plm in closed-loop consumer products - pdt...

PLM in closed-loop consumer products Circular Economy as the driver

Amir Rashid Associate Professor KTH- Department of Production Engineering PDT Europe 2014- Paris

2014-10-14 2 AMIR RASHID DEPARTMENT OF PRODUCTION ENGINEERING KTH ROYAL INSTITUTE OF TECHNOLOGY- STOCKHOLM

Contents

Closed-loop product systems- driven by circular economy

Closing the loop with multiple lifecycle products

Closed-loop and lifecycle management

Challenges for the PLM technology ResCoM and Collaborative platform for lifecycle

management




Stahel W R, 1994

Self-replenishing system loops: 1 = reuse, 2 = repair, 3= remanufacture, 4 = recycle

Presentatör

Presentationsanteckningar

He has been influential in developing the field of sustainability, by advocating 'service-life extension of goods - reuse, repair, remanufacture, upgrade technologically' philosophies as they apply to industrialised economies. He co-founded the Product Life Institute in Geneva, Switzerland, a consultancy devoted to developing sustainable strategies and policies, after receiving recognition for his prize winning paper 'The Product Life Factor' in 1982. His ideas and those of similar theorists led to what is now known as the circular economy in which industry adopts the reuse and service-life extension of goods as a strategy of waste prevention, regional job creation and resource efficiency in order to decouple wealth from resource consumption, that is to dematerialise the industrial economy



Resource conservation scenario


Economic case for circular economy Renault’s remanufacturing case:

Choisy-le-Roi near Paris, France Reengineering automotive mechanical subassemblies: water pumps to engines Sold at 50 to 70% of their original price With a one-year warranty

Generates revenues of US$ 270 million annually

Has achieved reductions of:

80% for energy 88% for water 77% for waste


SOURCE: Eurostat 2007 input-output tables for EU-27 economies; Ellen MacArthur Foundation circular economy team


Economic case for circular economy Remanufacturing mobile phones: 50% cost reduction per

device if: Easier to take apart Improved the reverse cycle Offered incentives to return devices that are no longer needed

High-end washing machines would be accessible for most

households if: They were leased instead of selling Customers would save one third per wash cycle Manufacturers would earn about a third more in profits




2014-10-14 AMIR RASHID DEPARTMENT OF PRODUCTION ENGINEERING KTH ROYAL INSTITUTE OF TECHNOLOGY- STOCKHOLM

8


Presentatör


1 Material input cost savings net of material costs incurred for reverse cycle activities, percentages as a share of total input costs in medium-lived complex product sectors 2 Most recent data for sector input costs on an EU level come from Eurostat 2007 input-output tables 3 Transition scenario: Conservative assumptions, focusing on changes in product designs, reverse cycle capabilities 4 Advanced scenario: Assuming more radical changes especially in terms of further developed reverse-supply-chain competencies, and other enabling conditions such as customer acceptance, cross-chain and cross-sector collaboration, and legal frameworks


Industrial pioneers in the closed-loop product systems



XEROX’s Waste Free vision: Asset Recovery programme starting in 1984 with

Reuse and recycling of parts diverted 161 million pounds of waste from landfills in 2003

Xerox maximizes the end-of-life potential of products by building into equipment design Easy disassembly Durability Reuse Recycling

100% of Xerox-designed equipment is developed with remanufacturing in mind


Presentatör


Sector: business services and document management. Headquarters: USA. Annual Sales: $22.5 billion. Number of employees: 134,000. Geographical presence: 160 countries around the world Pioneering industrial implementation of the closed loop manufacturing is XEROX where the idea was driven by the Zero Waste vision starting in 1984 with asset recovery programme



Xerox’s Docutech Printer remanufactured at Dundalk

Presentatör


Sector: business services and document management. Headquarters: USA. Annual Sales: $22.5 billion. Number of employees: 134,000. Geographical presence: 160 countries around the world Pioneering industrial implementation of the closed loop manufacturing is XEROX where the idea was driven by the Zero Waste vision starting in 1984 with asset recovery programme



Document Centre 220 New manufactured

Document Centre 220 Re-manufactured

Document Centre 440 Conversion: Factory Produced New Model



Wendy Kerr, et al.- Journal of Cleaner Production 9 (2001) 75–81

Closing the loop with multiple lifecycle products-


RICHO’s Comet Circle

Presentatör


a Japanese multinational imaging and electronics company According to Ricoh, GreenLine has grown rapidly (5% from 2012 to 2013), now accounting for 10 to 20% of Ricoh’s unit sales in these markets and earning a margin one-and-a-half to two times higher than Ricoh’s new products. Adding and managing the value by design

Closing the loop with multiple lifecycle products


Three essentials for simultaneous focus Design for closing the loop

Standardization and modularisation of components Upgradability Easier disassembly Purer materials flows

Innovative business models Access to service Performance based payment

Excellence in reverse supply chain Professionalism and transparency of forward supply chain Cost effective and high quality collection and treatment systems

Presentatör


The reverse supply chain may be a collaboration with third party suppliers similar to forward supply chain


Closed-loop systems are defined by dynamic interactions and causal relationships

Business models are the main drivers

Product design is driven by the business model

Supply chains- esp. reverse flows- are defined by both:

Business models Product design




Business model

Supply chain

Product design

Dynamic interactions and causal relationships



Dynamic interactions and causal relationships



H. Krikke et al., International Journal of Production Research, 41:16, 3689-3719

Challenges for the PLM technology


Closed-loop PLM for closed-loop product systems

Hong-Bae Jun et al., Computers in Industry 58 (2007) 855–868


Closed-loop PLM for closed-loop product systems

Seamless integration of information flow

Information acquisition, processing and use

Product embedded information devices (PEIDs)

Close collaboration with product designers and the

product system designers


ResCoM and Collaborative PLM platform

Main objective of the ResCoM project:

for the industrial implementation of closed-loop manufacturing systems. Develop an innovative and practical framework Supported by a lifecycle management software platform

The framework offers methodologies and business strategies with dynamic interactions included

Software platform offers enterprise-wide collaboration

for transparency and efficiency




Industry cases in ResCoM



Methodologies

Dynamic Modelling Data Bases & Analyses

Collaboration tools

2014-10-14 27

This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration under grant agreement No 603843

AMIR RASHID DEPARTMENT OF PRODUCTION ENGINEERING KTH ROYAL INSTITUTE OF TECHNOLOGY- STOCKHOLM

Contact Info:

Amir Rashid, PhD Associate Professor Department of Production Engineering School of Industrial Engineering and Management The Royal Institute of Technology Brinellvägen 68, SE-100 44 Stockholm, Sweden Ph: +46 8 790 6373, Fax: +46 8 210 851 e-mail: [email protected]


plm in closed-loop consumer products - pdt...

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