Eco-efficiency in the aerospace industry

Gonçalo Cardeal (IST)

Innovation Takes Off

2018 International Workshop for Global Sustainability. October 23, The Research Triangle Region of North Carolina

Mass Production

Introduction

With the fast increase in number of planned satellite launches, the need for mass production is becoming more evident.

Introduction

INDUSTRIAL LEADER

CORE PARTNERS

R&D Leader

Key Partners

PASSARO

Objectives

• Methodologies and tools for eco-efficient design or re-adaptation of production facilities based on co-evolving product-process-production systems.

• Improve resources utilization, increase productivity, energy efficiency and reduction of waste in the factories.

• Simulation tools for assessing both environmental and economic costs linked with the use of renewable materials and energy resources, as well as technologies to guide decision making.

Concept

Multidimensional Design Assessment Model

Multidimensional Design Assessment Model

Domains of Process Design

Eco-efficiencyCostsResource Efficiency

Operational Performance

Economical Dimension

Environmental Dimension

Non-value addedValue added

Integration

Eco-efficiencyProduct/Service Value

Environmental Influence=

7 Principles

Reduce the material intensity

Reduce energy intensity

Enhance recyclability

Reduce dispersion of toxic substances

Increase service intensity

Extend product durability

Maximize use of renewable resources

Eco-efficiency: Goal and Scope

Eco-efficiency core measurements suggest a paradigm: DOING MORE WITH LESS.

Methodologies and tools

Eco-efficiency: EcoPROSYS

Life Cycle Impact Assessment

Scope & Data Collection

Cost & Value Assessment

Environmental Performance Evaluation

KEPI Eco-efficiencyIndicators

Cost & Value Data

Environmental Profile

Eco-efficiencyRatios Value Profile

Con

tinuo

us Im

prov

emen

t

Indicators

Profile

Methodologies and tools

Efficiency: Multi-Layer Stream Mapping (MSM)

Value Stream Mapping (VSM) with application of Lean PrinciplesPillar 1: Assess Value Addition versus not adding value

Evaluating Variables (KPI) via efficiency ratios

Pillar 2: Systematic evaluate variables through efficiency

ratios

Calculate overall efficiency of processes/systems (bottom-up analysisPillar 4: Aggregate efficiency of unit processes (columns) and the variables (lines)

Visual ManagementPillar 3: Apply simple methodologies of Visual Management

Methodologies and tools

Efficiency: MSM Results

Methodologies and tools

Integrated efficiency framework

OF

FLIN

E (

“Gre

enfield

”, “

In S

itu

”) a

nd

ON

LIN

E (

Monitoring)

Assesm

ents

LEAN THINKING &

Manufacturing

PDCA, VSM, etc.

Resource,

Operations, Flow

Efficiency

Environmental

LCA, EPA

Eco-Efficiency

Economical

Value,

Cost, LCC

EFFICIENCY FRAMEWORK

http://maestri-spire.eu

Methodologies and tools

Integrated DMU (Digital Mock Up)3D environment

Integration with LCA framework

Data

Core Partner PASSARO

AssemblyProcesses

&Resources

PPRProductProcessResource

Case Study

KPIs

Integrated DMU 3D environment

Partner INEGI+ISQ

Integration with LCA framework

AssemblyProcesses

&Resources

PPRProductProcessResource

Case Study

Data input

Build process

Phase/station

Operation

Task

JigTool

kW consumptionTime of use

Consumablesurface of use

lengthweight

Number of holes, nuts, screws, stickers, etc.

Operator#

Time

VA NVA

Results

Resource

Costs

Environmental dimension (Pt)

Operational Performance

Eco-efficiency[Total; VA; NVA]Efficiency

Economical dimension

VA NVA VA NVA VA NVA

Case Study

Resource Efficiency

Eco-efficiency

Operacional Performance

Costs

Effi1 % Effi2 % Effi3 % Effi %

EE1 % EE2 % EE3 %

Per1 % Per2 % Per3 %

C1 % C2 % C3 %

AS1 % AS2 % AS3 % GlobalPerformance

EE %

Per %

C %

LDfX domains – AssemblyProcess design

Effi1 %

EE1 %

Per1 %

C1 %

Define the “ratios” and Functional and

Hierarchical perspective RAW DATA

0 – Operational KPIs

1 – Tactical KPIs

2 – Strategic KPIs

Board/top management

Middle management

workers

0 – Machine/Equipment

1 - Section

2 – Line/Product

3 – Department

4 – Company

5 – Group

“Equipment effi”

Case Study

3D virtual process design

Measure time and resource consumption

Assess efficiency, eco-efficiency & costs

Assembly process in real world

Real world Assess efficiency, eco-efficiency & costs

Analyse Virtual vs. Real world results

Available Assembly means per Asub

Fine tune Virtual assessment (β)

Case Study - Workflow

Next Steps

• Develop and integrate the digital mock up,

• Test the methodology with simulated data in a virtual scenario,

• Compare the results with a real case scenario,

• Expand the methodology to other assembly lines,

Conclusion

Thank you for your attention!

Questions?

Contacts:

Email: goncalo.cardeal@tecnico.ulisboa.pt

PASSARO