Planning of Eco-efficient Process Chains for Automotive Component Manufacturing (Sustainable Production, Life Cycle Engineering and Management)

"This book includes the introduction of emerging manufacturing technologies and planning cases with established technologies. The planning of eco-efficient process chains is crucial for manufacturing companies. However, in the state-of-the-art planning, various barriers exist towards the integration of the environmental dimension. Against this background, a concept for the integration of classic lean and environmental criteria into the three planning phases of process chains is presented. During concept planning, the Technology Assessment Tool supports planners in the identification of eco-efficient technologies. During rough planning, the Value Stream Design Tool enables the derivation of a production line based on workpiece characteristics. For detailed planning, tools for eco-efficient machine and process chain configuration are provided. Three case studies from large-scale automotive component manufacturing with established and emerging technologies demonstrate the tool applicability."-- Provided by publisher Series Editors’ Foreword Acknowledgements Contents Acronyms Symbols 1 Introduction 1.1 Motivation and Problem Statement 1.2 Research Objective and Work Structure References 2 Planning of Automotive Component Manufacturing Systems 2.1 Manufacturing of Automotive Components 2.1.1 Production Process and Production System 2.1.2 Production System Structures for Large-Scale Manufacturing 2.1.3 Selected Established and Emerging Manufacturing Technologies for Automotive Components 2.2 Production System Planning 2.2.1 Planning Procedures 2.2.2 Integration of Environmental Criteria into the Planning Process for Eco-efficient Production Systems 2.2.3 Established Methods and Tools for the Planning of Eco-efficient Production Systems 2.3 Preliminary Findings References 3 State of Research 3.1 Limitation of Research Scope and Research Question 3.2 Classification of Approaches and Definition of Evaluation Criteria 3.2.1 Selection and Classification of Approaches 3.2.2 Evaluation Criteria 3.3 Delimitation of Adjacent Fields of Research 3.3.1 Energy Management in Factories 3.3.2 Life Cycle Assessment of Manufacturing Technologies 3.3.3 Empirical Manufacturing Process Modeling 3.3.4 Energy Efficiency Evaluation and Improvement 3.3.5 Conclusions from the Adjacent Fields of Research 3.4 Presentation and Evaluation of Existing Approaches 3.4.1 Cross-Phase Planning Approaches 3.4.2 Concept Planning with Focus on Early-Stage Evaluation of Manufacturing Technologies 3.4.3 Rough Planning with Focus on Process Chain Configuration 3.4.4 Detailed Planning with Focus on Machine Dimensioning 3.4.5 Detailed Planning with Focus on Production System Simulation 3.5 Findings and Research Demand References 4 Concept for the Planning of Eco-efficient Process Chains and Implementation 4.1 Objectives and Requirements 4.2 Planning Tool Framework 4.2.1 Conceptual Framework 4.2.2 Potential Application Cycles 4.3 Technology Assessment 4.3.1 Tool Concept and Methods 4.3.2 TAT Implementation 4.4 Value Stream Design 4.4.1 Tool Concept and Methods 4.4.2 VSDT Implementation 4.5 Machine Configuration 4.5.1 MTC—Tool Concept and Methods 4.5.2 MTC Implementation 4.5.3 SPMM—Concept and Methods 4.5.4 SPMM Implementation 4.6 Factory Simulation 4.6.1 Tool Concept and Methods 4.6.2 Modeling of Material Flow System 4.6.3 Modeling of Technical Building Services and Periphery 4.6.4 Integration of Dynamic Component-Based Machine Models into DFS 4.6.5 Statistics and Reporting 4.6.6 DFS Implementation References 5 Exemplary Applications of Tools 5.1 Case Study A – Simulation Environment of the Open Hybrid LabFactory 5.1.1 Technology Screening Using the TAT 5.1.2 Machine Modeling Using SPMMs 5.1.3 LabFactory Simulation Using the DFS 5.2 Case Study B – Engine Component Manufacturing 5.2.1 Rough Line Design Using the VSDT 5.2.2 Machine Tool Configuration Using the MTC 5.2.3 Quick Simulation Using the DFS with Custom GUI 5.3 Case Study C – Battery Case Manufacturing 5.3.1 Battery Case and Process Chains for IML and OHLF 5.3.2 Manufacturing in an Incremental Manufacturing Lab 5.3.3 Manufacturing with OHLF Processes 5.3.4 Scenario Setup and Evaluation Method 5.3.5 Evaluation and Interpretation References 6 Concluding Remarks 6.1 Summary 6.2 Critical Review of Concept and Tool Applicability 6.3 Outlook References