1. No category

Energy Value Stream Mapping
Motivation and Objectives
Framework
Producer price index crude oil
Global energy consumption
in bn toe/a
500
Energy Value Stream Analysis
System Elements
20
Types of Energy Waste
•  Measure
•  Visualize
•  Analyze
250
10
Cause Consumer price index fossil fuels
0
1970
1990
2010
1996
2030
2000
2004
2008
Energy Value Stream Design
Scope of Action
Implementation
Source: iwb, Lernfabrik für Energieproduktivität
System Elements
Types of Waste
■  Technology & System
■  Organization & Management
■  Human & Behavior
LEAN Wastes
1 Overproduction
2 Waiting
Energy
consumption
3 Transportation
4 Inventory
Technical
Optimization
5 Defects
Operators &
Management
initial state
time
normal operation
implementation phase
Unused Human
8 Talent
Source: iwb, Lernfabrik für Energieproduktivität
Source: iwb, Lernfabrik für Energieproduktivität
Energy Value Stream Analysis
Measure
6 Motion
Over
7 Processing
■  Holistic consideration of all 3 system elements is
necessary for sustainable improvement of energy
efficiency
Pictures: BoschRexroth
Design Kit
•  Derive measures
•  Prioritize
•  Identify reciprocal effects
■  Analyze energy flows of a production site
■  Identify the factory’s key energy consumers and where the
greatest amount of energy is wasted
■  Improve energy efficiency in total
Source: Thomson Reuters
■  Overproduction, e.g. use of surplus
energy by an inefficient manufacturing
system
■  Waiting, e.g. energy used while
production is down
■  Transportation, e.g. inefficient
transportation of compressed air
■  Inventory, e.g. storing energy in batteries
■  Defects, e.g. the energy which was used
to manufacture a defective product is
wasted
■  Motion, e.g. inefficient transportation of
goods
■  Unused human talent, e.g. failure to
integrate employees when defining
energy efficient processes
Drawing an Energy Value Stream Map
•  Collec&ng data on process parameters, power, temperature, compressed air Prozess
Stromaufnahme
W
Stromverbrauch
Wh
Aktuell
Budget/ Durchschnitt/Stück
Stück
letztes Intervall
▪
Drehen
3.95
4.0
3.8
▪
Härten
2.82
3.2
3.3
▪
Dampfreinigen 4.23
5.0
4.9
▪
Schrumpfen
3.25
2.0
2.4
▪
Montage
0.31
0.5
0.5
▪
Roboter
0.80
0.8
0.9
▪
Druckluft
1.72
1.4
1.2
16.9
17.0
LEP gesamt
■  The energy value stream map consists of different
modules representing the different manufacturing
processes, transportation processes und supply units.
Process x
1
Legend Natural gas Electrical Energy Visualize
Furnace 0,1 •  Drawing and visualizing the energy value stream Waste heat
PT [Sec.] = 1680 CT[ Sec.] = 54 C/O [Sec.] = 2700 •  Bar length: Amount of waste
heat
Number of parts [Pcs.] = 18 Power[kW] = 0,4 Temperature [°C]= 728 el. Energy [kWh/Pcs.] = 87 Consumption
•  Evalua&on of the energy value stream using analysis methods Process
window
Cost threshhold
Current operation
point
Quality
threshhold
Energy consumption
Prod. quantity
150
Energy consumption
Produced quantity
Tuesday Wednesday Thursday
Friday
Saturday
Sunday
CT [Sec.] = 54
C/O [Sec.] = 728
Compressed air 12 bar Batch [Pcs.]= 6
Waste heat El. Energy [Wh/Stk.] = 376
Part temp. [°C]= 65
Continuous Process temp. [°C] = 165
State-dependent
Inventory [Pcs.] = 0
Compr. air [Bar] = 6
Compr. air [dm3/s] = 3
Energy use over time
Source: iwb, Lernfabrik für Energieproduktivität
Type of Consumption
Detailed
information
Defects [%] = 0
[Pcs.]
0
Basic information
PT [Sec.] = 43
Compressed air 6 bar 5
Process parameter analysis
Steam [Bar] = 0
Steam [kg/h] = 0
•  Continuous
•  State-dependent
Legend:
PT:
CT:
C/O:
Processing time
Cycle time
Change over time
Source: iwb, Lernfabrik für Energieproduktivität
Energy Value Stream Design
Summary and Future Work
Energy Value Stream Design
Scope of Action
•  Color: Type of energy
•  Bar length: Amount of energy
Extreme cold 10
Monday
0,1
Cooling water 15
50
0
Machining
Process heat 25
[Wh]
Process Module
Space hea&ng Conveyor Band 0 Batch [Pc.]= 6 Analyze
Influence 0
Design Kit
Derive measures
Several measures
are derived to
eliminate each
waste of energy
Waste 1 Waste 2 … Waste n Saskia Reinhardt © 2011 LMAS
contact email: [email protected]
Funding Sources: Institute for Machine Tools and Industrial Management (iwb)
Prioritize
■  Structured and methodological approach
■  Tool for energy visualization
■  Similarity to Lean Production profits from existing
knowledge
Identify reciprocal effects
Measures with
negative
reciprocal effects
are eliminated
Waste 1
Waste 2
Waste 3
M3
M6
M8
M7
….
Waste n
M 12
■  Apply method in different production
environments and improve each step
Source: iwb, Lernfabrik für Energieproduktivität
Berkeley
/
UNIVERSITY OF CALIFORNIA