REMake Koenig Lissabon 20130916 f€¦ · Smaller companies show higher savings measures are highly...

EXPERIENCE OF TOOLS FOR RESOURCE

REMakeREMakeEXPERIENCE OF TOOLS FOR RESOURCE

EFFICIENCY IN INDUSTRY

Dr. Uwe König

Outline

1. Chances and challenges of resource

efficient manufacturing

2. Levels of resource efficient innovation

3. Boosting resource efficiency with REMake –

experiences with adequate tools

4. Experiences of the German Material

Efficiency Agency - demea

5. The needs of manufacturing companies –

bottlenecks to overcome

1. Chances and Challenges of Resource

Efficient Manufacturing

Make manufacturing more profitable

Costs are about 40% material and energy

High innovation potentialHigh innovation potential

Highest benefit: Optimisation of value generation across the full life cycle

Situation is comparable all over Europe –

realization depends on national and regional

requirements

Resource Efficiency in Manufacturing

Modified version of value chain model used by the Royal Academy of Engineering, UK

(in: „Industrial Systems: capturing value through manufacturing“, 2012)

Processing Manufacturing

RawIntermediates

Harvesting,Excavation,

Forming,Machining,

Reuse,Recycling

RawResources

Intermediates

metals, polymers,paper, ceramics, …

Excavation,Melting, Chemistry, …

Machining,Coating,Assembly,Packaging

Products

SectorsMinerals, chemicals, steel & NF

metals, glass, ceramics, pulp&paper,cement …

SectorsMechanical engineering, fabricated metal

products, rubber & plastics products,electrical & optical equipment

450No. Companies (1.000)

6,8Employees (million)

1600Production value (bn €)

Relevance of Process Industries (2009)

450No. Companies (1.000)

6,8Employees (million)

1600Production value (bn €)

Relevance of Process Industries (2009)

740No. Companies (1.000)

11Employees (million)

1750Production value (bn €)

Relevance of Manufacturing Industries (2009)

740No. Companies (1.000)

11Employees (million)

1750Production value (bn €)

Relevance of Manufacturing Industries (2009)

Defining resource use through ecodesign & manufacturing optimisation

Statistical data sources : ▪ Eurostat; ▪ Cefic, EUnited et. al. 2011 („Proposal of a

Public-Private-Partnership on Sustainable Process Industries“)

Challenge:Manufacturing means SMEs!

Typical production cost shares in Manufacturing

Materials + energy add up to nearly half of all manufacturing costs.

Costs of raw materials

& suppliesDepreciation and other

Other costs

7 %

Materials & energy

Energy costs

Personnelcosts

and other investment costs 25 – 30 %

5 –15 %

30 –45 %

Materials +

Energy

45 – 50 %18 – 20 %

Materials & energy

use are interlinked.

Optimisation should

not be separated!

Take into account the specific conditions

2. Levels of Resource Efficient Innovation

Product design

o Huge impact on resource consumption, especially

environmental impact

Manufacturing efficiencyManufacturing efficiency

o Small changes results in large impact

Value chain optimisation

o Individual companies: short termed - about 10% of

resources

o Value chain: long termed – up to 50% savings

Specific requirements

Resource flow analysis at single company level

Analysis of 100 German case

studies + on-going analysis of

case studies from other countries

Very clear result: the saving

Average saving =

7% of material input

Smaller companies show higher savings

Very clear result: the saving measures are highly profitable

o Permanent reduction of annual

production costs

o Typically one-off investments,

pay-back time <<1 year

Frequency distribution of resource

savings

0

5

10

15

20

< 2% 2-4% 4-8% 8-12% 12-16% 16-20% >20%

Material savings related

to material input in %

Nu

mb

er

of

co

mp

an

ies

Savings potentials –Factory level vs. Value chain level

Mechanical

engineering Electroplating

Resource efficiency optimisation at individual companies: 7-10%

Mining Steel

Processing Manufacturing

Rawmaterials

company

Forming and

machining

Electroplating

company

Metal

coating

InterfaceInterface

Resource efficiency optimisation at value chain level: 55-70%

Mining

company

Raw material

production

Steel

company

Steel

productionIntermediates

InterfaceInterface

MachinedProducts

InterfaceInterface

FinishedProducts

• Impact analysis of 100 German case studies

AND on-going analysis of case studies from other countries

• Pilot study on value chain savings potentials using Life-Cycle Simulation

3. Boosting Resource Efficiency with REMake –

Experiences with adequate Tools

Eco-innovation support consulting tools

o Potentiality analysis, implementation support to RRE,

Life cycle, approaches, etc.

o But: to complicated for most companieso But: to complicated for most companies

Resource Efficiency Network

o Learning and helping Network for eco innovation

Voucher systems

o Quick tool to describe the companies situation;

First stage: RE audit – potentiality analysis

Second stage: Implement specific actions

REMake - a European test bed and Network for resource efficiency in Manufacturing

Industry needs /

access to SMEsAIMAIM

Key

6 national / regional

innovation agencies

Inn

ov

ati

on

ex

pe

rtis

e

Inn

ov

ati

on

ex

pe

rtis

e

Te

chn

olo

gica

l

kn

ow

led

ge

Financial, technical and managementsupport to manufacturing SMEs

• improve overall resource efficiency

• implement eco-design and life-cyclemanagement

• use standards and best practices enablingeco-innovation

Key stakeholder ‚mentalities‘ being integrated

4. Experiences of German Agency - demea

Long time experiences and support of German Ministry – cooperation between politics and agency

Accompanied by consultant for personal contactand to ensure side criteria (like funding conditions)

o Use of a simple and general online Self-Assessment Toolo Use of a simple and general online Self-Assessment Tool

o Building a pool of active consultants

• Personal contact – accepted by SME

• Support and advice – sector and company specific

Outcome:Average material savings: 7% of material/energy input(9% for small companies)

5. Needs of Companies - Bottlenecks

Compile technological feasibility

Financing is not crucial – but many companies do not know how to realize innovation

Support and advice is crucial

Activities depends on consumer acceptanceActivities depends on consumer acceptance

o e.g. automotive industry requires first sample reports to reach predefined requirements

o Change in production line could change requirements (important target)

Legislation about resource efficiency is generally considered positive

Cooperation with other sectors is helpful

Conclusions and Challenges

Stimulate and implement resource efficiency improvementof manufacturing SMEs o along the entire production value chain,

o looking at single factory level and upstream / downstream suppliers & customers

Help SME to understand the overall process along the value chaino Benefits of companies and industry sectors through resource efficiencyo Benefits of companies and industry sectors through resource efficiency

o Favouring business solution for overall branch

o Try to cooperate across sectors

Research and development on technological and organisational optimisation and re-engineering of manufacturing value chains

Particular focus on optimisation of value chain interfaces

Combine regulation with innovation- try to understand and cooperate

Build on existing initiatives for widespreadroll-out of RE support schemes and tools

Thank you very much for your interest and attention

More information and contact: www.ecomanufacturing.eu

Life Cycle Simulation of Manufacturing ChainsProduction chain ‘Steel’:

hydraulic piston rod

• Simulation results: Primary energy balance in MJ

• Savings potential:55 % of resource input

0

200

400

600

800

1.000

1.200

1.400

1.600

steel part, heat treatment

surface processing, welding

corrosion protection, packaging, transport

finish, degrease

hard chromium plating, purging

finishing treatment

MJ/FU worst case best case

55 % of resource input

Lessons learned

Practical case studies demonstrate: Resource efficiency (‘RE’)will foster growth and innovation in manufacturing SMEs

High potential to improve RE in Manufacturing; but don’t separate energy & materials optimisation

SMEs are willing to improve on RE; SMEs are willing to improve on RE; but need professional information and support

Efficient production processes and recycling will substantially contribute to securing raw materials

Applying ecodesign in developing manufactured products is important – ATEP standard and toolkit

Save handling of materials (REACH / ROHS directives) also related to RE