Sustainability is crucial for the world in the present and future, because the assumption that our planet resources are infinite is no longer acceptable. Sustainability will influence all human life and especially manufacturing, one of the pillars of modern life-style, which is responsible of huge amount of resources consumption and emissions. Sustainable manufacturing can be considered therefore very important for pursuing the vision of world Sustainable Development, especially by developing energy and resources efficient production systems and supply chains. Although many energy-efficient Best Available Technologies and Practices have been developed at different factory levels, some limits still exist about the applicability of the available solutions. In particular, one of the limits is the lack of systemic view of the factory. The current approaches focus on local optimizations at each level of the factory, missing opportunities for wider energy and resource usage optimization enabled by holistic and more global approaches. In this context, this work introduces the possibility to integrate energy efficiency in layout design process. Until now this problem has been faced through a traditional manufacturing perspective, lacking a clear implication of energy effects against the different choices taken by decision-makers. According to the aim just exposed, initially the work deals with the energy characterization of the most important resources in a production layout: the material handling systems and the production machines. Firstly, a conceptual model of the resources involved has been identified and developed, based on analytical modeling, in order to characterize their energy consumption behavior (power profile) in different operating states. Then a discrete event simulation model has been built up, able to link each power profile with the evolution of the operating states of the resources, in order to energetically characterize the resource behavior during operations in different configurations. Against this proposition, a new energy model for the conveyor, selected as main material handling system according to recent statistic report of USA manufacturing, has been developed and then validated with real data from conveyor suppliers. With the simulation model, once the energy characterization of each resource has been defined, the whole manufacturing system has been studied in order to highlight the dynamic relations among the different resources: machines and material handling systems, according to their possible operating configurations and the material flow as well. The analysis has been conducted in order to obtain an optimization model able to identify the layout with minimum cost solution through an energy perspective, without neglecting the traditional indicators of production performance. The possibility to obtain energy savings during the layout design phase, thanks to an energy-efficient characterization of the manufacturing resources, has been validated in different manufacturing scenarios, which have been classified according to their energy consumption level, through data collected at BIMU exhibition (Milan, October 2014). The scenarios feasibility and their economic advantages have been assessed through simulations. Later a specific manufacturing case (automotive) has been studied through the same perspective, in order to validate the efficacy of the proposed models again. This work allows to increase the energy awareness during the layout design, thanks to the possibility to identify an optimal layout from the energy efficiency viewpoint, by using the developed integrated models that take into account also the traditional manufacturing system performance.
La sostenibilità è un aspetto cruciale per il mondo presente e futuro: ipotizzare che le risorse del nostro pianeta siano infinite non è più accettabile. La sostenibilità influenzerà la vita dell’uomo e specialmente del settore manifatturiero, uno dei pilastri dello stile di vita moderno, che è responsabile di ingenti consumi ed emissioni. Quindi la sostenibilità manifatturiera può essere considerata molto importante per seguire la visione dello sviluppo sostenibile, specialmente sviluppando sistemi produttivi e supply chain energeticamente efficienti. Sebbene molte Best Available Technologies e pratiche per l’efficienza energetica siano state sviluppate in differenti livelli di fabbrica, alcuni limiti ancora esistono per l’applicabilità delle soluzioni disponibili. In particolare, uno dei limiti è la mancanza di una visione sistematica della fabbrica. Gli attuali approcci si focalizzano su ottimizzazioni locali ad ogni livello della stessa, non riuscendo in un’ottimizzazione più ampia dell’uso delle risorse e dell’energia, abilitata da approcci olistici e più globali. In questo contesto, il lavoro introduce la possibilità di integrare l’efficienza energetica nella progettazione del layout. Finora, il problema è stato affrontato con una visione manifatturiera tradizionale, ma manca un’implicazione degli effetti energetici rispetto alle scelte prese dai decision-maker. Secondo l’obiettivo appena esposto, inizialmente il lavoro tratta la caratterizzazione energetica delle risorse più importanti del layout produttivo: i sistemi di movimentazione e le macchine. Per primo, è stato identificato e sviluppato un modello concettuale delle risorse, basato su un modello analitico, ai fini di caratterizzare il loro comportamento energetico (profilo di potenza) nei diversi stati operativi. Poi è stato costruito un modello di simulazione ad eventi discreti in grado di legare ogni profilo di potenza con l’evoluzione degli stati operativi delle risorse, ai fini di caratterizzare energeticamente il comportamento della risorsa durante le operazioni in diverse configurazioni. Nei confronti di questa proposta, è stato sviluppato un nuovo modello energetico per il conveyor, selezionato, secondo recenti report statistici del manifatturiero statunitense, come principale sistema di movimentazione, e in seguito validato con dati reali dei fornitori di conveyor. Con il modello di simulazione, una volta definita la caratterizzazione energetica di ogni risorsa, l’intero sistema manifatturiero è stato studiato ai fini di sottolineare le relazioni dinamiche tra diverse risorse, in questo caso macchine e sistemi di movimentazione, secondo le loro possibili configurazioni operative, date dal flusso produttivo. Questa analisi è stata condotta per ottenere un modello di ottimizzazione in grado di identificare il layout con costo minimo attraverso una prospettiva energetica, senza dimenticare gli indicatori tradizionali di produttività. La possibilità di ottenere risparmi energetici durante la progettazione del layout, grazie ad una caratterizzazione energeticamente efficiente delle risorse, è stata validata in diversi scenari manifatturieri, classificati per livello di consumo energetico, con dati raccolti alla fiera BIMU (Milano, ottobre 2014). Inoltre la fattibilità degli scenari e i vantaggi economici sono stati valutati tramite simulazioni. Successivamente è stato studiato un caso manifatturiero specifico (automotive) sotto la medesima prospettiva al fine di poter validare nuovamente l’efficacia dei modelli proposti. Il lavoro dà l’opportunità di aumentare la consapevolezza energetica durante la progettazione del layout, grazie alla possibilità di identificare layout ottimali dal punto di vista energetico utilizzando i modelli integrati sviluppati, che tengono conto anche delle performance manifatturiere tradizionali.
Integrating energy aspects in layout design : holistic modelling of energy efficient material handling systems
FERRARIO, DAVIDE
2014/2015
Abstract
Sustainability is crucial for the world in the present and future, because the assumption that our planet resources are infinite is no longer acceptable. Sustainability will influence all human life and especially manufacturing, one of the pillars of modern life-style, which is responsible of huge amount of resources consumption and emissions. Sustainable manufacturing can be considered therefore very important for pursuing the vision of world Sustainable Development, especially by developing energy and resources efficient production systems and supply chains. Although many energy-efficient Best Available Technologies and Practices have been developed at different factory levels, some limits still exist about the applicability of the available solutions. In particular, one of the limits is the lack of systemic view of the factory. The current approaches focus on local optimizations at each level of the factory, missing opportunities for wider energy and resource usage optimization enabled by holistic and more global approaches. In this context, this work introduces the possibility to integrate energy efficiency in layout design process. Until now this problem has been faced through a traditional manufacturing perspective, lacking a clear implication of energy effects against the different choices taken by decision-makers. According to the aim just exposed, initially the work deals with the energy characterization of the most important resources in a production layout: the material handling systems and the production machines. Firstly, a conceptual model of the resources involved has been identified and developed, based on analytical modeling, in order to characterize their energy consumption behavior (power profile) in different operating states. Then a discrete event simulation model has been built up, able to link each power profile with the evolution of the operating states of the resources, in order to energetically characterize the resource behavior during operations in different configurations. Against this proposition, a new energy model for the conveyor, selected as main material handling system according to recent statistic report of USA manufacturing, has been developed and then validated with real data from conveyor suppliers. With the simulation model, once the energy characterization of each resource has been defined, the whole manufacturing system has been studied in order to highlight the dynamic relations among the different resources: machines and material handling systems, according to their possible operating configurations and the material flow as well. The analysis has been conducted in order to obtain an optimization model able to identify the layout with minimum cost solution through an energy perspective, without neglecting the traditional indicators of production performance. The possibility to obtain energy savings during the layout design phase, thanks to an energy-efficient characterization of the manufacturing resources, has been validated in different manufacturing scenarios, which have been classified according to their energy consumption level, through data collected at BIMU exhibition (Milan, October 2014). The scenarios feasibility and their economic advantages have been assessed through simulations. Later a specific manufacturing case (automotive) has been studied through the same perspective, in order to validate the efficacy of the proposed models again. This work allows to increase the energy awareness during the layout design, thanks to the possibility to identify an optimal layout from the energy efficiency viewpoint, by using the developed integrated models that take into account also the traditional manufacturing system performance.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/103324