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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 3 - MEMAN (Integral Material and Energy flow MANagement in MANufacturing metal mechanic sector)

Teaser

Summary

The MEMAN project aims at supporting European companies in the metal mechanical sector in their efforts to maximise their resource saving potential and increase competitiveness. The project is based on an innovative approach that will address resource efficiency optimisation of whole manufacturing value chains instead of isolated single company or process optimisation, and includes energy, raw materials, supplies and waste. MEMAN brings together fourteen partners from six countries, including enterprises, SMEs, and experts in eco-innovative models, who will be working on optimising resource efficiency across the complete metal mechanical value chain, from casting through machining to surface finishing.

CASTING
The casting sector comprises a large number of sectors, including mobility (aviation, railway, shipping, automotive), energy, agribusiness, and chemicals. The companies in all sectors directly employ around 34,960 people. Within the framework of MEMAN project, the cluster will test innovate technological processes of suspension control arm production, making us of light alloys and new design methods. The possibility of manufacturing the part in aluminium will be explored, together with the assessment of the alternative technologies such as new casting, cooling, and heat treatment processes.

MACHINING
Mecanic VallÃ©e is a business and innovation cluster, specialised in aeronautics, spare parts for automotive industry, and machines tools. It gathers 173 members, representing 87% of the employees and constituting 85% of the turnover (â‚¬1.85M) in the area. Within MEMAN,the cluster will analyse the Product Life Cycle of aero-structural and engine components of the CFM 56 jet engine, equipping Airbus A 320 and Boeing aircrafts. Activities carried out by project partners will include the assessment of alternative technologies in different process stages, including milling, drilling, boring, and laser cutting, amongst others. The aim is to significantly reduce the time, cost, and energy involved in the production of the component.

SURFACE FINISHING
The cluster, focused on surface technology and finishing, includes over 200 companies and factories. It employs 12,000 people and has an accumulated turnover of about â‚¬1.4 bn. The sector is strongly affected by higher resource costs, as energy accounts for 12%, and materials and chemical supplies for 25-35% of total operating costs. The MEMAN project is therefore expected to enable a better re-design and re-engineering of stainless steel hydraulic piston rod under a life-cycle perspective and their manufacturing processes. These optimisations will contribute to substantially increased resource efficiency in the manufacturing of chromium plated products with reduced chromium use and losses, as well as increased chromium recycling and safer handling procedures.

Work performed

WP1, led by MCC and WP2, led by CETIM were finished in the 1st PR.

The WP3, led by TUBS, has focussed on the modelling of a single factory where the requirements for the material and energy flow analysis and simulation have been identified choosing two software for that, UMBERTO NXT and ANYLOGIC. Also, in this WP the activity has focused on identifying and analysing the critical parameters that have influence between the actors of the value chain as well as on the performance of the value chain.

The goal of WP 4 is to carry out a comprehensive modelling approach of the value chains use cases, including eco assessment with MEFA tool (Umberto), LCA/LCC methods and dynamic analysis with simulation tool (AnyLogic). This approach includes the modelling of the actual states of the value chains and the simulation of the optimized value chains This WP is led by TECHNOFI, so in order to achieve the goal, it requires comprehensive information gathered in WP 2 and operational tool developed in WP 3. The outputs of WP 4 are needed to order to allow for assessing the value chains re-engineering in WP 5 as well as the implementation tasks in WP 8.

The WP5, led by EIFFO, has focused on the assessment and priority ranking of the scenarios for value chain optimization that have been developed and analysed in previous and parallel work (WP2, WP4 and WP8). This WP will be finished in the 3rd period with the Task 5.2 and 5.3.

The WP6, led by MCC, has focused on the design, development and implementation the software architecture that allows the data acquisition of the process parameters (energy, material consumption,....) at company level so it can be transferred in a secure way to a cloud based value chain data container with the goal to provide the data of the complete value chain to the Umberto users for LCA analysis. At the same time, a development of adapted MES system which is capable to provide automatically a set of data that have been identified as the most relevant for value chain optimization.

The WP7 is focused in the design of the new business models affordable by the different value chains and clusters of MEMAN project. To reach the goal, a modeling framework coping the three main components of value chain innovation has been defined based on existing business modeling techniques and methods. New business models have been modelled and an economic evaluation has been done.

CETIM is the leader of WP8. The mail goal is to validate the value chain simulation and modelling in industrial conditions by implementing the optimised value chain of the three example products and test tools on the 3 example products value chains. A new model for value chain developed in WP4 has been studied from technical and economical points of view and a detailed action plan has been defined.

The WP9, led by EIFFO, has the objective to develop an approach for a meaningful characterization of companies in terms their energy use. So, the work has focused on analysing and comparing the different existing approaches to foster and compare industrial energy efficiency efforts in Europe. Also, the design of the new energy characterisation scheme and the definition of the functionalities of the virtual demonstrator have started.

G!E is the leader of WP10. The consortium present very promising results, with high potential market impact, as such 17 individual exploitable results and 3 patent fields. Three videos and a final publication were produced and distributed to clearly explain project results and methodology to relevant stakeholders and policy-makers. Since its launch, the website attracted more than 13,000 views from over 3,900 users from all around the world. Partners presented the project in 15 events and 2 bilateral meetings and participated in 4 relevant events.

MCC has been performed project management activities according to the planning initially established. The main coordination responsibilities rely on the Project Coordinator (Mr Joseba

Final results

It is expected that the MEMAN project will modify the consumption patterns of the whole metalworking value chain, achieving a reduction of energy consumption and CO2 emissions of at least 30%, and over 10% of the product Life Cycle Cost from cradle to grave of existing and future products. Given the significantly increasing need to limit greenhouse gas emissions, as well as escalating costs of energy resources and raw materials, the project is of strategic importance for the European economy.