Increasing Energy Efficiency Using Energy Value Stream ... Klaus...Increasing Energy Efficiency Using Energy Value Stream Mapping National Energy Efficiency Conference and EENP Awards

Increasing Energy Efficiency Using Energy Increasing Energy Efficiency Using Energy Value Stream Mapping

National Energy Efficiency Conference and EENP Awards Ceremony 2011 Singapore, 24. – 25. May 2011

Dr. Klaus Erlach

Fraunhofer Institute forManufacturing Engineering and Automation IPA

www.wertstrom.dewww.valuestreamdesign.euwww.energiewertstrom.de

Factory Planning and Production Optimization© Fraunhofer IPA 2011Dr. Klaus Erlach

Folie 1 Energy Value Stream

Fraunhofer IPA in Stuttgart, Germany:Part of One of the Largest Applied Research and Consulting NetworksPart of One of the Largest Applied Research and Consulting Networks

Dortmund

D t dt

Dresden

Bremen

Hannover

Berlin

Rostock

Dortmund

D t dt

Dresden

Bremen

Hannover

Berlin

Rostock

Darmstadt

Karlsruhe

Saarbrücken

MünchenStuttgart

Freiburg

Darmstadt

Karlsruhe

Saarbrücken

MünchenStuttgart

FreiburgFraunhofer Centers USA

Representative Offices

illi

Association of 57 institutes

15 000 employees in 2008

pAsia, Middle East and

Moscow

German institutes

€ 30 million turnover, € 14,2 million from consulting

ca. 300 employees

15,000 employees in 2008

Budget of €1.4 billion in 2008

Integrated factory and layout planning Production Optimization and Value

Stream DesignFactory Planning and Production Optimization© Fraunhofer IPA 2011Dr. Klaus Erlach


Value Stream Mapping Analyzes the Current State of the Complete Production Process and Displays Potential ImprovementsProcess and Displays Potential Improvements

Method:Method: Creating a snap shot of your production at shop floor level

& in office Applied at IPA to all kinds of production in several branches

TotalQuality Control

TQC

Just-in-Time JIT

Jidoka (Autono-mation)

TotalQuality Control

TQC

Flexible Production

Toyota Produktion System TPS Set of Guidelines Describes the Approach for Designing the

Future StateResult: Gives a transparent picture of production including Flexible Production

Cost Reduction by Elimination of Waste

Origin: Element of Lean Production (TPS)

Gives a transparent picture of production including information flow

Emphasizes on waste in lead time and shows bottlenecks Creates a lean factory with lean planning processes



To reach a higher energy efficiency within production the procedure of the »Energy Value Stream Method« has been developed in analogy to VSM»Energy Value Stream Method« has been developed in analogy to VSM

Basic idea is using the principles of the Value Stream Method (VSM) – which is well-proven by lean

Energy Value Stream Energy Value Stream Realization

g p p ( ) p yproduction – for analyzing the energy efficiency of a factory:

Energy Value Stream Analysis

• Recording energy consumers and

i d

Energy Value Stream Design

Creating an increased future state with the h l f d i id li

Realization Implementation of the future

state with technical and organizational measures

consumption data• Identifying energy

efficiency potentials

help of design guidelines Identifying improvement

opportunities

Embedding energy efficiency in the business strategy –core of energy management

Result is a systematic procedure in three steps for 1. holistic collection and evaluation of energy consumption in production processes1. holistic collection and evaluation of energy consumption in production processes 2. increasing energy efficiency by using design guidelines3. finally optimization of energy consumption



The Energy Value Stream Method should reach the following goals

• Rough Analysis of energy consumptions with regard to production preconditions

• Identification of all relevant kinds of energy (e g electricity compressed air )• Identification of all relevant kinds of energy (e.g. electricity, compressed air …)

• Identification of all relevant energy consumers

• Creating transparency of production process-related energy consumptions

• Avoid the wastage of energy

• Providing the basis for optimization of energy consumption

• Key figures for estimation of the energy efficiency

• Estimation of energy efficiency potentials

• Systematic process for increasing energy efficiency

• Providing design guidelines for a systematic and completed search for improvement measuresmeasures

• Visualizing tool for an ideal future state as the target vision



1 Energy Value Stream Analysis1. Energy Value Stream Analysis

Efficient identification of energy consumption in the production



Factory audit against waste: Searching for deflagration of compressed air …

leak – not perceptible by hand, but clearly

leak – perceptible by hand: costs about 600 €/ay

detectible by ultrasound measurement: costs about 250 €/a

costs about 600 €/a



… and a lot of other spots

Leak at pressure cylinder (loud wheezing):wheezing):Estimated diameter is 2 mm= 2.340 €/a

Two leaks in tube – each big enough to dry Two leaks in tube each big enough to dry hands:Estimated diameter 3 mm each= 2 x 5.270 €/a = 10.540 €/a



Mobile measurement equipment for data acquisition enable the evaluation of the current state in the production very quicklythe current state in the production very quickly

pick off voltageclamps to measure electrical power



The curve of electrical power shows energy demand clearly in relation to working stepsworking steps

4.500E+3

5.000E+3

5.500E+3

3.000E+3

3.500E+3

4.000E+3

4.500E 3

W

powe

r

1.500E+3

2.000E+3

2.500E+3

3.000E 3

500 3

11:40:00.00015.06.2010

13:20:15.00015.06.2010

20 min/Div1:40:15 (h:min:s)

time

energy demand of a long running, thermal process with exothermic reaction



Main key figure of value stream is the »Energy Intensity«, which equates the production process-related energy consumption for one productproduction process-related energy consumption for one product

Energy Intensity (EI) =power input (P) x customer takt time (TT) x number of resources (#Res)

new parameters in value stream map:

electricity

gasInjection moulding

Painting Assembly

power input (P) x customer takt time (TT) x number of resources (#Res)

1 82 1 4

value stream map:

compressed air

EI Energy IntensityPT 60 sec

# pieces = 2

CT 15 sec

PQ 150

PT 40 min

CT 16 sec

PT 72 sec

CT 9 sec

A 98 %

1 82 1 4

A 92 %

54 kW

EI = 654 Wh

CO 45 min

28 kW

123 kW

EI = 910 Wh

730 W

420 W

EI = 15 Wh TT assembly, 2 shifts = 11,5 sec

TT production 3 shifts= 21,7 sec

Σ EI = 1.565 kWh651 Wh 910 Wh 15 Wh

TT production, 3 shifts 21,7 sec

Energy Intensity of the Value Stream =Σ Energy Intensity of single processesIdentifying energy intensive processes

EI = 151 kW x 21,7 sec x 1 = 910 Wh



The Degree of Efficiency compares the energy consumed in a manufacturing process to a reference value and serves as a measure for the process qualityprocess to a reference value and serves as a measure for the process quality

The Degree of Efficiency is the ratio of the required energy consumption according to state of the art technologies, specific energy consumption or an internally defined target and the actually used, specific energy consumption.

Reference for Energy Consumption

f l b i h di i i

Degree of Efficiency = Reference for Energy Consumption

Specific Energy consumption as measured

Reference Value can be weight per part, part dimensions or process time

Energy IntensitySpecific Energy Consumption =

Reference ValueSpecific Energy Consumption =



The Degree of Efficiency Diagram shows the improvement potential for the whole Value Streamwhole Value Stream

100 Degree of Efficiency

60

80

100 Degree of Efficiency

5577 88

20

40

0Spritzgießen Lackieren MontierenInjection moulding

Painting Assembly

Reference Value 1.6 kWh/kg(state of the art)

Example Injection moulding

Weight per part = 220 g

Degree of Efficiency = 1.6 kWh/kg

2.97 kWh/kg= 0.54 = 54%Energy Intensity

Weight per part654 Wh

220 g= = 2.97 kWh/kg



2 Energy Value Stream Design2. Energy Value Stream Design

Design Guidelines to Create Energy Efficient Production Processes

Energy savings

Red

uctio

energ

y de

Energy demand under

l Reduced

Energy savings

on

of

eman

d

normal operating conditions

energy demand



The Eight Design Guidelines of the Energy Value Stream Design give a valid procedure for creating an Improved Future Stateprocedure for creating an Improved Future State

Guideline 1: Manufacturing at an optimum operating pointGuideline 1: Manufacturing at an optimum operating point

Guideline 2: Reducing energy demand of resources by technical improvements

Guideline 3: Minimizing the energy consumption of resources during stand-by operation

Guideline 4: Minimizing energy consumption during turn on and turn offGuideline 4: Minimizing energy consumption during turn-on and turn-off

Guideline 5: Energy recovery

Guideline 6: Leveling energy consumption by smoothing the peak energyGuideline 6: Leveling energy consumption by smoothing the peak energy

Guideline 7: Laying down an energy efficient processing sequence for the largest energy consumer

Guideline 8: Synchronizing energy supply and energy consumption



Guideline 1: Manufacturing at an Optimum Operating Point

Objective: Resources have to be designed so that producing at an ideal operating point coincides with customer takt time

Energie-intensität

kWh

EnergyIntensity

kWhStck.

EnergieersparnisEnergy savings

Measures:

Produktions-taktoptimaler

BetriebspunktTeillastPart load Ideal

operating point Production takt

Measures:• Design resources so that production takt at minimum energy intensity coincides with

customer takt time• Choose adequate resources according to production requirements• Choose adequate resources according to production requirements• Operate resources at an ideal power rating• Avoid oversizing of resources as safety reserves



Example SMD-Line: The wave soldering has a capacity utilisation of only 55 percentThe wave soldering has a capacity utilisation of only 55 percent

PF: printed

1.200 piece/d

PF: printed circuit board

line 1

WT = 24 h

TT = 72 sec.

Per each printed circuit board needs are 110 Wh heating energy are p g gyconsumed – if the line had the double tact time, this demand would cut in half



Guideline 2: Reducing Energy Demand under Normal Operating Conditions

Objective: Reduction of resource energy demand in normal operation by technical improvements

Examples:• Replace inefficient drives by EFF1 engines• Replace slab laser by diode-pumped disc laser• Use of energy-saving hydraulic and gear oils

en

Energy

Energy savings

• Use of energy saving hydraulic and gear oilsRed

uctio

n o

fn

ergy d

eman

Energy demand under normal operating

Reduced energy

demand

Measures:d i d f ili i l h i l ( l i b dj i i

fndconditions

demand

• Use up-to-date equipment and facilities; replace technical components (not only engines but adjoining components, too, such as gears)

• Possibly, replace processesU ffi i t ti li• Use energy-efficient operating supplies

• Reactive power compensation (prevents inductive reactive power and thus reduces energy demand)• Train your employees in the efficient use of energy.



The cyclic energy demand of a robot shows the increased energy demand within normal operation caused by inappropriate programming within normal operation caused by inappropriate programming

Energy waste through active remaining in position (Robot waits for next working cycle) instead of a brake.

working cycle begins moving downwards: lower power consumption than within Stand-by.



The power consumption of two similar electric furnaces differs by factor 5

25 kW

20 kW

15 kW

5 kW

10 kWAverage: 9.1 kW

6 kW

5 kW

2 kW

3 kW

4 kW

Average: 1.96 kW

Electric Furnace11:17:00.00016.06.2010

11:44:55.00016.06.2010

5 min/Div27:55.000 (min:s)

2 kW

1 kW

Average: 1.96 kW



Guideline 3: Minimizing Energy Consumption of Resources during Stand-by OperationOperation

Objective: Minimize energy consumption during stand-by operation

Examples:• Turning off machinery during weekends and non-working shifts• Automatic turn-off of periphery when they are not usedm

Energy savings

reducedStand-by

Stand-by

p p y y

Requirements:• Machinery turn-off must not lead to unscheduled machine

breakdown

Stand

-by

min

imizatio

n

Stand-by

Energy

consumption

Energy

consumption breakdown • Product quality must not be affected by machine turn-off

consumption consumption

Measures:• Machinery turn-off outside production time• Using machine control for turn-off of machine periphery when not used• Lowering the level of energy consumption during stand-by operation• Avoid discontinued production flow for reducing short stand-by times• Train your employees to apply appropriate stand-by strategies



The curve shows the energy demand of a hydraulic press with a quite long stand-by-time between two working sequencesstand-by-time between two working sequences



Guideline 5: Energy Recovery

Objective: Using energy several times, if possible, within the same process, for other requirements that are not immediately related to production (e.g. heating)

E l Re-coverable

energyExample: • Energy recovery at a lift drive as used in

automated high bay warehouse

Requirements:

Energyconsumption

Process 1

Energyconsumption

Energyconsumption Energy

Energ

y recov

Energy savings

e e gy

Requirements:• Energy supply and required energy consumption

must be connected (in time and space)

Process 2Process 1

gyconsumption

Process 2

very

Measures: • Using industrial waste heat• Using heat accumulators for storing heat in discontinuance production processes• Using heat pumps for reaching a higher energy level • Recovery of braking energy



Consequent reduction of internal thermal load as well as usage of waste heatfor climatisation of factory hallfor climatisation of factory hall

Air Compressor

Oil coolingMetal-cutting

waste

therm

a

gmachine

machinery

eh

eat

Recuperator

l loadCooling

unitspindle

Hot waterstorage

tankspindle tank



3 Energy Value Stream Projects3. Energy Value Stream Projects

Case Studies

2 000E+3

1.600E+3

1.800E+3

2.000E+3

W

1.200E+3

1.400E+3

1000



Production of a »front bumper« made of 5 parts in 4 production steps – thecalculation of energy intensity demonstrates effect of product related approachcalculation of energy intensity demonstrates effect of product related approach

HydraulicP i

Stamping SpotW ldi

GasW ldiPressing

1 1PT 20 sec.# 2

1 1PT 2 x 2,2 sec. PT 88 sec.

CT 88 PT 88 sec.CT 88

Welding1 1

Welding1 1

# p 2CT 40 sec. HP 92 kW PH 22 kW

3 x 1,4 sec.# p 5CT 8,6 sec. 10 kW

CT 88 sec. Rob 6 kW WG 12 kWEI 440 Wh

CT 88 sec. Rob 11 kW WG 19 kWEI 734 Wh Σ EI = 2.465 kWh

EI 1.267Wh51 %

10 kWEI 24 Wh

EI 440 Wh EI 734 Wh Σ EI 2.465 kWh

1. Welding needs the same energy like hydraulic pressing, if you count per product

2. Stand-by consumption of pressing amounts 65 percent of total consumption



Production of bottle brackets with 40 cells each for a washing machine in beverage industry – stand-by losses caused by oversizing capacitiesbeverage industry – stand-by losses caused by oversizing capacities

CellProduction

1 2

PF: bottle bracket40 cells per bracket1 2

PT 22 sec.# p 40CT 440 sec.U 61%

20.000 Stck./aFD 250 d/aWT 16 h/dTT 12min

p

Spot Welding

hydraulic 2x 2.150W robotics 2x 580 W welding 2x 1.100W suction 555 WEI 1.000 Wh

Manual Weldingside part Force Fitting Conser ing

TT bracket 12min.= 720 sec.

TT cell 18 sec.

Spot-Weldingbracket

0 1PT 625 sec.CT 625 sec

FIFOFIFOFIFOFIFO FIFOFIFO FIFOFIFO

EI 1.000 WhE St-b 4.855 WEI St-b 378 Wh

side part2 1

PT 360 sec.

CT 180 sec.

Force Fittingplastic element


Conserving


TrueingOO

transportingCT 625 sec.U 87% 4,44 kW St-b 4,58 kWEI 770 WhEISt b 121 Wh

U 25% welding 2x 3.100W

suction 2.130W

EI 310 Wh

CT 300 sec.U 42% 990 WEI 83 WhEISt-b 116 Wh

CT 50 sec. 500 WEI 7 Wh

0 1PT 145 sec.# p 2CT 290 sec

FIFOFIFO PT 45 sec.CT 45 sec. 9.500 WEI 120 Wh

Σ EI 2 659 WhEISt-b 121 Wh EI welding 310 WhEI suction 106 Wh EISt-b-suction318Wh

CT 290 sec.U 40% 3.260 WEI 263 WhEISt-b 395 Wh

Σ EI 2.659 WhΣ EI St-b 1.328 Wh



4 IEC Standardization4. IEC Standardization

for Energy Efficiency through Industrial Automation

Technical Report to provide to the Standardisation Committees• a framework for the adaptation and development of documents• in order to achieve energy efficiency• in manufacturing, process control and industrial facility management.

Main PrincipleTo promote standardization of concepts on managed energy efficiency by• Measurement and management• Providing Key Performance Indicators (KPIs)

S d di i h k i f l / d i• Standardizing the network interface control / devices• Standardizing energy saving modes and commandsin addition to intrinsic energy efficiency of the components themselves.



IEC Standardization for Energy EfficiencyEnterprise-control system integration (reference to IEC 62264-1)Enterprise-control system integration (reference to IEC 62264-1)

Business planning& logistics

Level 4 Enterprise / factory layer:Carbon foot printCSR data management& logistics

Level 3

CSR data managementISO14001, ISO 5001 support

Plant / shop management management layer:

Ener

Manufacturing operations management

Energy intensity (basic cost)Energy cost managementAnalyse energy dataPlanning energy conservation

rgy

fun

c

Level 2

Batch Continuous Discrete

Process unit / equipment layer:Pump control by inverterMultiple unit control

ction

s

Level 1

Batch control

Continuouscontrol

Discrete control

Electric power meterEnthalpy calculation

Level 0 Mechanical layer:Exhaust heat recoveryThermal storageHeat pump



Thanks for your attention!If you have questions or any information is needed:If you have questions or any information is needed:

Your Contact:Fraunhofer IPAFactory Planning and Production OptimizationNobelstrasse 12Nobelstrasse 1270569 Stuttgart, Germany

Dr. Klaus ErlachPhone: +49 (0) 711 / 970 – 1293Mail: [email protected]

Klaus Erlach; Engelbert Westkämper:Energiewertstrom. Der Weg zur energieeffizienten Fabrik

Stuttgart 2009, ISBN: 978-3-8396-0010-8

www.wertstrom.dewww.valuestreamdesign.euwww.energiewertstrom.de



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Increasing Energy Efficiency Using Energy Value Stream ... Klaus...Increasing Energy Efficiency Using Energy Value Stream Mapping National Energy Efficiency Conference and EENP Awards