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Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation-Based Design

Author

Listed:
  • Alessandra Caggiano

    (Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT Naples), Department of Industrial Engineering, University of Naples Federico II, Naples 80125, Italy)

  • Adelaide Marzano

    (School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast BT7 1NN, UK)

  • Roberto Teti

    (Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT Naples), Department of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, Naples 80125, Italy)

Abstract

Modern manufacturing systems should satisfy emerging needs related to sustainable development. The design of sustainable manufacturing systems can be valuably supported by simulation, traditionally employed mainly for time and cost reduction. In this paper, a multi-purpose digital simulation approach is proposed to deal with sustainable manufacturing systems design through Discrete Event Simulation (DES) and 3D digital human modelling. DES models integrated with data on power consumption of the manufacturing equipment are utilized to simulate different scenarios with the aim to improve productivity as well as energy efficiency, avoiding resource and energy waste. 3D simulation based on digital human modelling is employed to assess human factors issues related to ergonomics and safety of manufacturing systems. The approach is implemented for the sustainability enhancement of a real manufacturing cell of the aerospace industry, automated by robotic deburring. Alternative scenarios are proposed and simulated, obtaining a significant improvement in terms of energy efficiency (−87%) for the new deburring cell, and a reduction of energy consumption around −69% for the coordinate measuring machine, with high potential annual energy cost savings and increased energy efficiency. Moreover, the simulation-based ergonomic assessment of human operator postures allows 25% improvement of the workcell ergonomic index.

Suggested Citation

  • Alessandra Caggiano & Adelaide Marzano & Roberto Teti, 2016. "Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation-Based Design," Energies, MDPI, vol. 9(10), pages 1-16, September.
    • Handle: RePEc:gam:jeners:v:9:y:2016:i:10:p:790-:d:79356
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    References listed on IDEAS

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    1. Björn Johansson & Anders Skoogh & Jon Andersson & Karin Ahlberg & Lars Hanson, 2015. "Power-level sampling of metal cutting machines for data representation in discrete event simulation," International Journal of Production Research, Taylor & Francis Journals, vol. 53(23), pages 7060-7070, December.
    2. Xian-Chun Tan & Yan-Yan Wang & Bai-He Gu & Ze-Kun Mu & Can Yang, 2011. "Improved Methods for Production Manufacturing Processes in Environmentally Benign Manufacturing," Energies, MDPI, vol. 4(9), pages 1-19, September.
    3. United Nations, 2016. "The Sustainable Development Goals 2016," Working Papers id:11456, eSocialSciences.
    4. Curran, R. & Gomis, G. & Castagne, S. & Butterfield, J. & Edgar, T. & Higgins, C. & McKeever, C., 2007. "Integrated digital design for manufacture for reduced life cycle cost," International Journal of Production Economics, Elsevier, vol. 109(1-2), pages 27-40, September.
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    Cited by:

    1. Yi-Xuan Wang & Chien-Hung Kuo & Rui Song & Allen H. Hu & Shu-Shen Zhang, 2017. "Potentials for Improvement of Resource Efficiency in Printed Circuit Board Manufacturing: A Case Study Based on Material Flow Cost Accounting," Sustainability, MDPI, vol. 9(6), pages 1-16, May.
    2. Sanober Hassan Khattak & Michael Oates & Rick Greenough, 2018. "Towards Improved Energy and Resource Management in Manufacturing," Energies, MDPI, vol. 11(4), pages 1-15, April.
    3. Amjad, Asim & Ikramullah Butt, Shahid & Agha, Mujtaba Hassan & Ahmad, Ayyaz & Zhang, Faping & Ahmad, Shamraiz, 2023. "Integrating Ergonomics and sustainability: A framework with LDA methodology and implementation roadmap," Technology in Society, Elsevier, vol. 75(C).

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