A Method for Real-Time Aggregation of a Product Footprint During Manufacturing

Abstract

To assess cost, time investment, energy consumption and carbon emission of manufacturing on a per-piece basis, a bottom-up approach for aggregating a real-time product footprint is proposed. This method allows the evaluation of the environmental impact of a batch or even single product using monitoring or simulation data. To analyze the infrastructure, the production plant is decomposed into modules that are in relation to each other via inputs and outputs. Distinguishing between modules for production, logistics, energy system, buildings and auxiliary systems, the different approaches for distributing resource consumption between the products are presented. Special attention is paid to typical scenarios that occur in production plants and problems that may arise from them. For example, the incorporation of standby-, setup-and ramp-up times, the energy consumption of the administration and the allocation of different products and by-products manufactured at a machine are taken into account.

Review of simulation-based life cycle assessment in manufacturing industry

“…The second most popular approach is to use the results of production simulation models. In this approach, the material or energy consumption figures obtained from a production simulation model are scaled according to the predefined functional unit and applied in LCA studies (Andersson, et al, 2011;Smolek, Leobner, Heinzl, Gourlis, & Ponweiser, 2016). Over half the reviewed studies use a combined approach, as it is often difficult to collect all the desired data using any single approach.…”

“…Type (Johansson, Mani, Skoogh, & Leong, 2009) Methodology and evaluation (Bengtsson et al, 2010) Conceptual work Conceptual work Conceptual work (Shao, Kibira, Lyons, & Asme, 2010) Conceptual work (Andersson, et al, 2011) Conceptual work (Brondi & Carpanzano, 2011) Methodology and evaluation (Harun & Cheng, 2011) Methodology and evaluation (Lindskog et al, 2011) Methodology and evaluation (Löfgren & Tillman, 2011) Methodology and evaluation (Muroyama et al, 2011) Methodology and evaluation (Andersson, Johansson, Berglund, & Skoogh, 2012) Conceptual work (Widok, Schiemann, Jahr, & Wohlgemuth, 2012) Conceptual work (Andersson, 2013) Methodology and evaluation (Mani et al, 2013) Conceptual work (Alexander Sproedt et al, 2013) Methodology and evaluation (Thiede, Seow, Andersson, & Johansson, 2013) Literature review (Zhang et al, 2013) Conceptual work (Heinemann et al, 2014) Methodology and evaluation (Kim et al, 2015) Methodology and evaluation (A. Sproedt et al, 2015) Methodology and evaluation (Orji & Wei, 2016) Methodology and evaluation (Schönemann et al, 2016) Methodology and evaluation (Smolek et al, 2016) Methodology and evaluation (Cerdas, Thiede, Juraschek, Turetskyy, & Herrmann, 2017) Methodology and evaluation (Ramanujan, Bernstein, Chandrasegaran, & Ramani, 2017) Literature review (Gbededo, Liyanage, & Garza-Reyes, 2018) Literature review…”

Hybrid Building Performance Simulation Models for Industrial Energy Efficiency Applications

“…The converted power output (Pout) can be seen in eq. (8). The expression either uses the incoming power (Pin) to calculate the output or, if the maximum capacity is reached, outputs the capacity.…”

“…By monitoring, predicting and optimizing the energy demand of the production as a whole as well as the expenditures of individual products, the tool chain provides reporting of energy performance indicators and ongoing management of the dynamic energy demand. This can for example be used for assessing the bottom-up Carbon dioxide (CO2) footprint of products [8] or for Demand Side Management [9]. According to Deng et al [10] most dynamic Demand Side Management approaches and tools share the characteristic that they are formulated as an optimization problem and the user behaviour is mathematically modelled.…”

Simulation-based Strategies for Smart Demand Response

“…The models are used to make predictions about future energy demand of different operation scenarios. Furthermore, the simulation can also be used for complementary tasks such as the determination of a product footprint, as described in more detail in [29].…”