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Life Cycle Oriented Milling Tool Management in Small Scale Production Available online at www.sciencedirect.com ScienceDirect Procedia CIRP 29 ( 2015 ) 293 – 298 The 22nd CIRP conference on Life Cycle Engineering Life cycle oriented milling tool management in small scale production a b a Dominik Heeschen * Fritz Klocke Kristian Arntz aFraunhofer-Institute for Production Technology (IPT), Steinbachstraße 17, 52074 Aachen, Germany bLaboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Steinbachstrasse 19, 52074 Aachen, Germany * Corresponding author. Tel.: +49-241-8904-324; fax: +49-241-8904-6324. E-mail address: [email protected] Abstract The milling technology is characterized as the most important manufacturing technology in a variety of industries. Moreover, recent developments in hardware and software issues have increased technology’s complexity which is, beyond others, caused by different milling variants and a high number of different milling tools. Milling tools are responsible for a significant cost position in manufacturing driven companies which is shown in the paper by an industry wide survey. Due to the costly and wasteful production it can be shown that this is a significant cost driver. This paper introduces an integrated life cycle oriented approach for the standardization and optimization (including the reuse of tools by standardized repair processes) of milling tools in order to enhance the life cycle of milling tools, reduce overall costs and therefore raise the company’s sustainability. © 20152015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (Peerhttp://creativecommons.org/licenses/by-nc-nd/4.0/-review under responsibility of the International). Scientific Committee of the Conference “22nd CIRP conference on Life Cycle PeerEngineering.-review under responsibility of the scientifi c committee of The 22nd CIRP conference on Life Cycle Engineering Keywords: Life Cycle Management; Life Cycle Optimization; Life Cycle Costing; LCC; Manufacturing; Milling Tools 1. Introduction equipment and projects [5]. A more detailed definition is proposed by Landers [6]: “Life cycle costs are summations of Manufacturing is a significant important industry for many cost estimates from inception to disposal for both equipment economies. About 16 % of global GDP in 2012 is contributed and projects as determined by an analytical study and estimate by the manufacturing industry [1]. In the context of of total costs experienced in annual time increments during manufacturing, especially European companies have to cope the project life with consideration for the time value of with global cost competition. Their financial and technical money”. Main purpose of LCC is determining cost- performance must remain at the desired and competitive level. effectiveness of alternative investments and business Many improvement projects are targeted to enhancement of decisions, from the perspective of an economic decision performance levels which can be seen in current literature [2]. maker such as a manufacturing firm or a consumer [7]. Life Cycle Engineering is a key to enhance financial and LCA is characterized as “a technique to assess technical performance by concurrent considering their environmental impacts associated with all the stages of a environmental impact. The question of how to minimize product’s life from cradle-to-grave” [8]. According to environmental loads and resource consumption throughout a Klöpffer the basic principles of LCA are the following [9]: product life cycle (LC) is a major issue in the manufacturing industry [3]. Analyzing the literature, two methodologies were x The analysis from cradle-to-grave developed during the past years to analyze life cycles as well x All mass and energy flows, resource and land-use, etc., and as to evaluate costs and environmental impacts generated the potential impacts connected with these ‘interventions’, along the whole life cycle: Life Cycle Costing (LCC) and Life are set in relation to a ‘functional unit’ as a quantitative Cycle Assessment (LCA) [4]. measure of the benefit of the system(s) LCC is characterized as “cradle-to-grave costs summarized as an economic model of evaluating alternatives for 2212-8271 © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the scientifi c committee of The 22nd CIRP conference on Life Cycle Engineering doi: 10.1016/j.procir.2015.02.048 294 Dominik Heeschen et al. / Procedia CIRP 29 ( 2015 ) 293 – 298 x LCA is essentially a comparative method (also Tool Work Tool storage M ac hining Tool storage Tool disposal improvements of one system are compared to the status procurement preparation quo). Tool Tool measuring checking Literature review shows that the main objective of LCC Regrinding and LCA lies in development or selection of LC optimized Core processes products within the B2B or B2C business. Up to now, there is no discussion for the case that the user is not able to influence Figure 2: Rough analysis of milling tool's life cycle the product design or the product design is not sufficient for adaption on life cycle oriented design. In spite of this lack of companies. exertion of influence, life cycle engineering can be used to optimize the cost and environmental effectiveness of 2. Investigation of life cycle analysis of milling tools industrial goods. This paper introduces an innovative approach for enhancement of cost effectiveness by using life As a first step for life cycle oriented management of cycle engineering tools for products which cannot be milling tools their detailed life cycle within a manufacturing influenced by the decision-making company. That means that company was analyzed. This analysis was conducted top- out of the three fundamental phases in life cycle management down, which means that the first step was a rough analysis of we focus on the life time management. involved departments, their interactions, in process loops and For this purpose the authors selected the application of necessary data flows. This rough analysis is based on a flow milling tools as prime example for an industrial good which chart development, which is shown in Figure 2. cannot be influenced by a company. Milling is next to turning The flow chart shows the life cycle of a single milling tool the most applied cutting technology in manufacturing which begins with the procurement and subsequent storage of companies. Furthermore, cutting tools are a relevant cost the tool. After measuring and determination of needed driver in modern manufacturing companies. A study was technological process parameters the tool is applied within the conducted in Germany with 292 participants. Beyond others it machine tool. If the predicted milling tool’s life time is was identified that cutting tools have a share of about 12% of reached during processing, the tool will be transferred to tool overall manufacturing costs (see Figure 1). checking. The tool checking will investigate if the milling tool The technology is characterized by multiple process is still operational, a regrinding is required (and possible), or a variants which also include different kinds of milling tools. It disposal is necessary. In the case that the tool is still is possible to characterize milling tools beyond others in terms operational the tool is moved back to the start of the process of their shape, application fields, material, diameter, etc. flow. If a regrinding is necessary, the tool is moved to the Furthermore, the life cycle oriented management focused on regrinding and subsequently moved to the start of the process manufacturing industries is characterized by small scale flow, too. production. That means that there are small lot sizes of This rough analysis has shown that the level of detail is not workpieces and these do not have any repetition frequency. sufficient for a holistic life cycle analysis, which is caused by This results in a further complexity enhancement since two facts. First life cycle data cannot be integrated within the process flows and milling tool consumption vary. Moreover, flow chart in order to perform a quantitative analysis. But a there is no consistent tool wear so that predictability of tool quantitative analysis is required in order to execute an lifetime and process flow is limited. optimization. Second milling tool’s process flow could not be The process flow of milling tools in manufacturing analyzed with the necessary level of detail, since the companies is highly complex and experience shows that there transparency of the chart does not provide a detailed analysis. are many inefficiencies within the process flow. Due to this For this reason, it was decided to apply a special process fact, this paper shows that the process flow of milling tools modelling language which was specifically developed for non- can be optimized by using life cycle engineering tools in order standardized processes and offers a maximum of transparency. to enhance the cost effectiveness of manufacturing 20 21,6 20,4 20,2 15 13,7 10 12,1 12,0 Costs [%] 5 0 Others Services External External Cutting Tools Raw Material Standard Parts Manufacturing Figure 1: Cost shares within manufacturing Figure 3: Process element of aixperanto modelling language Dominik Heeschen et al. / Procedia CIRP 29 ( 2015 ) 293 – 298 295 This modelling language is called aixperanto and was tool application so that tool procurement is highly project developed by researchers at the Laboratory for machine tools related. This lack of standardization causes many (WZL) at Aachen University in Germany. Developed for the inefficiencies within the life cycle which will be described at industry practice it has been used for scientific topics, too. selected process steps. Albers et al. used aixperanto for modelling a reference process After tool procurement the milling tools have to be stored for tool-based micro technologies [10]. in a central tool storage since the machine internal storages Main components of aixperanto are horizontal swimlanes, have limited space.
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