Maintenance for sustainable manufacturing

1
Maintenance for sustainable manufacturing

• An initiative in Sustainable Manufacturing MTP
• Marco Garetti Sergio Terzi,
• Politecnico di Milano
• Erkki Jantunen, VTT

2
Overview

• Manufacturing must be sustainable in terms of
• Performance and Quality of products (including
  services) and processes
• Safety of people
• Workers and other people affected by
  manufacturing processes or facilities and their
  products but also of the related facilities and
  infrastructure
• Maintenance of manufacturing facilities is
  important to sustain (i) the quality of processes
  and (ii) safety.
• Session 1 Sustainable Manufacturing of the IMS
  Seminar Strategies for Global Manufacturing (A
  European View), held in Zürich, 15-16 November
  2007
• Maintenance plays a strategic role for achieving
  sustainability in manufacturing
• Especially when the whole lifecycle of the
  manufactured products is considered

3
Sustainability and Maintenance

• The new constraints coming from limits to
  environmental pollution for industry are
  demanding for improvements of the maintenance of
  industrial machinery
• Since maintenance is responsible for equipment
  availability optimization in the use of resources
  and waste reduction is dependant of the quality
  of maintenance
• Maintenance is responsible for internal (workers)
  and external (environment) safety
• The maintenance of machinery counts for a very
  great cost to European industry
• Maintenance costs in Europe are hundreds of
  billions!
• OEE can significantly be improved with good
  maintenance

4
Upcoming Changes

• Products
• Lower energy consumption, lower emissions
• Last long, can be maintained
• Recycling of components
• Production processes
• Higher overall efficiency, lower energy
  consumption
• Lower emissions
• Production equipment
• See products, maintenance very important

5
Maintenance becomes very important

• Well maintained
• Higher efficiency
• No unnecessary polluting starts and stops
• In many processes the starts and the stops cause
  very high emissions
• Machines last long - no new need to be
  manufactured
• No emissions and use of raw material
• Consequently the quality of maintenance becomes
  very important
• Maintenance should be carried out only when it is
  needed
• Unnecessary maintenance causes waist and can
  cause failures of the machinery
• Maintenance research becomes much more important

6
Objectives of the initiative

• Promote the role of maintenance for supporting
  manufacturing sustainability from a technical and
  social point of view
• Develop new maintenance business models (MBM) for
  successfully implementing new ICT and non ICT
  technology in maintenance operation and
  management
• Develop proposals for new maintenance policies in
  respect of manufacturing sustainability (i.e., by
  means of maintenance policy planning that is
  aware of sustainability)
• Develop and disseminate, as a leverage for
  manufacturing sustainability, the concept of
  e-maintenance and related ICT technology and
  supporting business processes

7
Workplan

• Activity 1 Discussion Forum on the role of
  Maintenance for sustainable manufacturing
• This activity involves the deployment of wikis
  and blogs to allow the community to share
  information and discuss maintenance for
  sustainability related topics
• Activity 2 Workshops Dissemination
• Two international workshops are planned during
  the period of this initiative
• Furthermore, members of the initiative will
  organize sessions in known relevant conferences,
  special issues in scientific journals etc.
• Activity 3 Targeted expert exchanges
• This activity involves visits of experts to
  others places with concrete targets, for
  example common work on a specific task of a
  project of the hosting organization, writing of a
  common paper, preparation of a new project etc.

8
Prospective participants

• Regions involved EU-NOR, Switzerland
  (discussions with potential partners from other
  regions are in progress)
• Projects involved Dynamite, INCOCO-S, Promise
  (other projects from other regions are welcome)
• Partners involved EPFL (Switzerland), POLIMI
  (Italy), CRAN (France), VTT (Finland)