Abstract
Improving energy efficiency in manufacturing has to be considered from a holistic perspective. Investigating and optimizing manufacturing processes in an isolated manner may neglect possible energy intensive pre- and post-processes, and thus may miss an overall optimum. Instead, the whole process chain has to be accounted for being able to find an optimum for the production of a certain product. The presented method for the evaluation of process chains therefore integrates a detailed analysis of the core as well as necessary pre- and post-processes, and enlarges this approach for a factory wide optimization. Single steps of a process chain are energetically modeled using a detailed mapping of each step’s energy profile, generalized by investigating the product variant related energy profiles for each machine. The result provides the base for improving the energy efficiency of a factory as well as for calculating the embodied energy of a product, fostering the energetically optimization of its manufacturing processes. Furthermore, factories in most cases produce multiple variants of similar products, requiring an optimization not for one product but for the overall product mix of the considered manufacturing site. The introduced method is therefore extended following a sustainability technology roadmap approach.
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