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ECO-innovative Energy FACTory Management System based on enhanced LCA and LCCA towards resource-efficient manufacturing

Periodic Reporting for period 1 - ECOFACT (ECO-innovative Energy FACTory Management System based on enhanced LCA and LCCA towards resource-efficient manufacturing)

Reporting period: 2020-10-01 to 2022-03-31

The main objective of ECOFACT is to develop and demonstrate up to TRL 7 an ECO-innovative Energy FACTory Management platform based on improved dynamic LCA and LCCA towards holistic manufacturing sustainability. Focus is on the effective combination of ICTs for advanced data collection and processing, which enables a streamlined decision-making process within the production chain, also enhancing interoperability and flexibility to maximize the replication, upscaling and standardization potential within different plant sizes and manufacturing sectors.
ECOFACT will gather cutting-edge knowledge and experience from production processes, professional simulation tools as well as energy and resource planning standards, to develop and demonstrate an integrated approach, methodology and platform for boosting efficiency of both energy and material resources at factory level while the impact on the whole value chain is considered.

5 Scientific and Technological Objectives (STO), together with 3 Non-Technological Objectives (NTO) have been identified.

STO1: Enabling the integration of massive energy data into production management systems thanks to improved connectivity between the Information Technology and Operations Technology domains

STO2: Helping manufacturing operations and maintenance (O&M) staff to forecast problems, do better planning and improve performance in the use of (energy and material) resources thanks to a prognosis-based Energy and Resource Management System (ERMS).

STO3: Contributing to better control the environmental signature of manufacturing processes and supply chains, enabling green production and product design as a cost-saver and marketing tool for manufacturing businesses.

STO4: Development of practical guidelines (ECOFACT methodology) and user-centric tool (ECOFACT software platform) for holistic (process, energy, environment) sustainable manufacturing management supported by the combination of enabling smart ICTs.

STO5 | Demonstration of ECOFACT methodology and platform at TRL7 in 4 case studies across different manufacturing sectors.

NTO1: Providing inputs to new standardization, certification and regulation schemes on integrated, sustainable manufacturing management.

NTO2: Development of exploitation strategies for the validated ECOFACT approach and platform creating attractive business cases and fostering early replication.

NTO3: Dissemination, communication and capacity building
The results obtained according to the project objectives are:

1. Analysis and characterization of the most relevant manufacturing processes/sectors in terms of potential energy optimization, to tailor ECOFACT developments and maximize exploitation benefits.
2. Definition of a holistic baseline for the ECOFACT demonstration cases.
3. Elaboration of the methodological guidelines for an intelligent data-driven manufacturing management.
4. Definition of a reference KPI framework for the evaluation of the project achievements and support of sustainability assessments during the operational phase.
5. Design of the architecture for decentralized monitoring networks.
6. Definition of the Digital Twin platform components specification and functional manual.
7. Establishment of the demos data sources for dynamic LCA/LCCA
8. Definition of the ECOFACT platform architecture and common IT framework
9. Definition of the ECOFACT unified data model.
10. Description of the ECOFACT pre-demos sites and validation plan.
11. Description of the ECOFACT demos and definition of the implementation plans for the project demonstration activities.
12. Study and report on the Report on the standardization landscape and applicable standards.
13. Study and report on framework analysis for sustainable manufacturing certification
14. Analysis and report on regulatory framework on energy efficiency and life-cycle sustainability in manufacturing environments
15. First definition and characterization of the ECOFACT Key Exploitable results.
16. Communication and Dissemination materials like the project website, social media, promotional video and several webinars and joint workshops.
1. Smart data collection in manufacturing environments: A connection of all levels of the automation pyramid to the IIoT infrastructure will be realized so that an overall monitoring and optimizing of energy and resource can take place. Besides, the ECOFACT IIoT infrastructure will not only consider high-level threads but also security issues on the field level side. By adding an administration level in the network, new sensors will need to identify themselves and broken sensors (“babbling idiot”) will be taken out of the network.
2.- Industrial digital twin: ECOFACT will implement evolving digital profiles (digital twins) of demo factories considering an integrated view (energy + materials) across the entire project lifecycle conveying the right data to the different stakeholders and enabling a new way to explore factory processes and data-flow. It will combine OT and IT fields in an intelligent way to provide efficient solutions guaranteeing a secure data exchange.
3.- Energy disaggregation analytics: ECOFACT will adapt the concept and methodologies designed for the domestic market to accommodate the industrial needs of energy disaggregation providing the capacity to operate as much as possible online. Cutting-edge Deep Machine Learning techniques will be used. ECOFACT will help not only optimize Industrial energy assets and achieve energy savings but also to detect potential equipment malfunction before further deterioration causes more significant issues.
4.- Supply chain collaboration (SCC) service: ECOFACT SCC service will establish a bidirectional flow of environmental and economic information between suppliers and producers, paving the way towards further optimization of the production processes along the value chain. ECOFACT aims to speed up collaboration ability through a technology-enabled collaboration, speeding up environmental impact information flow and reducing redundant and non-value-added tasks that can be replaced with real-time information to all parties in the chain.
5.- Dynamic LCA/LCCA open-source toolkit: Factors for dynamic LCA/LCCA are focused on economic aspects and most studies are only at concept stage. The information on these topics is still scarce and no real application exists. ECOFACT will tackle this problem from a practical approach, providing a fully functional tool to be implemented in real industrial processes.
6.- Holistic management platform for sustainable manufacturing: ECOFACT will enable the integration of massive energy data into production management systems thanks to improved connectivity. Besides, it will develop and demonstrate an eco-innovative energy management platform based on improved dynamic LCA and LCCA towards holistic manufacturing sustainability, thus providing an integral, flexible service that combines and enhance the benefits separately provided by currently existing tools and platforms.
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