Equipment Availability and Energy Efficiency a Contradiction?

Equipment Availability and Energy Efficiency a Contradiction? Verfügbarkeit und Energieeffizienz im Widerspruch? Dr. Patrick Reichen March 5, 2015

Energy Efficiency vs. Availability Source: BMW, i3 Source: Hummer, H2 Energy consumption 12.9 kwh/100km Energy efficiency label A Empty weight 1270 kg Power 125 PS Acceleration 7.2 s Availability? Energy consumption ~207 kwh/100km Energy efficiency label? Empty weight 2903 kg Power 300 PS Acceleration 11.0 s Availability? Higher dynamics, stiffness, faster movements require more energy! 2 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

/kwh /kwh Energy Efficiency Becomes Important Financial and political drives favor energy efficient processes Trend to higher energy cost Commitment of Bühler to decrease energy consumption by 25% until 2020 0.12 0.1 0.08 0.06 0.04 0.02 0 Electricity increased by 45% since 2004 0.05 0.045 0.04 0.035 0.03 0.025 0.02 0.015 0.01 0.005 0 Gas price increased by 86% since 2004 EU Average Germany France Source: Price development for industrial consumers, Eurostat EU Average Germany France Gas 3 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Agenda 1 2 3 Standardized Energy Consumption of DCM Effective Energy Consumption of DC Cells Cost Impact: Availability vs. Energy Efficiency source: Autoweek NL source: IHK source: Fotolia 4 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Principles of the VDMA Cycle The VDMA-Specification was elaborated by a working group of the Foundry Machinery Association within VDMA, because manufacturers of pressure metal diecasting machines were increasingly asked for energy efficiency and power consumption. This VDMA-Specification describes a standardized procedure to measure energy, whose boundary conditions and the documentation of the results considering in equal measure the interests of both manufacturer and equipmentuser. according to VDMA24499 Part and die independent measure of a die casting machine Measure for a DCM and NOT a DC Cell Energy consumption of peripheral components (die tempering, dosing, spraying, etc.) are not considered Represents a process near cycle! Applicable to hot and cold chamber DCM 5 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Standardized Reference Cycle Cycle 1 Cycle 2 Process steps 1 2 3 4 5 6 7 8 9 10 11 1 Die Closing Dosing Time 1) Plunger Forward Solidification Time 1) Die Opening Ejector Forward Extracting Time 1) Ejector Backward Spraying Time 1) Plunger Backward Waiting Time 2) 1) Process-related times defined according to machine size 2) Time for the DCM to reach status ready for next cycle for cold chamber DCM only 6 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

VDMA Standard Cycle for a DCM Die Closing Die Opening/Ejector Plunger Backward Solidification time Ejector Backward VDMA Reference Cycle Dosing time Plunger Forward Extraction Time Spraying Time 7 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

VDMA Test Report for DCM Energy Certificate for DCM Disclosure of key information Machine size: Carat 320c Energy consumption:1.615 kwh/cycle Cycle Time: 84.7 s Represents a process near cycle NOT a dry cycle! 8 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Agenda 1 2 3 Standardized Energy Consumption of DCM Effective Energy Consumption of DC Cells Cost Impact: Availability vs. Energy Efficiency 9 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Effective Energy Consumption How to benchmark energy consumption in a real production environment? Definition Boundary Conditions DC Cell 12% 1-3% DC Machine Definition of Parts Al Preparation 50% Energy Consumption (complete factory 100%) Goal: in depth evaluation of the total energy consumption Focus on electrical energy, compressed gas and cooling water Results measured in specific energy consumption (related to part weight) Confidential 10 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Results Energy Measurement Protocol Document to show the current energy consumption of a specific process Equipment and product dependent protocol Confidential 11 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Results For oil pan, bedplate, shock tower Part Cooling Dosing Furnace Extraction Robot 2.0% 1.3% 7.7% DCM 4.9% 2.8% 5.9% 0.3% 1.1% 2.0% 6.2% 5.6% Press 14.0% 25.0% 31.3% 41.7% Die Tempering 36.6% 13.5% Spraying 39.8% 15.0% 32.9% 10.5% Oil Pan Bedplate Shock Tower Approx. Machine Size ~800t ~1800t ~2800-4000t Values for 1 part Oil pan Bedplate Shock Tower Electrical [kwh elec /cycle] 1.542 3.879 3.870 Air [Nm 3 /cycle] 3.407 0.378 6.972 0.774 4.479 0.497 Cooling Water [kwh th /cycle] 0.893 0.013 2.183 0.033 2.159 0.033 Total Energy [kwh/cycle] 1.934 4.685 4.400 Specific Energy [kwh/kg]* 0.921 0.509 0.969 * part weight Confidential 12 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Agenda 1 2 3 Standardized Energy Consumption of DCM Effective Energy Consumption of DC Cells Cost Impact: Availability vs. Energy Efficiency Confidential 13 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Availability Known as OEE Calculation of OEE Planned Production: 660 min Downtime: 93.2 min Required Information of planned production time: Theoretical cycle time: 82.8 s # of produced parts: 405 parts # of parts out of spec: 14 parts 5 automatic 4 semi-automatic 3 manual 2 setup 1 off 0 emergency off # of parts that should have been produced in the available time (uptime/theo. cycle time) OEE = 567 min 405p 391 p = 0.818 660 min 410.7p 405 p 0.859 0.986 0.965 **Results based on measurements on Carat180 7.7.2014 Confidential 14 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Impact on Cost and Energy Savings Based on energy measurement of a standard die casting cell A) Cost for machine utilization 1) 150.- /h f(oee) B) Energy costs 0.09 /kwh f(oee, Energy) Production: 7.728 kwh/cycle, Stand-by: 4.694 kwh/cycle e.g. OEE from 0.6 0.75; Energy reduction by 15% 15% 18.9% 1.5% 10x higher impact! Impact of OEE improvement much bigger on the costs per part 1) Personal and structural, maintenance, capital, consumables, die 15 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

Summary Improvement of OEE with higher impact on cost savings Effective energy consumption as specific value Quality requirements Availability of an installation Hardware configuration Comparison of different systems only by standardized procedures e.g. VDMA 24499 for DCM Equipment Availability and Energy Efficiency a Contradiction? No!! 16 Bühler 15 th International Die Casting Conference Bad Homburg March 5, 2015

17 Bühler www.buhlergroup.com

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