| Line 1: |
Line 1: |
| − | == Cluster-KPIs == | + | {{AccessControl/Public}} |
| | + | ==Cluster-KPIs== |
| | + | <br /> |
| | + | ====<u>OEE-Potential</u>==== |
| | + | The KIproBatt project aims at increasing the Overall Equipment Effectiveness (OEE) by improving the quality factors: |
| | | | |
| − | === OEE(Overall Equipment Effectiveness)-Potential ===
| + | *Reduction of scrap parts |
| − | <math>Availability \times Performance \times Quality
| + | *Reduction of reworking parts |
| − | Availability = \frac{actual production time}{possible production time} \times 100
| + | *Integration of real-time sensor data |
| − | Performance = \frac{actual output}{possible output} \times 100
| |
| − | Quality = \frac{flawless products}{actual output} \times 100</math>
| |
| | | | |
| − | Current estimated OEE:
| |
| − | * Availability = 77,82 %
| |
| − | * Performance = 72,98 %
| |
| − | * Quality = tbd
| |
| − | → <math> 77,82% \times 72,98% \times tbd = </math>
| |
| | | | |
| − | Target OEE:
| + | <math>OEE = Availability \times Performance \times Quality</math> |
| − | * Availability = 77,82 %
| |
| − | * Performance = 72,98 %
| |
| − | * Quality = tbd + x%
| |
| − | → <math> 77,82% \times 72,98% \times tbd = </math>
| |
| | | | |
| − | === TCO-Potential === | + | <math>Availability = \frac{\text{actual production time}}{\text{possible production time}} \times 100</math> |
| | | | |
| − | <math> TCO = Acquisition costs + Personnel costs + '''Energy costs''' + Maintenance costs + Downtime costs + Running costs (e.g., training courses) + Opportunity costs + Costs for operating materials + Disposal costs + Energy efficiency + '''CO_2 balance''' </math> | + | <math>Performance = \frac{\text{actual output}}{\text{possible output}} \times 100</math> |
| | | | |
| − | Saving potential energy costs:
| + | <math>Quality = \frac{\text{flawless products}}{\text{actual output}} \times 100</math> |
| − | * Forming process: The forming process accounts for approx. 9.4 % of the energy costs in the processes considered (packaging to forming).
| |
| | | | |
| − | Current estimated TCO:
| |
| − | * Current energy consumption of forming process: 15 Ah per 870 mAh cell
| |
| | | | |
| − | Target TCO:
| + | '''Base value''' |
| − | * Reduction of energy consumption in the forming process by 20 % results in a reduction of total energy costs by approx. 2 % (<math>20 % \times 9.4 %</math>)
| |
| | | | |
| | + | The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries). |
| | | | |
| − | == Project-KPIs == | + | <math>Quality = \frac{\text{no. produced parts - (no. rework + no. scrap)}}{\text{no. produced parts}}</math> |
| | | | |
| − | === Material consumption per unit === | + | |
| | + | '''Current state''' |
| | + | |
| | + | No improvement achieved yet, as laboratory battery production has not yet started. |
| | + | |
| | + | |
| | + | '''Target value''' |
| | + | |
| | + | The quality parameter should be increased by approx. 5%. |
| | + | |
| | + | |
| | + | |
| | + | ====<u>TCO-Potential</u>==== |
| | + | |
| | + | The KIproBatt project aims at decreasing the Total Cost of Operations (TCO) by improving the subsequent factors: |
| | + | |
| | + | *Reduction of energy consumption |
| | + | *Cost of operating materials (e.g., reduction in the use of operating materials, avoidance of waste) |
| | + | *Integration of real-time sensor data |
| | + | |
| | + | |
| | + | '''Base value''' |
| | + | |
| | + | The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries). |
| | + | |
| | + | |
| | + | '''Current state''' |
| | + | |
| | + | By using the reference process in the forming process, the energy consumption and the associated energy costs are already reduced compared to the original process. Energy consumption is thus reduced by approx. 2% (20% reduction in energy consumption in the forming process, 9.4% share of forming in total energy consumption). |
| | + | |
| | + | |
| | + | '''Target value''' |
| | + | |
| | + | The TCO should be decreased with respect to two factors: |
| | + | |
| | + | *Reduction of energy consumption by approx. 5%. |
| | + | *Reduction of costs of operating materials by approx. 5% (see 3^rd Project-KPI) |
| | + | |
| | + | |
| | + | ==Project-KPIs== |
| | + | |
| | + | ====<u>Material consumption per unit</u>==== |
| | Models can be used to estimate the amount of electrolyte required and to reduce it. In contrast to the active material, a greater potential for reduction is seen here, since the active material has a direct influence on the energy content of the cell. | | Models can be used to estimate the amount of electrolyte required and to reduce it. In contrast to the active material, a greater potential for reduction is seen here, since the active material has a direct influence on the energy content of the cell. |
| | + | → Contributes to the reduction of production costs (not listed in OEE/TCO). |
| | + | |
| | | | |
| − | Current electrolyte consumption:
| + | '''Base value''' |
| − | * 4 ml per 870 mAh cell
| |
| | | | |
| − | Target electrolyte consumption:
| + | Electrolyte consumption of 4 ml per 870 mAh cell |
| − | * 3.5 ml per 870 mAh cell
| |
| | | | |
| − | Contributes to the reduction of production costs (not listed in OEE/TCO)
| |
| | | | |
| − | === Energy consumption per unit ===
| + | '''Current state''' |
| − | The energy consumption per unit can be reduced by optimizing the forming process.
| |
| | | | |
| − | Current energy consumption:
| + | No improvement achieved yet, as laboratory battery production has not yet started. |
| − | * 15 Ah per 870 mAh cell
| |
| | | | |
| − | Target energy consumption:
| |
| − | * 12 Ah per 870 mAh cell
| |
| | | | |
| | + | '''Target value''' |
| | | | |
| − | === Variable production costs ===
| + | The material consumption per unit should be reduced to by approx. 12.5%. The target value for electrolyte consumption is 3.5 ml per 870 mAh cell. |
| − | The variable production costs are composed of the energy, material, scrap and manufacturing costs. | |
| | | | |
| − | Current variable production costs:
| |
| − | * 100%
| |
| | | | |
| − | Target variable production costs:
| + | ====<u>Share of digital interfaces</u>==== |
| − | * 90%
| + | The KIproBatt project aims at increasing the share of digital interfaces that are integrated in the production process. This share is measured by combining two factors: |
| | | | |
| | + | *Share of data points that are recorded for a single cell. |
| | + | *Share of data points that is assigned to a single cell without human intervention (automatically). |
| | + | <math>\text{KPI2}=\frac{\text{no. recorded data points}}{\text{no. considered parameters}}\times\frac{\text{no. assigend data points}}{\text{no. considered parameters}}</math> |
| | | | |
| | | | |
| − | == Literature == | + | '''Base value''' |
| | + | |
| | + | The base value stems from the data point assessment prior to installation of additional sensors and the total number of data points included in the project's process impact matrix. |
| | + | *Recorded data points: 52% |
| | + | *Automatically assigned data points: 23% |
| | + | |
| | + | |
| | + | '''Current state''' |
| | + | |
| | + | |
| | + | {{#ask: [[-has parameter.-HasPart::Fraunhofer_ISC/Processes/KIproBatt_v1/Process]] |
| | + | |?HasType |
| | + | |mainlabel=- |
| | + | |format=jqplotchart |
| | + | |charttype=bar |
| | + | |min=0 |
| | + | <!-- |chartlegend=e--> |
| | + | |distribution=yes |
| | + | |distributionsort=desc |
| | + | |datalabels=value |
| | + | |valueformat=%d |
| | + | }} |
| | + | |
| | + | |
| | + | {{#ask: [[Fraunhofer_ISC/Processes/KIproBatt_v1]] |
| | + | |?HasParameterCount=Total Parameters |
| | + | |?HasUnrecordedParameterCount=Unrecorded Parameters |
| | + | |?HasRecordedParameterCount=Recorded Parameters |
| | + | |?HasManuallyRecordedParameterCount=Manually Recorded Parameters |
| | + | |?HasAutomaticallyRecordedParameterCount=Automatically Recorded Parameters |
| | + | |?HasShareOfRecordedDatasets#-p0=Recorded/Total |
| | + | |?HasShareOfAutomaticallyRecordedDatasets#-p0=Automatically Recorded/Total |
| | + | |format=table |
| | + | |transpose=true |
| | + | }} |
| | + | |
| | + | KPI2 = {{#expr: |
| | + | 0.01*{{#show: Fraunhofer_ISC/Processes/KIproBatt_v1 |?HasShareOfRecordedDatasets # -n }} |
| | + | * 0.01*{{#show: Fraunhofer_ISC/Processes/KIproBatt_v1 |?HasShareOfAutomaticallyRecordedDatasets # -n }} |
| | + | round 2 }} |
| | + | |
| | + | '''Target value''' |
| | + | |
| | + | *Recorded data points: 92% |
| | + | *Automatically assigned data points: 90% |
| | + | |
| | + | |
| | + | |
| | + | ===Variable production costs=== |
| | + | Production costs are made up of several variable costs. In the context of the project, the energy, material, scrap and manufacturing costs are considered. |
| | + | <math>\text{KPI3}=\frac{\text{total var. production costs}}{\text{costs for flawless batteries}}</math> |
| | + | |
| | + | |
| | + | '''Base value''' |
| | + | |
| | + | The base value stems from the assumption of having 10% scrap products (KPI 3 ≈ 1.11). The base value for the laboratory battery production process is to be determined on the basis of the first battery batch produced (approx. 50 batteries). |
| | + | |
| | + | |
| | + | '''Current state''' |
| | + | |
| | + | No improvement achieved yet, as laboratory battery production has not yet started. |
| | + | |
| | + | |
| | + | '''Target value''' |
| | + | |
| | + | The variable production costs should be reduced by approx. 5% (KPI 3 ≈ 1.05). |
| | + | |
| | + | |
| | + | |
| | + | |
| | + | ==Literature== |
| | Rao et al.: Enhancing Overall Equipment Effectiveness in Battery Industries through Total Productive Maintenance, International Journal of Engineering Research in Mechanical and Civil Engineering (2017) | | Rao et al.: Enhancing Overall Equipment Effectiveness in Battery Industries through Total Productive Maintenance, International Journal of Engineering Research in Mechanical and Civil Engineering (2017) |
| | + | |
| | Pettinger, K.-H.; Dong, W.: When Does the Operation of a Battery Become Environmentally Positive? Journal of The Electrochemical Society 164 (2017) | | Pettinger, K.-H.; Dong, W.: When Does the Operation of a Battery Become Environmentally Positive? Journal of The Electrochemical Society 164 (2017) |