: Models to navigate through and to follow the built up Case Studies Questions and answers to apply your knowledge The questions are taken from the book. Start.

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This tutorial includes: Models to navigate through and to follow the built up Case Studies

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  1. Process Oriented Analysis For Design and Optimizationof Industrial Production Systems • This tutorial includes: • Models to navigate through and to follow the built up • Case Studies • Questions and answers to apply your knowledgeThe questions are taken from the book. Start Navigation buttons through the tutorial are placed at the top on the right hand side of the slides.

  2. POA Toolbox Select a tool of your interest. Click on one of the six tools in the toolbox. Project POA Toolbox Static Analysis Tools Goal VFD Value Flow Diagram Flow Diagram RFD Resource Flow Diagram Dynamic Analysis Tools Simulation Model State Chart Real-Time Control

  3. Flow Diagram Toolbox • Build up a model of a Flow Diagram on the example of a bar. • Apply Your Knowledge:Question 1: Flows are incorrect named. Re-label the flows.Question 2: Draw the context diagram of a bakery. • POAdesignerDraw you own diagrams with the demo version of POAdesigner.This demo version allows to design single diagrams. They cannot be connected in the hierarchy or in a model. To install the demo version of POAdesigner:- Download POAdesigner-demo.zip.- Decompress the zip-file. It contains the setup.exe-file of the demo version of POAdesigner.- Execute the program by clicking on the icon on your desktop. To run POAdesigner, you need the .NET Framework v2.0. It is a free download from Microsoft.

  4. Customer.hungry+thirsty 1 Serve Customer.satisfied customer Flow Diagram – Model of a Bar Flow Diagram Toolbox Follow step-by-step the built-up of a model In this case, it is the model of a bar. For each next step, click on the forward button. Step 1: State the purpose of the bar What is the purpose of the bar? Express it in one sentence: „Make customers happy by serving them good drinks and food.“ This purpose can be depicted as a simple Flow Diagram with a single process “Serve customer”.

  5. Customer.still-thirsty+hungry Customer. hungry+thirsty 1.1 Food Customer Place .waiting Drink customer + Customer .served take order 1.2 waitress Serve drink + food 1.5 Customer waitress .needs Eat food + drink table Customer.fine 1.4 1.3 Use Ask for bill + restroom pay for food Customer .satisfied restroom Customer.ok table Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 2: Product flow with the main processes Child diagram of process 1 “Serve customer”

  6. a Customer.hungry+thirsty c Water Customer Bill.Request Environment Electricity Bill.paid Customer.satisfied Waste 0 Sewage Make b Order.Goods customer Restroom. Supplier Goods.new happy Infrastructure Bill.Goods bar Kitchen. Waitress Infrastructure e Manager d Bar. Personnel Cleaner Infrastructure Infrastructure Barkeeper Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 3: System boundary with the context diagram

  7. Customer.hungry+thirsty Sewage Restroom.Infrastructure Electricity Customer.satisfied 1 Waitress Water Serve Water-1 customer Menu Electricity.Bar waitress Bill.Request AirCondition-1 Bill.paid Plate.removed 4 Electricity.Cooking Distribute resources Drink 2 Water-3 + remove waste Prepare Food.onPlate + clean Air drinks CustomerOrder.Drink Condition-5 + food employee CustomerOrder.Food bar + Barkeeper Waste. Food-Drink kitchen Bar.Infrastructure Account.Bar 3 Manager Manage Goods.stocked bar + buy Order.Goods Drink.missing Kitchen. goods Infrastructure Food.missing Goods.new owner Cleaner Waste.Shopping Waste Bill.Goods Waste.Decor Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 3: System boundary with the context diagram Next level of the model, showing process 1 “Serve customer” and additional processes.

  8. Flow group Flow type Line style product product blue solid bold various material material blue solid waste black solid information paper gray solid verbal gray dotted resources water black dashed electricity black dashed labor black dot-dashed infrastructure black dot-dashed-dot Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 4: Flow types and subtypes

  9. 0 Make customer happy 1 Serve customer 1.1 Place customer + take order 1.2 Serve drink + food 1.3 Ask for bill + pay for food 1.4 Use restroom 1.5 Eat food + drink 1.6 Operate cash register 2 Prepare drinks + food 3 Manage bar + buy goods 3.1 Make planning + organize 3.2 Calculate + control cost 3.3 Purchase good 3.4 Decorate bar 3.5 Handle complaints of customer 4 Distribute resources + remove waste + clean Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 5: Hierarchy of processes and flows

  10. Customer.still-thirsty/hungry Customer. hungry+thirsty Food.onPlate Electricity.Bar-1.2 1.1 Electricity.Bar Drink Place Menu customer + Electricity.Bar-1.5 Customer take order .waiting Customer .served 1.2 Customer Order.Drink Serve drink AirCondition-1 + food Menu. served CustomerOrder.Food waitress Restroom. Infrastructure 1.5 Waitress-1.1 Waitress-1.2 Waitress Eat food + drink Customer.fine Waitress-1.6 Waitress-1.3 Plate.empty Water-1 table 1.6 Operate 1.3 Customer cash .needs Bill.Request Ask for bill + register pay for food 1.4 Bill.open waitress Customer.ok Use table restroom restroom StatementAccount.Bar Plate.removed Bill.paid Sewage Customer.satisfied Waste Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 5: Hierarchy of processes and flows Child diagram of process 1 “Serve customer” with all flows.

  11. Manager Manager-1 Manager-2 3.1 Reservation Budget Make planning + Reservation .confirmation 3.2 Examination organize Calculate + control Planning costs Account.Purchase Manager-3 Planning.Decor 3.3 3.4 Waste Order.Goods .Decor Purchase Decorate Goods.new goods bar Decor.new Bill.Goods Manager-5 3.5 Goods.stocked Drink.missing Handle Complaint Food.missing complaints Measure Waste.shopping of customer Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 5: Hierarchy of processes and flows Child diagram of process 3 “Manage bar + buy goods”.

  12. Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 6: Balance model While detailing processes into child diagrams, one learns more about the model and draws more flows going in and out of the child diagram than there are flows going in and out of the parent process. This is normal within the procedure of designing a model. Therefore, from time to time you need to check the level balance. Check the flows of the parent processes against the flow of the child diagram for the model of the bar. Some flows are not balanced. Do you find them?

  13. Description Description Description Make customers happy by serving them drinks and food. The customer leaving the bar is fine, and no longer hungry or thirsty. He/she had some entertaining chats with other customers and the waitress. He/she liked the food, and he/she is likely to come back. Includes all the infrastructure of the kitchen. This includes the space with the pertaining rent, utilities, depreciation, and interests. These serve to calculate costs for preparing meals. Person who wants something to drink and/or eat. The management of the bar includes the task of organizing, scheduling, human resources, planning, purchasing of goods, and organization of maintenance and repairs. Flow type Product Customer.hungry+thirsty Flow type Infrastructure Flow type Product Customer.satisfied Description Kitchen.Infrastructure 3 Manage bar + buy goods owner Flow Diagram – Model of a Bar Flow Diagram Toolbox Step 7: Element specification

  14. 5 Supervise laundry CustomerAddress SalesSlip Instruction Feedback Laundry Feedback Instruction Instruction owner Washing 1 Wash laundry Laundry Feedback Agent Feedback 2 Dry laundry Laundry washing machine 3 Iron + pack laundry Waste tumble dryer Laundry Water Electricity Bag Water Electricity 4 Prepare + distribute resources Electricity Electricity Water Water Flow Diagram –Question 1 Flow Diagram Toolbox Some of the flow names of the Flow Diagram of doing the laundry are incorrect. They violate Rule F7 (Chapter S1.3.5) that states that each flow name within a model must be unique. Re-label the flows with unique names and find a way to label them in a logical and easy to understand manner. Solution Help

  15. 5 Supervise laundry CustomerAddress SalesSlip Instruction Feedback Laundry Feedback Instruction Instruction owner Washing 1 Wash laundry Laundry Feedback Agent Feedback 2 Dry laundry Laundry washing machine 3 Iron + pack laundry Waste tumble dryer Laundry Water Electricity Bag Water Electricity 4 Prepare + distribute resources Electricity Electricity Water Water Flow Diagram – Question 1 Flow Diagram Toolbox Incorrect labeled flows are highlighted. Solution

  16. Flow Diagram – Question 1 Flow Diagram Toolbox Re-labeled Flow Diagram of doing the laundry. 5 Supervise laundry CustomerAddress SalesSlip Instruction.Washing Feedback Laundry Feedback-1 Instruction.ironing Instruction .drying owner Washing 1 Wash laundry Laundry.washed Feedback-2 Agent Feedback-3 2 Dry laundry Laundry.dry washing machine 3 Iron + pack laundry Waste tumble dryer Laundry.finished WasteWater-1 Electricity-1 Bag Water-1 Electricity-2 4 Prepare + distribute resources Electricity Electricity-3 Water WasteWater

  17. Flow Diagram – Question 2 Flow Diagram Toolbox Context diagram for industrial bakery For this question, a system is described in words: An industrial bakery is to be investigated. The bakery produces different products. The investigation contains only the production line for cookies. The production line of the cookies begins with the mixing of dough, for which various ingredients are needed, and ends with the finished cookies, packed into a box for shipping. The administration and the sales department of the industrial bakery are not objects of the investigation and should be indicated on the context diagram as external entities. Draw the context diagram to et the boundaries of the system to be investigated. Solution

  18. Electricity Resource Product Recipe supply Water development ProductionPlan Flour 0 Warehouse Cookies.packed Sugar Stock Produce ingredients Eggs cookies Butter Other Ingredients Crust & Co. WasteEnergy Environment PackingMaterial Waste Stock material WasteWater Labor Administration Feedback + sales ProductionOrder Flow Diagram – Question 2 Flow Diagram Toolbox Context diagram of an industrial bakery.

  19. Value Flow Diagram Toolbox • Case Study: Cost analysis in a weaving mill. • Investment analysis for a new loom. Support for the decision making. • Apply Your KnowledgeQuestion 1: Flow classification in a production line. Question 2: Process balance and calculation in split and merge

  20. Warp Weft VFD – Case Study of a Weaving Mill VFD Toolbox The VFD models here shows the costs calculated for 100 m of finished fabric. You can see the context diagram and the diagram of the next level with the main processes. The diagram with the main processes is listed several times. Each time with the product flow and one other flow group. The flow groups in this model are: - Materials - Information - Resources - Monetary resources

  21. VFD – Case Study of a Weaving Mill VFD Toolbox Context diagram of the waeving mill. Dye+chemicalCU 227.47 Service.Waste Removal Various BrineCU 2.00 Environment material CU 2.48 VariousMaterialCU 4.62 FreshWater ElectricityCU 43.89 CU 1.09 Energy PropaneCU 4.65 Waste.Disposed Oil CU 18.37 CU 0.00 SewageCU -71.16 YarnOrder CU 0.00 Yarn supplier Produce fabric WeaveFine CustomerOrder Customer YarnCU 543.31 CU 0.00 YarnInvoice Acknowledgment CU 0.00 CU 0.00 Wrapping.back Inquiry CU 0.00 CU 2.00 Statistics CU 0.75 Fabric02CU ??? Pay ShippingDocu CU 442.36 CU 0.00 Maintenance ProductionPaper CU 49.90 Administration + other costs Product development SpaceCU 120.11 CU 3.00 MarketingCU 32.55 Mach.Dep+IntCU 104.52 Pay.AdministrationCU 71.43

  22. 3 Color+chemical 1 CU 227.47 Sell fabric Finish + Fabric.finished RawFabric.Buffer schedule CU 1,509.99 sales CU 780.54 fabric department 2 finishing Yarn Weave + CU 534.31 CU 578.13 schedule raw Wrapping.back fabric CU 2.00 Various 4 5 weaving Material-3 Prepare CU 246.31 Forward + CU 3.04 resources bill article VariousMaterial-2 Waste.weaving CU 1.30 CU 18.69 forwarding VariousMaterial CU 164.15 CU 4.62 PackingMaterial 6 CU 0.28 Fabric.without Dispose Waste. Waste.finishing CU 12.40 PassedOnCosts of waste disposed Waste.forwarding CU 0.12 CU 1,522.90 CU 33.69 VFD – Case Study of a Weaving Mill VFD Toolbox Product and material flows.

  23. Customer.inquiry CustomerOrder Fabric.finished Acknow- Order CU 33.74 1 3 ledgment CU 1,509.99 Agreement-SF Sell Finish + Order.orig CU 3.72 Statistics fabric Order.deadline schedule CU 0.75 Agreement-FF fabric sales Order.opened 5 Coupon.ready CU 6.75 department finishing Prepare Order.copy RawFabricStock resources Order. Invoice CU 2.25 opened-4 WeaveOrder CU 11.17 Forwarded CU 33.74 ID-Coupon Yarn 2 4 CU 534.31 Weave + Forward + RawFabric.Buffer schedule YarnOrder Finish Order. waste bill article CU 780.54 raw fabric Yarn. Agreement-FW Invoice forwarding Weaving ProductionPaper-3 CU 2.00 Fabric. ProductionPaper-2 Forwarding without CU 1.00 .waste Passed 6 OnCosts Dispose CouponCard.waste ProductionPaper CU 1,522.90 of waste CU 3.00 WeavePaper.waste Shipping.docu CU 26.22 [Flows without a value label have the value CU 0.00.] VFD – Case Study of a Weaving Mill VFD Toolbox Information flows

  24. ElMachine-3 CU 23.89 3 Light-3 CU 0.96 Finish + 1 AirCondition-3.2 CU 0.04 Fabric. schedule Sell fabric ElForklift-3.2 CU 0.04 finished fabric CU 1,509.99 ElComp-3 CU 0.05 sales finishing Water-3 CU 1.09 department Propane-3 CU 4.65 Oil.HotWater-Washing CU 2.70 6 RawFabric .Buffer CU 780.54 Oil.HotWater-Dye CU 11.76 Dispose of waste CU 4.73 Oil.Steam-Dye Sewage-3 CU -71.16 Yarn CU 534.31 5 Electricity 2 ElMachine-2CU 11.95 CU 43.89 Light-2CU 1.59 Prepare Weave + FreshWater resources schedule raw AirCondition-2 CU 3.75 CU 1.09 fabric ElForklift-2CU 0.03 Brine CU 2.00 ElComp-2CU 0.03 weaving Propane CU 4.65 Oil CU 18.37 4 Light-4 Sewage Fabric. Forward + CU 0.13 CU -71.16 without bill article PassedOn Value.Office CU 39.16 ElComp CU 0.01 Costs forwarding ProcessCost-5 CU 14.18 ElForklift-4 CU 0.01 CU 1,522.90 VFD – Case Study of a Weaving Mill VFD Toolbox Resource flows

  25. Pay 1 Pay-1 Pay-3 CU 442.37 CU 72.72 Sell fabric CU 222.87 Pay-5 sales dep 3 Fabric CU 6.43 Space CU .finished Finish + 120.08 Space-3 CU 32.84 CU 1,509.99 schedule Maintenance-3 Space-5 fabric Service.WasteRemoval CU 37.39 CU 42.55 CU 2.48 finishing Mach.WD+Int-3 Waste.Fee CU 60.61 5 CU 0.51 RawFabric.Buffer Prepare CU 780.54 Waste.Wood resources Yarn CU 0.22 CU 534.31 Pay-2 2 CU 124.27 Space-2 Weave + Waste.industrial CU 35.98 schedule CU 1.75 Maintenance-2 fabric 6 CU 10.13 Dispose Mach.WD+Int-2 weaving Pay-4 Mach. of waste CU 43.15 WD+Int-5 CU 16.08 4 CU 0.72 Space-4 Maintenance-5 CU 8.73 Forward + CU 0.97 bill article Fabric. Maintenance-4 Maintenance without PassedOn CU 49.91 CU 1.42 forwarding Mach.WD+Int-4 Mach.Dep+Int Costs CU 0.02 CU 104.50 CU 1,552.90 VFD – Case Study of a Weaving Mill VFD Toolbox Monetary resource flows

  26. VFD – Investment Analysis VFD Toolbox The VFD is a very helpful tool in deciding on a potential investment. For example, the replacement of an old machine by a new one requires only a few changes to the parameters and their quantities in some element specifications. In this example, an investment analysis is shown for a weaving mill. An old loom should be replaced. The process and the flows below are labeled with the actual values. Warp CHF 393.74 WeavePaper CHF 13.19 Work.Operator CHF 59.57 Electricity-4 CHF 14.86 4 Weft CHF 239.09 Fabric CHF 773.42 Weave fabric Climatization-4 CHF 3.20 WeavePaper.done Room-4 CHF 16.27 CHF 13.19 Loom Maintenance-4 CHF 6.33 Waste.Loom CHF 140.59 CHF 7.17 Depreciation+Interests-4 CHF 47.00

  27. VFD – Investment Analysis VFD Toolbox The process specification shows the parameters of the old and the new loom side by side. The parameters that differ are highlighted in orange. 4 Weave fabric old loom new loom Comment WeaveTime = WeftDensity * WarpLength / Speed * Efficiency Loom is shut down over weekend for 1 ½ days. Looms work 132 h/week. Speed is dependent from yarn. slower faster Efficiency normal is 90% many breakdowns better efficiency Parameter Number of looms 50.00 mach 50.00 mach WeaveHours per Week 132.00 h/week 132.00 h/week Maintenance per machine 2‘100.00 CHF/y 3‘500 CHF/y Depreciation + interests per machine 15‘600.00 CHF/y 30‘000.00 CHF/y Efficiency 80.00 % 90.00 % WeftDensitiy 16.00 weft/cm 16.00 weft/cm WarpLength 3‘094.00 m/warp 3‘094.00 m/warp Speed 300.00 pics/min 330.00 pics/min WeaveTime per warp in weeks 2.60 weeks/warp 2.10 weeks/warp Fabric – (Werp + Weft) = 773.42 – (393.74 + 239.09) = 148.41 CHF/100m 159.72 CHF/100m Key Value added

  28. VFD – Investment Analysis VFD Toolbox As an example of a flow specification, the „Electricity-4“ is given here. The parameter „Consumption electricity machine“ is different for the old and the new loom. Electricity-4 old loom new loom Comment Time is defined in the process „Weave Fabric“ Flow Type Electricity Parameter Consumption electricity machine 5.30 kW 8.40 kW Prices electricity 0.15 CHF/kW 0.15 CHF/kW Consumption * WeaveTime * PriceElectricity * [Standardization] = 5.30 kW * 2.30 week/warp * 132 h/week * 0.15 CHF/kW * [100 m / 1836 m] Calculation Flow Value 14.36 CHF/100m 19.02 CHF/100m

  29. VFD – Investment Analysis VFD Toolbox This diagrams show the values of the old and the new loom. The values that change for the new loom are indicated in orange on the diagram. It can be seen, that the „Fabric“woven on the new loom is more expensive than „Fabric“ woven on the old one. In this case, the investment in a new loom is not recommended. Warp CHF 393.74 WeavePaper CHF 13.19 Work.Operator CHF 59.57 Electricity-4 CHF 14.86 CHF 19.02 4 Weft CHF 239.09 Fabric CHF 773.42 Weave fabric CHF 802.11 Climatisation-4 CHF 3.20 CHF 3.20 WeavePaper.done Room-4 CHF 16.27 CHF 13.14 CHF 13.19 Loom Maintenance-4 CHF 6.33 CHF 8.52 Waste.Loom CHF 140.59 CHF 7.17 Depreciation+Interests-4 CHF 47.00 CHF 169.28 CHF 73.00

  30. VFD – Question 1 VFD Toolbox Solution The following Flow Diagram describes the noodle production on pasta line 2. Do the classification for the flows of this production line in form of a list, with flow categories, flow groups, and flow types. Production Labor Labor.supervisor 4 Order Feedback1 Supervise Instruction Labor-1 Instruction1 pasta line Report Labor-2 Egg supervisor Instruction2 1 Dough Recipe Mix dough Labor3 Flour Waste.reusable Water Instruction3 pasta line 2 2 Salt Feedback2 Waste1 Form + dry Feedback3 noodles HotAir Noodles.dry Electricity1 Waste2 pasta line 2 3 Electricity2 Waste3 Waste Pack noodles Maintenance1 Electricity Electricity3 Maintenance2 packing Maintenance Maintenance3 Noodles.forQualityControl Noodles.packed PackingMaterial

  31. VFD – Question 1 VFD Toolbox Table for classification of flows for a noodle production.

  32. Production Labor Labor.supervisor 4 Order Feedback1 Supervise Instruction Labor-1 Instruction1 pasta line Report Egg Labor-2 supervisor Instruction2 1 Dough Recipe Mix dough Labor3 Flour Water Waste.reusable Instruction3 pasta line 2 Salt 2 Feedback2 Waste1 Form + dry noodles Feedback3 HotAir Noodles.dry Electricity1 Waste2 pasta line 2 3 Electricity2 Waste3 Waste Pack noodles Maintenance1 Electricity Electricity3 Maintenance2 packing Maintenance Maintenance3 Noodles.forQualityControl Noodles.packed PackingMaterial VFD – Question 1 VFD Toolbox Flow Diagram with classified flows.

  33. CU 115.00 Fabric.Wool 1 Produce business suit TopSuit Inc. CU 4.45 Buttons BusinessSuit Zip+Button CU 0.50 Waste Lining CU 3.20 Labor Pattern Electricity (El) ProductionInfo Maintenance+facilities (MF) VFD – Question 2 VFD Toolbox The two diagrams (on this and the next page) describe the production of a business suit. Calculate the missing flow values of the parent and child diagram. CU stands for Currency Unit, a neutral monetary unit.

  34. VFD – Question 2 VFD Toolbox Solution ProductionInfo CU 2.00 Fabric.Wool (5 m) CU 115.00 Labor.Supervisor 1.6 CU 4.80 Buttons.Jacket CU 4.45 1.1 Instruction-1.1 Supervise shop floor Pattern CU 0.80 Cut Pieces fabric Waste (20 %) Instruction-1.2 .Jacket Labor-1.1 CU 3.20 (3.5 m) cutter Pieces.Trousers (1.5m) 1.2 Sew El-1.1 Lining Labor-1.2 jacket CU 0.2 CU 3.20 Labor CU 52.00 El-1.2 jacket line Electricity (El) CU 0.2 El-1.3 CU 0.1 Labor-1.3 CU 11.00 Instruction-1.3 1.3 Sew Labor-1.4 CU 3.00 El-1.4 CU 0.4 trousers Zip+Button CU 0.50 Jacket trousers line MF-1.3 CU 2.00 1.4 MF-1.1 Iron suit + control quality Maintenance+facilities CU 1.20 Instruction-1.4 (MF) Trousers BusinessSuit MF-1.4 CU 0.90 MF-1.2 CU 4.50

  35. VFD – Question 2 VFD Toolbox Flows and processes with calculated values. CU 115.00 Fabric.Wool 1 Produce business suit TopSuit Inc. CU 4.45 Buttons BusinessSuit CU 184.14 Zip+Button CU 0.50 Waste CU 25.31 Lining CU 3.20 Labor CU 74.00 CU 0.80 Pattern Electricity (El) CU 0.9 ProductionInfo CU 2.00 CU 69.14 Maintenance+facilities (MF) 8.60 CU

  36. VFD – Question 2 VFD Toolbox ProductionInfo CU 2.00 Fabric.Wool (5 m) CU 115.00 CU 4.80 Labor.Supervisor 1.6 Buttons.Jacket CU 4.45 1.1 Instruction-1.1 CU 1.70 Supervise shop floor Pattern CU 0.80 Cut Pieces fabric Waste (20 %) Instruction-1.2 .Jacket CU 25.31 CU 1.70 Labor-1.1 CU 3.20 (3.5 m) cutter Pieces.Trousers CU 70.87 CU –13.76 (1.5m) 1.2 CU 30.37 Sew El-1.1 Lining Labor-1.2 jacket CU 0.2 CU 3.20 Labor CU 74.00 CU 52.00 El-1.2 jacket line Electricity (El) CU 0.2 CU 0.9 CU 61.60 El-1.3 CU 0.1 Labor-1.3 CU 11.00 Instruction-1.3 1.3 CU 1.70 Sew Labor-1.4 CU 3.00 El-1.4 CU 0.4 trousers Zip+Button CU 0.50 Jacket trousers line CU 132.47 MF-1.3 CU 2.00 CU 15.30 1.4 MF-1.1 Iron suit + control quality Maintenance+facilities CU 1.20 Instruction-1.4 (MF) CU 8.60 Trousers CU 1.70 BusinessSuit CU 45.67 CU 6.00 MF-1.4 CU 0.90 CU 184.14 MF-1.2 CU 4.50

  37. Resource Flow Diagram Toolbox • Navigate through the hierarchy of a model: Case study of croissant production. • Built up a model of a RFD: Gas station. • Apply Your KnowledgeQuestion 1: Mass balance. Question 2: Embodied energy. For this question, please see Question 8 of the Chapter „Apply your knowledge“ of Section S3 of the book. Given here is the solution for this question.

  38. Ready-to-bake Croissants.bag 389.3 kg 11,797.5 pieces Retail market Product waste 24.2 kg Bags 1,972 pieces Cattle food Raw material Water 107.3 kg delivery supply Flour 302 kg Broken bags 15 pieces P0 Produce ready-to-bake croissant P0 Waste disposal Butter 87 kg Waste water P5 10.1 kg Ingredients 14.1 kg Cleaning agent 0.1 kg Waste energy 251.5 kWh Flour P2 10 kg Steam 83.2 kg Electricity + gas 251.5 kWh Energy Environment Labor 195 WMK supply RFD – Navigate through model RFD Toolbox To navigate through the hierarchy, click on the parent process to show the child diagram.

  39. Ingredients 14.1 kg Butter 87 kg Electricity P1 20 kWh Flour 292 kg Prepare dough P1 Labor P1 30 WMK Water 97.3 kg Product waste P1 10.4 kg Dough.cooled 480 kg Waste energy P1 20 kWh Flour P2 10 kg P2 Prepare raw croissant Dough waste P2 14.5 kg Electricity P2 5 kWh Waste energy P2 5 kWh Labor P2 75 WMK Trays clean Waste energy P5 5 kWh 600 pieces RawCroissant.tray 475.5 kg 11,887.5 pieces Water P5 10 kg P5 Clean tray Cleaning agent 0.1 kg Electricity P5 5 kWh Electricity P3 8kWh P3 Pre-bake croissant Trays dirty Waste water P5 10.1 kg Waste energy P3 600 pieces 113 kWh Thermal Energy P3 Croissant waste P3 105 kWh 1 kg Gas 211 kWh P6 Burn gas Ready-to-bake Steam 83.2 kg Croissant.baked Waste energy P6 391.3 kg 106 kWh 11,857.5 pieces Broken bags 15 pieces P4 Pack croissant Electricity P4 2.5 kWh Croissant waste P4 Bags 1,972 pieces 2 kg, 60 pieces Labor P4 90 WMK Waste energy P4 2.5 kWh Ready-to-bake Croissant.bag 389.3 kg 11,797.5 pieces RFD – Navigate through model RFD Toolbox First level of detail „Produce Ready-to-bake Croissants“ Exergy analysis

  40. Flour P2 Electricity P2 5 kWh Electricity P2.1 2 kWh Electricity P2.2 10 kg 3 kWh Trays clean 600 pieces Labor P2 Labor P2.2 Labor P2.1 RawCroissant.tray P2.2 P2.1 Rolled-out dough 475.5 kg Roll-out Form Dough.cooled 11,887.5 pieces dough croissant 480 kg 477 kg Waste energy P2.1 Waste energy P2.2 3 kWh 2 kWh Waste energy P2 5 kWh Dough waste P2.1 3 kg Dough waste P2 14.5 kg Dough waste P2.2 11.5 kg RFD – Navigate through model RFD Toolbox Second level of detail „Prepare raw croissant“

  41. Electricity P3.2 Electricity P3.3 Electricity P3 8 kWh Electricity P3.1 2 kWh 3 kWh 3 kWh Thermal Thermal energy P3 energy P3.1 35 kWh 105 kWh Thermal energy P3.2 P3.3 Cool croissants 70 kWh RawCroissant.tray P3.1 Pre-cure croissant 475.5 kg 11,887.5 pieces Croissant. pre-cured Croissants. pre-baked 391.3 kg 475.5 kg P3.2 Pre-bake croissant Steam 83.2 kg Ready-to-bake Croissant.baked 391.3 kg 11,857.5 pieces Trays dirty Croissant waste P3 600 pieces 1 kg Waste energy P3.1 Waste energy P3.1 Waste energy P3 72 kWh 38 kWh 113 kWh RFD – Navigate through model RFD Toolbox Second level of detail „Pre-bake croissant“ 1st level

  42. Croissant waste P4 2 kg, 60 pieces Ready-to-bake Ready-to-bake Croissants.bag 389.3 kg 11,797.5 pieces Croissant.baked Croissant. feed-back 130.8 pieces P4.2 Fill-in croissant 391.3 kg 11,857.5 pieces Croissant.bag 11,797.5 pieces Croissants. P4.1 Dose croissant Pack bags into boxes P4.4 counted Bags.labeled 11,988.3 pieces Waste energy P4.1 Waste energy P4.2 Electricity P4.2 Waste energy P4 2.5 kWh Electricity P4.1 Labor P4 90 WMK Electricity P4.3 Waste energy P4.3 Electricity P4 2.5 kWh P4.3 Prepare bag Broken bags 15 pieces Bags 1,972 pieces RFD – Navigate through model RFD Toolbox Second level of detail „Pack croissant“ 1st level

  43. P2 Prepare raw croissant Flour P2 10 kg Dough.cooled 480 kg Dough.waste P2 14.5 kg RawCroissant.tray 475.5 kg, 11,887.5 pieces Exergy 0 kWh P3 Pre-bake croissant Electricity P3 Exergy 8 kWh WasteEnergy P3 ThermalEnergy P3 Gas 18.8 cbm Exergy 46.2 kWh Exergy 105 kWh Exergy 211 kWh Croissant.waste P3 Ready-to-bake croissants.baked 391.3 kg 1 kg Exergy 0 kWh P6 Burn gas WasteEnergy P6 Steam 83.2 kg 11,857.5 pieces Exergy 106 kWh Exergy 5.5 kWh Exergy 7.7 kWh P4 Pack Ready-to-bake Croissant.bag Croissant.waste P4 croissants 389.3 kg 11,797.5 pieces 2 kg, 60 pieces RFD – Navigate through model RFD Toolbox First level of detail: Exergy analysis (extract from diagram)

  44. RFD – Model of a Gas Station RFD Toolbox Build up an RFD model of a gas station. Main processes with product flow and mass calculation for a gas station. P2 P1 Car.filled-up_dirty 1,529.9 kg Car.ready 1,529 kg Car.dirty_tank.empty 1,500 kg Fill Clean gasoline car Gas pump Car wash P3 Pay bill Cash desk

  45. RFD – Model of a Gas Station RFD Toolbox Main processes (1stlevel of detail) with product and resource flows and values. Water gas station 120 kg Electricity WashingStation 8 MJ Electricity GasStation 11.5 MJ Chemicals 0.2 kg Electricity GasPump 2 MJ P2 P1 Car.filled-up_dirty 1,529.9 kg Car.ready 1,529 kg Car.dirty_tank.empty 1,500 kg Fill Clean gasoline car WasteWater GasStation 121.1 kg Electricity CashDesk 1.5 MJ Gas pump Car wash WasteEnergy Carwash 8 MJ Gasoline 30 kg WasteEnergy GasPump 2 MJ GasEmissions 0.1 kg P3 WasteEnergy CashDesk 1.5 MJ Pay bill WasteEnergy GasStation 11.5 MJ Cash desk

  46. Electricity WashingStation Electricity Mainwash Electricity prewash Electricity finish Car.ready 1,529 kg Chemicals P2.1 Car.filled-up_dirty 1,529.9 kg Prewash P2.3 P2.3 car Finish Finish Wax car car WasteWater Prewash+ Car_dirty Detergent WasteWater finish Water finish WasteWater GasStation Water prewash Water Mainwash Water GasStation Car.prewashed P2.2 P2.2 WasteEnergy finish Clean car in main wash Car.washed WasteWaster Mainwash+Car_dirty WasteEnergy CarWash WasteEnergy Prewash WasteEnergy Mainwash RFD – Model of a Gas Station RFD Toolbox Second level of detail RFD with product flow and values.

  47. Electricity WashingStation Electricity Mainwash Electricity prewash Electricity finish Car.ready 1,529 kg Chemicals 0.2 kg P2.1 Car.filled-up_dirty 1,529.9 kg Prewash P2.3 P2.3 car Wax 0.1 kg Finish Finish car car WasteWater Prewash+ Car_dirty 30.4 kg Detergent 0.1 kg WasteWater finish 10 kg Water finish 10 kg WasteWater GasStation 121.1 kg Water prewash 30 kg Water Mainwash 80 kg Water GasStation 120 kg Car.prewashed 1,529.5 kg P2.2 P2.2 WasteEnergy finish Clean car in main wash Car.washed 1,528.9 kg WasteWaster Mainwash+Car_dirty 80.7 kg WasteEnergy CarWash WasteEnergy Prewash WasteEnergy Mainwash RFD – Model of a Gas Station RFD Toolbox Second level of detail, product and resource flows with value mass.

  48. RFD – Model of a Gas Station RFD Toolbox Mass calculation.

  49. Electricity WashingStation 8 MJ Electricity Mainwash 5 MJ Electricity prewash 2 MJ Electricity finish 1 MJ Car.ready 1,529 kg Chemicals 0.2 kg P2.1 Car.filled-up_dirty 1,529.9 kg Prewash P2.3 P2.3 car Wax 0.1 kg Finish Finish car car WasteWater Prewash+ Car_dirty 30.4 kg Detergent 0.1 kg WasteWater finish 10 kg Water finish 10 kg WasteWater GasStation 121.1 kg total energy5.1 MJ Water prewash 30 kg Water Mainwash 80 kg Water GasStation 120 kg Car.prewashed 1,529.5 kg P2.2 P2.2 WasteEnergy finish Clean car in main wash Car.washed 1,528.9 kg WasteWaster Mainwash+Car_dirty 80.7 kg WasteEnergy CarWash 2.9 MJ WasteEnergy Prewash WasteEnergy Mainwash RFD – Model of a Gas Station RFD Toolbox Second level of detail, product and resource flows with value total energy.

  50. RFD – Model of a Gas Station RFD Toolbox Total energy calculation.

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