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Faurecia Interior Systems
Internal LCA Tool
Green & Light materials WardsAuto Interiors Conference, May 17th, 2012
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Agenda
Introduction : Faurecia Interior Systems vision
EcoT : Faurecia simplified LCA tool
LCA
EcoT
NAFI : Natural Fiber by Injection
Faurecia Roadmap
NAFI : Description & Technical datasheet
NAFI : parts applications
EcoT applied to NAFI
Conclusion
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Introduction : Faurecia Interior
Systems vision
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Introduction : Faurecia Interior Systems vision
High environmental pressure on automotive industry (Use of renewable and recycled materials, elimination of dangerous substances, lightweight,
CO2 emission reduction, end of life recycling..)
..But Environmental considerations are complex and making most relevant choices for “eco-design” is not a obvious task !
Faurecia is one the biggest PP consumer in automotive industry
Face a huge crude oil price evolution 54$ in 2004 with a max peak, 145$ in July 2008.
Alternative to crude oil-based material needed
Weight saving is a huge challenge in automotive industry -> Target : -55g CO2/km in 2020
-> for environmental reason (Kyoto, greenhouse effect…)
-> for economical reason (oil consumption)
PP : Polypropylene
NAFI : Natural Fiber by Injection -> Faurecia : pro-active actions on sustainability
Need for global Environment understanding,
evaluation & orientation
-> Specific LCA Tool
Competitiveness guarantee while
developing new Green & light materials
-> Biomaterial Roadmap
& NAFI material
2 main stakes :
- Renewable materials
- Lightweight
Crude oil price evolution ($)
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EcoT : Faurecia simplified LCA tool
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LCA (ISO 14040-14044) is a Life cycle based methodology for quantifying the environmental
impacts of our products/ activities from the raw materials extraction (cradle) to the end of life
elimination way (grave).
& multi-impacts Approach based on :
Complete Life Cycle
Life Cycle Assessment (LCA) : Overview
LCA
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LCA :
Complex, with too much criteria, takes lot of time
EcoT To ol : Why ?
Generic database, FAURECIA specific products &
process not integrated
Evaluation and modification must be done earlier
possible when exhaustive BOM not available
“Towards an Eco-Innovative organization: Operationalisation of the Life Cycle Analysis in Design by a
simplification based on a Typology as product families”, [H.Andriakaja, D.Millet, G. Bertoluci, 2011]
We decided to develop FAURECIA specific LCA Methodology and tool
(with 1 Doctorate during 3 years + 1 Engineer during 1 year)
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EcoT - Integration in the early development process
Manual Data
input
Semi-auto input :
copy/paste from BOM
2 possible data
input ways
In both cases, evaluation of the product is linked to :
Part name
Mass
Material
Process
Use phase
Transportation (if known)
End of life scenario (typical scenarios proposed during evaluation)
EcoT is directly usable by non expert people, thanks to a rich database (adapted our parts) :
106 materials
4 transportation scenarios (supply chain)
29 processes with internal validation
2 use scenarios (Benzin & Diesel)
6 predefined end of life scenarios
EcoT : a Specific Faurecia LCA Tool
EcoT : Eco assessment per product Typology
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2 main outputs
Complete products
evaluation
Exhaustive result (all indicators)
Relative result (New vs. old
products average)
Detail analysis possible
Evaluation by scenario
comparaison
Scenario vs scenario (up to 3)
Detailed profile with all indicators,
scenario by scenario
Env.
impact
EcoT - Integration in the early development process
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EcoT :
Tool available for Instrument Panels & Door panels
External critical review & validation done
- A specific & simplified LCA tool
- With possible comparison to a reference per product family
- Usable by engineering team in environment decision making
- A complement and database for Innovation LCA Management
…An opportunity for external communication and mutual development
-> robust Methodology, mentioned as an industrial best practices
EcoT - Integration in the early development process
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NAFI – Natural Fibres for Injection
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Renewable ressources used
CURRENT bio-based
composites proposals
Concept
MID TERM
Concept
SHORT TERM
•Industrial solutions = Mats in « NF + oil based binders » for compression process
• « NF composites with oil based matrix » for injection process (1st step)
•New lightweight and/or visible mat for compression
•Biomat project :
Composite 100% bio
based for injection (2nd
step)
• Composite 100% bio based for compression
TTM : 2012-2013
TTM : 2013-2014
Faurecia Roadmap
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Develop our own green material: Polypropylene + 20%
Natural fiber compound to substitute P/E MD20
Injection molding of DP covered trim parts (thermocasing
and overmolding), covered IP inserts and air ducts
Significant weight saving -25% compared to P/EMD20, due
to reduced density and part thickness reduction
Compound
COMPOUNDING
PP&
additives
Natural
fiber
INJECTION OR BACKINJECTION
Natural Fibers for Injection – NAFI
Description
Covered IP insert
IP, airducts
Covered DP parts
Process
1 Patent filled
(close partnership)
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NAFI – Technical datasheet
Unit Value Method Trade name: PF 2555
Low density
Vs P/E MD20
Good thermo
& meca
compromise
= interest
Thermo & Mechanical properties
Tensile modulus at 23°C ISO 527 MPa 2610
Notched Izod impact at 23°C ISO 180/A kJ/m2 6,4
HDT Bf ISO 75 °C 135
Other properties
Spiral flow length FIS cm > 70
Shrinkage FIS % 0,4 – 1,0
Density AFT g/cm3 0,97
Filler content FIS % 20
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PROCESS
• Injection and back-injection OK
• Impact of process on fiber morphologies OK
• Thermocovering OK
• US Welding (samples and parts) OK
PRODUCT
• Adhesion skin/insert after different agings Conform flamming needed as PP
• Drop test (20J) OK
• Top roll dimensional behavior OK
• NAFI Top roll after heat & climatic ageing OK
Corolla top roll - 2 mm thick
C4
308 Medallion - 2,5 mm thick C4 medallion - 2,5 mm thick C4 top roll- 2,5mm thick
NAFI DP validations
Results Corolla
NAFI material validated for top roll & medallion
with reduced thickness (2mm)
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PROCESS
• Injection OK
• Weakening by laser (air bag) OK
• TPO positive Thermocovering OK
• Vibration welding assembly OK
PRODUCT
• Dimensional behaviour (top cover) Same or better than standard material
• Sunload 120°C / Climatic aging In progress
• AB deployment/ Head impact Conform
• Smell/VOC on IP (VDA 276-1) Conform
• Tightening/ Metallic clip Conform
NAFI IP validations
Results on DS3 TPO thermocased IP
Part th=2 mm Part th=2 mm Part th=2 mm except AB area 3 mm
Validations quasi finalized.
To be ended for Q3 2012
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EcoT applied to NAFI
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LCA on complete Life Cycle, concept "X"
Specific Focus on NAFI parts perimeter
-1,00E-11
0,00E+00
1,00E-11
2,00E-11
3,00E-11
4,00E-11
5,00E-11
6,00E-11
Raw material &
Production
(NaFi)
Raw material &
Production (PP)
Use (NaFi) Use (PP) End of life (PP) End of life (PP) Total (NaFi) Total (PP)
POCP
ODP
GWP
EP
AP
ADP
Global impact
reduction with
NAFI is 23 %
Production : small
advantage to NAFI
2
1
Use Phase : NAFI
strong benefit
EoL : small & similar
impact if validated(*)
3
LCA on complete Life Cycle, concept "X"
Specific Focus on NAFI parts perimeter
-1,00E-11
0,00E+00
1,00E-11
2,00E-11
3,00E-11
4,00E-11
5,00E-11
6,00E-11
Raw material &
Production
(NaFi)
Raw material &
Production (PP)
Use (NaFi) Use (PP) End of life (PP) End of life (PP) Total (NaFi) Total (PP)
POCP
ODP
GWP
EP
AP
ADP
Bette
r
Env.
impact
Cycle
phase
LCA applied to one dashboard concept with NAFI
2 scenario comparison (NAFI Vs P/E MD20)
(*) : specific recycling project ongoing, validations with recycling companies (industrial wastes and ELV shredding)
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Conclusion
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Light weight reduction: 25% compared to standard
solutions (0.97 density, 0.5mm thickness reduction)
C02 reduction & 20% saving on Life Cycle Assessment
Processable with our traditional injection machines
Green material = Natural fibers + Thermoplastic matrix
intermediate step to 100% bio-based
Unique Faurecia solution on the Market !
NAFI & Environment
Significant weight saving and better environmental impact, NAFI is a clear
answer to lightweight concept which is a trend in automotive business.
NAFI is available for new programs
NAFI Benefits
A specific & simplified LCA tool
With possible comparison to a reference
per product family
LCA Tool
Validated for DP top roll & medaillon
Quasi validated for IP
NAFI validations
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Questions ?
Life Cycle Assessment
Faurecia EcoT Tool
EcoDesign
Biomaterial Roadmap
NAFI material
Contacts :
Sebastien KAH
Pole of Competence EcoDesign Leader
Laurence DUFRANCATEL
Bio-Mat & Process Innovation Group Leader
