Environmental Product Lifecycle Management Customizing the Enterprise Specific Manufacturing Processes

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1 Environmental Product Lifecycle anagement Customizing the Enterprise Specific anufacturing Processes Benjamin Kuhrke 1, Eberhard Abele 1, Stefan Feickert 1, Frank-Dieter Clesle 2 1 Technische Universität Darmstadt, Institute of Production anagement, Technology and achine Tools, Germany 2 TechniData AG, Germany The most recent EU Directives lay down new conditions toward the environmental responsibility of producers and their products. The requirements to the products lifecycles rise continuously. ethods and tools for Life Cycle Assessment (LCA) of products become more and more important for the industry. Highly sophisticated tools, offering a wide range of environmental data and functionalities are already available. However, due to the high scientific level of these tools, the applications are very complex. They result often in a lack of integration in the daily practice. This paper describes the Environmental Product Lifecycle anagement approach which integrates the LCA in standard software systems like the mysap Business Suite. This will be realized by extending the SAP module Compliance for Products (CfP) of TechniData AG. Nowadays the CfP manager provides many solutions concerning the material declaration (e.g. check of the fulfilment of certain material lists), RoHS Compliance and many other material based questions. The product structure within the CfP anager will be extended by the processes of the product life cycle; material production, manufacturing, use and disposal. The main focus of this paper lies on the manufacturing phase of the product and in particular on the customization of the enterprise manufacturing processes. In this context, customization means to preset all environmental process information, needed for an LCA. The aim is to enable the calculation of the environmental impact when manufacturing a specific product within an LCA Compliance tool. After the customization, the user has to enter the product specific information only. In the background the tool combines the manufacturing specific information and the product specific information and calculates the energy and material flows that are defined in advance. Keywords: Product Lifecycle anagement, anufacturing, Life Cycle Assessment, SAP 1

2 Transfer-Unit 55 Ökobilanzierung in SAP Benjamin Kuhrke Ökobilanz-Werkstatt 2006 Background Research Department: Environmentally sound products and processes Institute for Productionmanagement, Technology and achine Tools Technical University Darmstadt Transfer-Unit 55 Optimised Processes, ethods and Instruments for the Development of Environmentally- Friendly Products C1 C2 C3 C4 C5 2

3 Overview motivation and approach status quo of the e-business solution underlying concept of the Lifecycle Assessment within the e-business solution example to point out the concept with the focus on the manufacturing processes otivation and Approach of the Project otivation Industry Challenges Requirements from product related environmental protection: legislation customer requirements environmental policy Problems isolated application time consuming difficulties in interpreting the results Scientific Solutions Life Cycle Assessment methods instruments software solutions Approach use of environmental information which is already kept in the enterprises Life Cycle Assessment with SAP CfP Compliance for Products 3

4 Compliance for Products CfP AIAG IDS Jeita - Compliance Connect Sheet IEC and IPC are planned Data Collection Tool - Technidata General Concept Information/Data Environmental Assessment within SAP Requirements specification Definition Guidlines Untersuchungs - Ziel Goal rahmen and Scope Enterprise External aterials from EH&S Bill of material from Working plan from PP Supplier Disposer LCI Impact Assessment odellierung des Computer Lebenswegsbased Inventory Analysis Berechung der Sachbilanzdaten Klassifizierung Computer based Impact Charakterisierung Assessment Gewichtung / Abwägung Presentation of results Definition Inventory Sachbilanz Analysis Ziel Goal Untersuchungs - Scope rahmen odelling odellierung of the des Life Lebenswegs Cycle Berechung Calculation der of the Sachbilanzdaten Inventory Data BASIS Klassifizierung the main challenge of the LCA-tool Classification Charakterisierung development is the automatic Charakterization inventory analysis Wirkungsabsch Impact Assessment ätzung Gewichtung / Weighting Abwägung Interpretation Life Cycle Assessment ISO

5 Concept for the Computer based Life Cycle Inventory Analysis Supplier Bill of materials from SAP /PP aterials from SAP EH&S Information Working plan from SAP PP Disposer IDS, AIAG, IPC, own Tool Product A B A1 A2 B1 Product structure in CfP aterial X, kg aterial Y, kg aterial X, kg Transportation km, kg aterial X, kg Production process A Process, Time B2 aterial X, kg Recycling Quote Inventory Analysis Production Scenarios Inventory Analysis Inventory Analysis Inventory Analysis Inventory Analysis Inventory Data Requirements specification Use Processes Lifetime, Frequency of Usage etc. Scenarios IA Example: Electric Brush from Kärcher battery operated (NiCd-Accumulator) input power 1,6 W operating time 20 minutes 5

6 Gathering and Processing of the Transport Data Switch cpl black Vendor Plastro GmbH Distance 1000 km eans 40 t Truck = ton kilometer 0,00013 tkm Transport data Customizing the anufacturing Processes Workflow of the application: Goal: automatic calculation of lifecycle inventory data attribution attribution ecological ecological activity activity type type Working plan from SAP PP Other data sources Product B B1 Product structure aterial X, kg Production process A process time Production process process time time other other activity activity types types energy-, energy-, material material consumption consumption and and emissions emissions Inventory Analysis elementary elementary inand inand output output flows flows Goal: odeling environmental process parameter to enable the automatic Lifecycle Inventory of the Production Processes Analyzing the production processes odeling the product specific material and energy flows Estimation of the pre-process chains 6

7 Customizing the anufacturing Processes Analyzing the production processes Selection of relevant production processes added value -> no transport environmental impact cost center 1 P P P cost center X defining of process boundaries cost center cost center 2 machine peripherie defining the system boundary defining the structure of the process (Process machine and periphery systems) e.g. process time defining the ecological activity types to get product specific energy- and material flows Customizing the anufacturing Processes odeling the product specific material and energy flows energy demand: ecological activity type = process time E process workplace = P workplace machine t P = P + P process periphery / machine P machine = f correction P connection f correction with measurement or expert survey Psystem T j system/ year Psystem = j / machine N Ti i= 1 P system/machine = pro rata Power of one system T i = machine operating time Pperiphery / machine = Psystem j / machine j= 1 7

8 Customizing the anufacturing Processes odeling the product specific material and energy flows operational supplies and waste flows: ecological activity types = process time, others time depending consumption and waste parameter value Cp ( t ) = CPVp tprocess Wp ( t ) = WPVp tprocess 1. Consumption per time is equivalent CPVp = Cp/year N T i i =1 2. Relation of consumption per time is known same procedure Cp/yearfor waste and N parameters emissions CPVp,i = x i 1 (x i =1 1 i 1 Ti ) 3. yearly consumption per machine is known CPVp,i = Cp,i/year Tmachine Cp,i/year= consumption per machine Customizing the anufacturing Processes e.g. machining process energy demand: Eprocess = Pworkplace tprocess Pworkplace = Pmachine + Pperiphery Pmachine = fcorrection Pconnection 8

9 Energy measurement connection power (43 kva) tool change machine tool: Power [VA] modern 5 axis Pmeasured = 10,1 kw machining center rapid feed material: = 4 times less connection actual power power Titanium Alloy process time: 22 min 65 sec correction factor can be estimated with f = 0, measured base power (8,18 kva) Zeit [sec] Customizing the anufacturing Processes e.g. machining process energy demand: Eprocess = Pworkplace tprocess Pworkplace = Pmachine + Pperiphery Pmachine = fcorrection Pconnection Pmachine = 10,32 kw Pperiphery = 171,8 kw 4422 h/a 3840 h / a 120 Pworkplace = 10,32 kw + 1,64 kw operational supplies and waste flows: CPVlubricant = kg/a ( ) min/ a 120 CPVlubricant = 1, kg/min 9

10 anufacturing Accu Brush push button injection moulding PD tree for production processes Process data Process parameter Energy parameter Resources Emissions Waste achine data achine parameter Energy parameter Resources Emissions Waste Auxiliary machine data achine parameter Energy parameter Resources Production Specification Emissions Waste Exact Procuction Process Specification Injection push button oulding Production Process power hydraulic pump 55 kw installed total power 89 kw standby power 40 kw Injection oulding active proc... 0,026 kwh Example: worst case 89 kw * 0,03 H / 100 0,026 kwh Calculation Structure Ressource Quantity Entity Working Place push button K50_ _1 100 piece push button injection 0,03 hour injection moulding Use Phase Accu Brush Power Charging Power non Charging Lifetime Charging Time Operating Time per charged Battery 1,6 W 0,2 W 4 years 8 hours 20 min. Operating Time per Lifetime Charging Time per Lifetime Scenario 12 hours 4 years 10

11 Electric and Electronical Waste Treatment Scenarios Category Volume [l] Weight [kg] Example Recycling Disposal Smallest Appliances < 1 < 0,5 obile Phone, Watch 20 % 80 % Small Appliances ,5.3 Telephone, Coffee achine 50 % 50 % edium Appliances >15 75 >3 15 Vacuum Cleaner, icrowave 75 % 25 % Large Appliances > 75 > 15 TV, Air Conditioner 98 % 2 % Volume = 1,5 l50 % Disposal Combustion Weight = 1,98 kg 50 % Recycling Shredder Disposer Disclosure Recycling rates Ferrous etals 95% Non Ferrous etals 95% Thermoplasts PP, PS, ABS 35 % Residual 0 % Electric and Electronical Waste Treatment Example: Axis of the Wheel Weight 4 g Product Category Small Appliance Recycling in % 50 % Disposal in % 50 % Recycled Fraction Combusted Fraction 1,9 g 2,1 g 11

12 Zusammenfassung der berücksichtigten Werte 100 % aterial mit Idemat Lediglich 700 g Injection oulding Alle Transporte von den Zulieferen Alle Nutzungsprozesse Entsorgung mit vorhandener Datenbasis Ergebnisse nur eigene Produktion 100% 80% 60% 40% 20% Produktnutzung Transporte Produktion Entsorgung Akkubesen Werkstoffe 0% -20% abiotic depletion global warming (GWP100) ozone layer depletion (ODP) human toxicity fresh water aquatic ecotox. marine aquatic ecotoxicity terrestrial ecotoxicity photochemical oxidation acidification eutrophication 12

13 Ergebnisse alle Produktionsprozesse 100% 80% 60% 40% 20% Produktnutzung Transporte Produktion Entsorgung Akkubesen Werkstoffe 0% -20% abiotic depletion global warming (GWP100) ozone layer depletion (ODP) human toxicity fresh water aquatic ecotox. marine aquatic ecotoxicity terrestrial ecotoxicity photochemical oxidation acidification eutrophication 3 Abschlussfragen Ist die Abbildung der Produktionsprozesse ausreichend? Welche Daten muss oder kann ich mindestens von meinen Zulieferern bekommen? Bestehen Alternativen zu dem Datenaustausch mit den Zulieferern? 13

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