value characterization across the product lifecycle to support green plm … · 2019. 1. 22. ·...
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Value Characterization across the Product Lifecycle to Support Green PLM and Business Creation__________________PLM Center of Excellence
Katherine Ortegon, Ecol. Sciences & Eng. (ESE-IGP)Dr. Loring Nies, Civil Eng. & EEE
Dr. John W. Sutherland, Head EEEOctober 16th, 2012
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OutlineI. Introduction
› Green PLM and Goal of the project
II. Value› Value creation and Value consumption
III. VPLC Model› System Dynamics methodology› Decision-making
IV. Wind Turbines› Estimation of parameters
IV. TimelineVI. Summary
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I. IntroductionProduct Lifecycle Management Green Product Lifecycle Management
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PLM: Technology for computer-based product development and information management from product concept to end-of-life
GPLM: Evolving concept that considers multi-use lifecycles and considers resource consumption and waste streams.
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I. Introduction This is important because it…
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1. Allows designers to create products that avoid value erosion over time.
2. Promotes the design of products with multiple use lifecycles.
3. Anticipates and fosters the creation of new business opportunities.
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II. VALUE Value is an attribute of a product or service. Customers pay for value. Design
and manufacturing create value. Generally, when a customer uses the product or service, value is consumed. In a enterprise, different sources might
contribute to generate the total value of the system.
∫=td
t
dttStV0
)()( 0
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III. Value Product Lifecycle (VPLC) Model
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System DynamicsA system is a set of interrelated elements, where any change in any elementaffects the set as a whole (Bertalanffy, 1969). Systems thinking has itsfoundation in the field of system dynamics (Forrester, 1961). SystemDynamics (SD) studies how a system changes over time, the interactionbetween its elements, and how to improve the overall system performance(Sterman, 2000).
SD 2. Formulation1.
Conceptualization
4. Implementation
3. Testing
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III. VPLC ModelPurpose
The model for Value across Product Lifecycle (VPLC) will describe the change of product value over time (production through recovery and capitalize on secondary markets).
The VPLC will analyze the impact of maintenance, remanufacturing, and recycling in the creation of the economic value for the business under study.
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SD
1. Conceptualization
Overall business (system) value
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III. VPLC ModelValue & wind turbines
Complex Design (Still in
development)
Material and Energy
intensive
Durable and repairable good with records of
maintenance
High residual value and
opportunities for business
creation
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Design Manufacturing Use End-of-Use
Impa
ctSD
1. Conceptualization
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III. VPLC ModelDecision-making
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SD
1. Conceptualization
1. How the total value generated by the system changes when an end-of-use (EOU) recovery policy is considered?
2. What conditions provide the highest value for the system: open or closed remanufacturing? open or closed recycling?
3. What is the long term impact of maintenance on reliability and the EOU state of the product?
4. How the value generated at EOU varies with remanufacturing and recycling rates?
5. What is the long term impact of technology obsolescence on the value generated at EOU?
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III. VPLC ModelStock and Flow Diagram (SFD)
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SD 2. Formulation
Auxiliary variables to transform
flows
Rate of increase/decrease
of StocksIndicate the state of the
system
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VPLC MODELValue across Product Lifecycle
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III. VPLC general model 1/
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The general model includes the material flow from product manufacturing, collection at end-of-use (EOU), remanufacturing, recycling, and disposal.
SD 2. Formulation
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III. VPLC : maintenance1/
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The maintenance model includes the effect preventive and corrective maintenance over the reliability of products at EOU and effect on remanufacturing as an alternative for recovering.
SD 2. Formulation
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III. VPLC : Total Value Creation1/
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The Total Value Model includes the effect of remanufacturing and recycling on the total supply chain profit. In other words, the total value generated in the system.
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15
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0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,00020
00
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
2024
2026
2028
2030
Inst
alle
d C
apac
ity (M
W)
No.
of w
ind
turb
ines
(un
its)
Annual Demand of WTs Annual Installed capacity (MW)
IV. Value & wind turbinesEstimation of parameters - Demand
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16
Projected Demand
(Sources: DOE, AWEA)
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0
1000
2000
3000
4000
5000
6000
7000
800019
85
1990
1995
2000
2005
2010
2015
2020
2025
2030
Num
ber o
f WTs
(uni
ts /
yr)
Year
WTs at End-of-Use (EOU)
Annual WTs installed WTs at EOSL
IV. Value & wind turbinesEstimation of parameters – used WTs
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Today: 74% Small
25% Medium
Future: 54% will be
large (>1MW)
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IV. Value & wind turbinesEstimation of parameters - Operation
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Frequency of failures
Severity of failures
(Source: Spinato et al., 2009)
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IV. Value & wind turbinesEstimation of parameters - Remanufacturing
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Critical components with the highest frequency or severity of failure are replaced and upgraded.
Tower, Nacelle, hub, bed frame, and blades are preserved and remanufactured (86% of total weight, 60% of the cost).
Estimate components and materials demand
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IV. Value & wind turbinesSecondary Market - Remanufacturing
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Reman WT(V44)
New WT(E48)
Rated Power (kW) 600 600
Operational life (yrs) 15 20
AEP (kWh/yr) ~ 683,709 ~ 697,214
Warranty (yrs) 2 2
Installed Cost (US$)* 718,558 (~50-60% original cost)
1,200,000(~ $2,000/kW)
(Sources: NREL, DOL, DESIRE) the installed cost includes: remanufacturing, foundation, transportation, assembly, grid connection, and engineering costs
Schools
Small business
Communities
R e m a n u f a c t u r i n g
Used WTsWind farm
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IV. Value & wind turbinesSecondary Market-Recycling
(7 t/blade – fiberglass, composites)
(16 t- Steel, Al, Cu)(2 t - Steel)
(6.5 t- Steel, Cu)
(158 t - Steel)
(5 t – Steel, Cu)Total ~240 tons (2MW )
$100
$180
$214
$2,455
$6,798
$6,818
$-
$1,000
$2,000
$3,000
$4,000
$5,000
$6,000
$7,000
$8,000
Cement
Raw steel
Steel Scrap
Aluminum
Copper
Rare earthmagnets
Dollars per metric ton ($/t)
Mat
eria
l
(Source: USGS 2010)
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V. Timeline1/
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PLM meeting
Model Development
Model Validation
Sensitivity Analysis
Analysis & Conclusions
PLM final report
OCT NOV DEC JAN FEB MAR APR MAY JUN
---2012---- ----------2013-------------
JUL AUG
Funded by PLM Center of Excellence : Aug 2012 - 2013.
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VI. Summary1/
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Model
How the value of a product change over
time
Effect of Maintenance,
Remanufacturing, and Recycling on
value at EOU
4 sub-models: General, Maintenance,
Satisfaction, and Total value
Methodology
System Dynamics to analyze changes over
time
4 Phases: conceptualization,
formulation, testing, implementations
Wind Turbines
Emerging technology, fast growth, capital intensive,
and high potential of value recovery
Business opportunities:Remanufacturing of
whole system, components, and critical materials.
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Value Characterization across the Product Lifecycle to Support Green PLM and Business Creation�__________________�PLM Center of ExcellenceOutlineI. IntroductionI. Introduction II. VALUE III. Value Product Lifecycle (VPLC) ModelIII. VPLC Model�PurposeIII. VPLC Model�Value & wind turbinesIII. VPLC Model�Decision-makingIII. VPLC Model�Stock and Flow Diagram (SFD)VPLC MODEL�Value across Product LifecycleIII. VPLC general model III. VPLC : maintenanceIII. VPLC : Total Value CreationSlide Number 15IV. Value & wind turbines�Estimation of parameters - DemandIV. Value & wind turbines�Estimation of parameters – used WTsIV. Value & wind turbines�Estimation of parameters - OperationIV. Value & wind turbines�Estimation of parameters - RemanufacturingIV. Value & wind turbines�Secondary Market - RemanufacturingIV. Value & wind turbines�Secondary Market-RecyclingV. TimelineVI. SummaryThanks