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== Cluster-KPIs ==
==Cluster-KPIs==
=== OEE(Overall Equipment Effectiveness)-Potential ===
===OEE(Overall Equipment Effectiveness)-Potential===
<math>Availability \times Performance \times Quality
<math>Availability \times Performance \times Quality</math>
Availability = \frac{actual production time}{possible production time} \times 100
<math>Availability = \frac{actual production time}{possible production time} \times 100</math>
Performance = \frac{actual output}{possible output} \times 100
<math>Performance = \frac{actual output}{possible output} \times 100</math>
Quality = \frac{flawless products}{actual output} \times 100</math>
<math>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>
→ <math> 77,82% \times 72,98% \times tbd = </math>
Target OEE:
'''Target OEE:'''
* Availability = 77,82 %
* Performance = 72,98 %
*Availability = 77,82 %
* Quality = tbd + x%
*Performance = 72,98 %
*Quality = tbd + x%
→ <math> 77,82% \times 72,98% \times tbd = </math>
→ <math> 77,82% \times 72,98% \times tbd = </math>
=== TCO-Potential ===
===TCO-Potential===
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'''
Saving potential energy costs:
Saving potential energy costs:
* Forming process: The forming process accounts for approx. 9.4 % of the energy costs in the processes considered (packaging to forming).
*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 estimated TCO:
* Current energy consumption of forming process: 15 Ah per 870 mAh cell
*Current energy consumption of forming process: 15 Ah per 870 mAh cell
Target TCO:
Target TCO:
*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>)
=== Material consumption per unit ===
==Project-KPIs==
===Material consumption per unit===
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:
Current electrolyte consumption:
* 4 ml per 870 mAh cell
*4 ml per 870 mAh cell
Target electrolyte consumption:
Target electrolyte consumption:
*3.5 ml per 870 mAh cell
=== Energy consumption per unit ===
===Energy consumption per unit===
The energy consumption per unit can be reduced by optimizing the forming process.
The energy consumption per unit can be reduced by optimizing the forming process.
Current energy consumption:
Current energy consumption:
* 15 Ah per 870 mAh cell
*15 Ah per 870 mAh cell
Target energy consumption:
Target energy consumption:
*12 Ah per 870 mAh cell
=== Variable production costs ===
===Variable production costs===
The variable production costs are composed of the energy, material, scrap and manufacturing costs.
The variable production costs are composed of the energy, material, scrap and manufacturing costs.
Current variable production costs:
Current variable production costs:
* 100%
*100%
Target variable production costs:
Target variable production costs:
*90%
== Literature ==
==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)
