Digital Transformation Value Indicators for a Sustainable and Circular Economy
Element Analysis FEA ), simulate , and improve process operations ( Computational Fluid Dynamics - CFD and Discrete Element Models – DEM ) and increasing manufacturing operations ( Discrete Event Modeling ). Many organizations have been able to demonstrate shorter product development times , design for manufacturability , increase in product quality and increase in equipment / workforce utilization .
An example , from a confidential company , illustrates how process operations can be improved using simulation and computational fluid dynamics ( CFD ) for industrial mixing operations . The simulation demonstrated that the manufacturing cycle time could be reduced between 15-20 % per batch . The first reaction is cost savings , capacity constraint reduction and overall equipment effectiveness ( OEE ) increase . However , in this case , reducing the cycle time also provides additional benefit and helps achieve sustainability goals as well . In this case , the manufacturing site was able to save nearly 1000 hours of cycle time in one mixing vessel . This reduction in time saved 14,910 kWh , or 6.46 Tons CO2 annually for this one operation alone .
Augmented Reality ( AR ) provides maintenance and training organizations with the opportunity to reduce equipment downtime , travel , improve operator effectiveness to troubleshoot and pinpoint equipment malfunction .
A situation where AR can play an integral part in decreasing energy consumption in addition to production downtime and overtime , vendor on site travel and support is around a typical packaging line ( filling , capping , labeling , heat sealing , primary / secondary packaging and inspection systems ).
Let ’ s consider a hypothetical plant and packaging line located in Chicago . The filling equipment is not functioning as needed , reducing the fill speed and overall line efficiency ( OEE ) by 25 %. The local engineering and maintenance team is not able to determine what the issue is and what part ( s ) are needed . The OEM manufacturer for the filling equipment is located in New Jersey .
In the past , the factory would contact the OEM vendor , arrange a site visit , while continuing to operate at the reduced line speed . This type of situation can historically take up to 2-3 days to resolve and in some instances longer . In this example , the line is running at a reduced efficiency ( 25 %), requiring additional shifts and equipment operating time . If we assume his line uses between 200-250kW and the line requires three additional shifts ( 8 hours ), the facility will consume an additional 4800-6000 kWh and will generate 0.97 Ton / kWh CO2 [ 10 ] ( 4100-5300 Tons CO2 ). Adding CO2 impact from travel and onsite OEM support , approximately 1-2 Tons CO2 .
In this example , the OEM service technician guides the end user factory mechanic / electrician by means of smart glasses enabling “ see what I see .” The remote OEM technician provides verbal instructions through the audio of the smart glasses by means of the images transmitted , incorporating AR into a factory digital transformation as described :
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