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MEMAN Report Summary

Project ID: 636926
Funded under: H2020-EU.

Periodic Reporting for period 1 - MEMAN (Integral Material and Energy flow MANagement in MANufacturing metal mechanic sector)

Reporting period: 2015-01-01 to 2016-02-29

Summary of the context and overall objectives of the project

The MEMAN project aims at supporting European companies in the metal mechanical sector in their efforts to maximise their resource saving potential and increase competitiveness. The project is based on an innovative approach that will address resource efficiency optimisation of whole manufacturing value chains instead of isolated single company or process optimisation, and includes energy, raw materials, supplies and waste.
MEMAN brings together fourteen partners from six countries, including enterprises, SMEs, and experts in eco-innovative models, who will be working on optimising resource efficiency across the complete metal mechanical value chain, from casting through machining to surface finishing. This will be done through the full validation of new business models that allow for collaboration of different companies along the whole value chain, and provide tools for practical decision-making support.
The development of approaches for organisational and technological optimisation at value chain level will be led by three competence clusters in three industrial sectors: Casting (led by Mondragon Corporation - Entrepreneurial Innovation Cluster, Basque Country, Spain) in the automotive sector, Machining (by Mecanic Vallée- Entrepreneurial Association, Limousin and Midi-Pyrénées Regions, France) in the aerospace sector and Surface Finishing (by EIFFO - Industrial Innovation Cluster, Germany – Austria) in mechanical engineering. The real life demonstration of the resource saving potential will be validated on four concrete examples: a control arm component in the automotive sector, aero-structural and engine components in the aerospace sector and hydraulic piston rods regarding mechanical engineering applications.

Led by MONDRAGON Corporation - Entrepreneurial Innovation Cluster, Basque Country, Spain
Partners involved: MONDRAGON Corporation (and third parties IK4-Ikerlan, Aurrenak and MSI), Loramendi, Fagor Ederlan (and third party Edertek), Insertec and Acciona
The casting sector comprises a large number of sectors, including mobility (aviation, railway, shipping, automotive), energy, agribusiness, and chemicals. The companies in all sectors directly employ around 34,960 people. Within the framework of MEMAN project, the cluster will test innovate technological processes of suspension control arm production, making us of light alloys and new design methods. The possibility of manufacturing the part in aluminium will be explored, together with the assessment of the alternative technologies such as new casting, cooling, and heat treatment processes.

Led by CETIM – Technical Centre with Mecanic Vallée – Business Cluster, Limousin and Midi-Pyrénées Regions, France (and third parties FIGEAC AERO and AD INDUSTRIE)
Partners involved: MONDRAGON Corporation, Eiffo, Technofi
Mecanic Vallée is a business and innovation cluster, specialised in aeronautics, spare parts for automotive industry, and machines tools. It gathers 173 members, representing 87% of the employees and constituting 85% of the turnover (€1.85M) in the area. Within MEMAN,the cluster will analyse the Product Life Cycle of aero-structural and engine components of the CFM 56 jet engine, equipping Airbus A 320 and Boeing aircrafts. Activities carried out by project partners will include the assessment of alternative technologies in different process stages, including milling, drilling, boring, and laser cutting, amongst others. The aim is to significantly reduce the time, cost, and energy involved in the production of the component.

Led by Eiffo - Industrial Innovation Cluster, Germany - Austria
Partners involved: Stahl Judenburg, THOMA (and third party DiTEC and SOFTEC)
The cluster, focused on surface technology and finishing, includes over 200 companies and factories. It employs 12,000 people and has an accumulated turnover of about €1.4 bn. The sector is strongly affected by higher resource costs, as energy accounts for 12%, and materials and chemical supplies for 25-35% of total operating costs. The MEMAN project is therefore expected to enable a better re-design and re-engineering of stainless steel hydraulic piston rod under a life-cycle perspective and their manufacturing processes. These optimisations will contribute to substantially increased resource efficiency in the manufacturing of chromium plated products with reduced chromium use and losses, as well as increased chromium recycling and safer handling procedures.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

covered by the report and main results achieved so far.
In Work Package 1 “Clustering and detailed definition of the case products”, led by MONDRAGON Corporation, the main actors and stakeholders from each technical cluster have proceeded to make a detailed analysis of the selected industrial scenarios, identifying which are the key aspects and parameters affecting the energy and raw material flows, as well as the environmental impact. These analyses have been made according to the actual picture of processes and equipment, but having in mind future optimisation possibilities.

The activity on Work Package 2 “Technological analysis of the value chain processes and interfaces, definition of functional process units”, led by CENTRE TECHNIQUE DES INDUSTRIES MECANIQUES (CETIM), has focussed on the data collection of the technical information on the value chains considered in MEMAN. It means to get quantitative data on processes involved in the value chains either on the existing situation or on alternative options identified as possibly relevant for the optimisation of the resource efficiency.

This work is based on the technical specifications of the value chains as defined in WP1, and it will lead to relevant information for the WP3 dealing with design of the simulation tool, the WP4 focused on modelling of value chains and WP5 focused on overall assessment of the value chains.

The Work Package 3 “Tool development for value chain analysis”, led by TECHNISCHE UNIVERSITAT BRAUNSCHWEIG (TUBS), has focussed on the modelling of a single factory where the requirements for the material and energy flow analysis and simulation have been identified choosing two software for that, UMBERTO NXT and ANYLOGIC. Also, in this work package the activity has focused on identifying and analysing the critical parameters that have influence between the actors of the value chain as well as on the performance of the value chain. A value chain simulation decision tool has been developed, dealing with environmental and economic impacts throughout an entire value chain.

In the last two months of the 1st periodic reports some work packages has been started, such as WP4, WP5, WP6, WP7, WP8 and WP9.

The goal of WP 4 “Value chain simulations & modelling with integrated MFA/LCA” is to carry out a comprehensive modelling approach of the value chains use cases, including eco assessment with MEFA tool (Umberto), LCA/LCC methods and dynamic analysis with simulation tool (AnyLogic). This approach includes the modelling of the actual states of the value chains and the simulation of the optimized value chains (i.e. taking into account alternative improvement options). This WP is led by TECHNOFI, so in order to achieve the goal, it requires comprehensive information (i.e. technical and production data) gathered in WP 2 and operational tool developed in WP 3. The outputs of WP 4 are needed to order to allow for assessing the value chains re-engineering in WP 5 as well as the implementation tasks in WP 8.

EIFFO, as leader of WP 5 “Interdisciplinary assessment of value chain optimisation and re-engineering scenarios and development of detailed business cases” has started to draft the overall concept of developing the parameter sets, assessment criteria, and key performance indicators ('KPIs') to be used for the scenario assessment.

The Work Package 6 “Development of information/control routines and adapted MES”, led by MONDRAGON, is focused on the design, development and implementation the software architecture that allows the data acquisition of the process parameters (energy, material consumption,....) at company level so it can be transferred in a secure way to a cloud based value chain data container with the goal to provide the data of the complete value chain to the Umberto users for LCA analysis. At the same time, feedback from the Umberto environment must be integrated in the company´s applications like MES and ERP which have to be adapted for this purpose.

The Work Package 7 “Development of new business models for value chains and competence clusters” is focused in the design of the new business models affordable by the different value chains and clusters of MEMAN project. The objectives for the first period have consisted on setting the base concepts for the Networked Business Model framework

CETIM is the leader of Work Package 8 “Implementation and validations”. Some industrial partners of the CASTING cluster started to work in their modified value chain in order to have enough time for the validation of the parameters.

The Work Package 9 “Energy characterisation of individual companies and across the value chain”, led by EIFFO, has focussed in the revision of the implementation plan of WP9.

Greenovate! Europe (G!E) is the leader of Work Package 10 “Exploitation of knowledge created in MEMAN, communication and dissemination”. Its activity during this period has focused on elaborating a communication and dissemination plan that describes the overall communication strategy of the consortium. Also, communication material has been developed and designed such as project logo, MS-Word and MS-Power Point templates, the project website and leaflet, poster and a roll-up banner. In addition, a website of the project has been developed, different communication activities have been undertaken by G!E and networking activities through events, conferences and presentations have been carried out. On the other hand INVERSTORNET, as third party of G!E has started with the exploitation activities like identify the exploitable results of MEMAN project , their IPR management and risk management plan.

During this 1st periodic report, MONDRAGON has has been performed project management activities according to the planning initially established. The main coordination responsibilities rely on the Project Coordinator (Mr Joseba Bilbatua). Also, the project coordinator has been assisted by the Technical Coordinator, TUBS (Dr Sebastian Thiede). The general coordination of MEMAN project has required a very important effort to MONDRAGON due to the big size of the consortium and the quantity of activities and issues going on at the same time.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

It is expected that the MEMAN project will modify the consumption patterns of the whole metalworking value chain, achieving a reduction of energy consumption and CO2 emissions of at least 30%, and over 10% of the product Life Cycle Cost from cradle to grave of existing and future products. Given the significantly increasing need to limit greenhouse gas emissions, as well as escalating costs of energy resources and raw materials, the project is of strategic importance for the European economy.

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