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“ LCA to go ” - Environmental assessment of machine tools according to requirements of Small and Medium-sized Enterprises (SMEs) CASE Study EDM Carl Diver, CDAMC Rainer Pamminger,Vienna University of Technology, Institute for Engineering Design. Background. Vienna University of Technology

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  1. “LCA to go” - Environmental assessment of machine tools according to requirements of Small and Medium-sized Enterprises (SMEs)CASE Study EDM Carl Diver, CDAMC Rainer Pamminger,Vienna University of Technology, Institute for Engineering Design

  2. Background • Vienna University of Technology • Basis research on Sustainable Product Development, EU-Projects • Development of methodologies • Education, University eLearning course, etc. • Information plattform www.ecodesign.at • ECODESIGN company – Spin-off • Strategy for sustainable product development • Product improvement • LCA, Product Carbon Footprint • Company trainings • www.ecodesign-cmpany.com

  3. Analysis of Environmental Impacts ECODESIGN+ guides you through the assessment process, illustrates your results, helps developing eco products!

  4. Projects

  5. Why? We are facing three crisis… • Climate ChangeGlobal WarmingFloodings, etc. • Energy crisis volatile Oil priceOld infrastructureInvestment 350 Bill.$/a neededavailability/demand • Nutrition crisesgrowing energy plants There is a need for ECO-intelligent products?

  6. Implementation of ECODESIGN LCA, PCF, CED, … communication improvement analysis PILOT, QFD, TRIZ, … EPD, PCF, label …

  7. Analyses: Life Cycle Thinking Product life cycle: • Production of • polystyrene • glass • sheet steel • aluminium • ... • injection moulding • extrusion • machining • welding • casting • ... • truck • train • ship • airplane • ... • Consumption of • paper • electricity • detergent • ... • incineration • recycling • landfilling • ... Goal: Identifying the significant environmental impactsof a product for further product improvement

  8. Case studyinjectionmouldingmachine Environmental profile drive dosing heating cooling control

  9. Product improvement • Isolation of plastification unit

  10. Energyefficiency Label ofPlasticprocessingmachines (2007) • Goal was a • Credible, objective comparison of the energy efficiency • Energy efficiency as buying decision • Opportunity to market energy-efficient machines • Project steps • Energymeasurementstandard • Energyefficiencycriteria • Energyefficiencyinstrument • List ofimprovementmeasures

  11. Energymeasurementstandard (2008) Efficiency classes (2013) Reference: www.euromap.org

  12. Label Design Company Engel (2013)

  13. Advantages through ECODESIGN • Derive new product ideas • Improve environmental performance of own products and communicate it • beneficial cost structures Sustainability of the company

  14. LCA to go Boosting Life Cycle Assessment Use in European Small and Medium-sized Enterprises • 18 partners from 9 countries • Duration: January 1, 2011 – December 31, 2014 • funding from the European Union Seventh Framework Programme (FP7) under grant agreement n° 265096 Challenges to develop LCA tools to • Enhance credibility - robust, reliable, transparent: Methodology • Easy to use: Provide easy-to-use tools (lower barrier for acceptance)

  15. LCA to go Target sectors • Industrial machinery • Sensors • Smart textiles • Renewable energy • Bio-based plastics • Electronics • Semiconductors • Passive Components • Printed Circuit Boards

  16. CDAMC • Established January 2008 • Based in Donegal • Research & Development Consultancy – Manufacturing • Special focus on micro-machining • Products- Diesel Fuel Injection Systems • Customers – Delphi Diesel Systems, Continental Automotive, … • National & European Funding support services

  17. CDAMC & LCA to go • Previous LCA experience • SME partner • Working closely with Technical University of Vienna’s ECO design group • Focus on Industrial Machines • Case study SME’s • Identified one of our suppliers in the Automotive sector • Posalux EDM machine manufacturer - Switzerland

  18. Posalux - EDM • Design and Assembly • Process Development • Industrial Machines • No previous LCA experience or expertise • Supplier to Delphi, Continental, Bosch, Denso, …

  19. Posalux – Small Holes These machines are used to drill micro holes from 50μm up to typically 300μm in 1mm thick diesel fuel injection nozzles

  20. Software flow PRODUCT Definition STEP 1: Rough analysis: CED, entire life cycle “The CED is an environmental indicator, which describes the primary energy needed by a process.” STEP 2: Detailed analyses: Relevant life cycle phases CED in detail IMPROVEMENT STRATEGIES for SME Energy and Materials CED…Cummulative Energy demand

  21. Step 1: Rough assessment – Data Input

  22. Step 1 Rough assessment -Result • Hot spots • Materials, Use • -> included in Step 2 • improvedataquality • deriveimprovements

  23. Step 2: Detailed assessment – Gathering data: Raw materials Goal: - improve data quality - derive improvements

  24. Iterations • Breakdown of each component and its weight in Kg • The breakdown of the calculated energy consumption from Posalux • To calculate the energy consumption due to the assembly of the machine we worked out that they should calculate their electricity consumption for their shop floor and the number of machines produced. – first indication • They calculate 20 years for the product life

  25. Gathering data: use phase • Typical usage scenario • How many days per week • Hours per day • Planned maintenance • Typical Uptime (taking into consideration unplanned stoppages) • Active Power (kW), Apparent Power (kVA), Current Consumption (A)

  26. Iterations We had a number of iterations where Posalux supplied information and we had to go back and clarify certain aspects. Areas like the definition of : • stand-by • Idle • In operation • Taking into consideration down time due to planned maintenance and un-planned stoppages. • Calculating a figure for time in operation based on different customers 24/7 or 5 days a week with 2 shifts

  27. Step 2: Detailed assessment – Result CED…Cummulative Energy demand

  28. Predominat phase - Use • Posalux predominantly carry out assembly operations • They design & assemble the machine but buy standard equipment • From the analysis of the information provided the USE phase is the dominant phase

  29. Recommendation “Any improvement strategies should foremost be focused on the use phase. Improvements to the electricity and compressed air consumption when the machine is “In production” have the highest impact potential.”

  30. Materials analyses

  31. Tool output:Improvement measures

  32. DMG example

  33. DMG example

  34. Next Steps • Launch Industrial Machines software later in 2013 • Sign-up SME’s to test the software and receive free training • Continue disseminating information • Paper accepted to 30th IMC conference in UCD in September • Software demonstration at Hanover EMO Messe in September

  35. Thank you Carl Diver Carl.diver@cdamc.ie @carldiver www.cdamc.ie 086 354 0300

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