| 1. |
- Abdoli, Shiva, et al.
(författare)
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Analyzing the Environmental Consequences of Production Processes from a System of Systems Perspective : A Case of Gear Manufacturing in the Automotive Industry
- 2021
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Ingår i: The 28th CIRP Conference on Life Cycle Engineering, March 10 – 12, 2021, Jaipur, India. - : Elsevier BV. - 2212-8271. ; 98, s. 376-381
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Konferensbidrag (refereegranskat)abstract
- Many research studies have been done to investigate different aspects of environmental challenges. In the product development context, there have been attempts to reduce the environmental impacts of associated activities including the production processes themselves. As a result, various technological improvements have been made and new production processes e.g. powder metallurgy technologies have been introduced that may demonstrate a lower environmental footprint compared to conventional processes e.g. cutting machining technologies. However, a production process with a lower environmental impact may lead to reducing the quality/performance attributes of the produced parts (gear) and probably of final products (transmission box). Therefore, the efforts intended to produce more sustainable products by using production processes with less environmental footprints may lead to some unintended consequences such as increased maintenance requirements and/or demand. This is a rebound effect from a system of systems (SoS) perspective. This paper aims to analyze the impacts of more environmentally friendly production processes on the total environmental impact associated with a product given they may have a negative impact on a part/product's quality and performance or usage. This paper introduces a methodological approach to analyze the environmental sustainability of a production process at a SoS level. This is done by including the entire supply chain of a product-system and its interacting systems by using the results of the attributional/consequential life cycle assessment (LCA) method. The approach validity approach is demonstrated in the case of gear manufacturing in the automotive industry.
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| 2. |
- Diegel, Olaf, et al.
(författare)
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Additive manufacturing and its effect on sustainable design
- 2016
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Ingår i: Handbook of Sustainability in Additive Manufacturing. - Singapore : Springer Singapore. - 2345-7651 .- 2345-766X. - 9789811005497 - 9789811005473 ; 1, s. 73-99
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Bokkapitel (övrigt vetenskapligt/konstnärligt)abstract
- 'Sustainability' is an emerging issue that product development engineers must engage with to remain relevant, competitive and, most importantly, responsible. Yet, on examining the term 'sustainable', a plethora of definitions emerges, many of which are contradictory and confusing. This confusion and a general lack of understanding means that sustainability often gets relegated to an afterthought or a buzz-word used on marketing material, no matter how 'sustainable' the product actually is. The role of the 'sustainable' product developer is to look for new opportunities to design products that minimize harmful effects on the environment and to seek to develop environmental, social, and economically beneficial product solutions. The advent of additive manufacturing technologies presents a number of opportunities that have the potential to benefit designers greatly and contribute to the sustainability of products. Products can be extensively customized for the user, thus potentially increasing their desirability, pleasure and attachment-and therefore longevity. Additive manufacturing technologies have also removed many of the manufacturing restrictions that may previously have compromised a designer's ability to make the product they imagined which, once again, can increase product desirability, pleasure and attachment. As additive manufacturing technologies evolve, design methodologies for lightweighting, such as topology optimization, become more advanced, more new materials become available, and multiple material technologies are developed, the field of product design has the potential for great change. This chapter examines aspects of additive manufacturing from a sustainable design perspective and looks at the potential to create entirely new business models that could bring about the sustainable design of consumer products. It first gives a brief literature review both on sustainable product development and on additive manufacturing, and then examines several case study products that were made with additive manufacturing. It concludes that there is a likelihood that additive manufacturing allows more sustainable products to be developed, but also that more quantifiable research is needed in the area to allow designers to exploit better the features of additive manufacturing that can maximize sustainability.
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| 3. |
- Kianian, Babak
(författare)
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A comparative cost analysis of conventional wrought steel and powder metallurgy (PM) gear manufacturing technologies
- 2019
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- The transportation industry landscape is going through a massive transformation due to trends such as autonomous and electrified vehicles. The electrification trend has already started to display its ample influence on the automotive industry. New modern power and drivetrains need to be designed and manufactured based on the raising automakers’ requirements e.g. higher performance, better noise vibration harshness (NVH) behaviour. Meanwhile, cost must be minimized in order to obtain or secure market competitiveness.In the highly cost-competitive atmosphere of the manufacturing sector,particularly within the automotive industry, which is the focus of this licentiate,manufacturing firms uninterruptedly seek to develop, adopt and utilise cost models and methods in order to evaluate e.g. their existing production systems or planning new investment for adoption and deployment of new technologies.The industrial case studies, investigated in this licentiate, have gearmanufacturing as the focus. The gear and transmission component manufacturingindustry is an important sector as it provides one of the basic mechanical parts toindustrial segments where motion and power transfer are needed. Two gearmanufacturing techniques namely conventional wrought steel and powdermetallurgy (PM) are compared from a cost perspective. Given the requiredperformance and quality for automotive transmission application, the gearmanufacturing processing routes and their production steps and cost drivers areanalysed and compared through the utilisation of the selected cost model, calledperformance part costing (PPC).The industrial applicability of PPC model is compared with the commonly usedstandard costing, its use and its modified variations among practitioners through the case studies. The pros and cons of each approach are discussed. Given the assumptions made and reported in this licentiate for two different scenarios, the gear manufacturing cost of the analysed PM processing route were 12% to 38% cheaper compared to the conventional wrought steel processing route. However, the acquisition cost for the analysed PM processing route were almost three times higher than that of the conventional wrought steel gear.
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| 4. |
- Kianian, Babak, et al.
(författare)
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Additive Manufacturing Technology Potential: A Cleaner Manufacturing Alternative
- 2016
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Ingår i: INTERNATIONAL DESIGN ENGINEERING TECHNICAL CONFERENCES AND COMPUTERS AND INFORMATION IN ENGINEERING CONFERENCE, 2015, VOL 4. - : AMER SOC MECHANICAL ENGINEERS. - 9780791857113
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Konferensbidrag (refereegranskat)abstract
- This paper focuses on an emerging manufacturing technology called Additive Manufacturing (AM) and its potential to become a more efficient and cleaner manufacturing alternative. This work is built around selected case companies, where the benefit of AM compared to other more traditional technologies is studied through the comparison of resource consumption. The resource consumption is defined as raw materials and energy input. The scope of this work is the application of AM in the scale model kit industry. The method used is the life cycle inventory study, which is a subtype of life cycle assessment (LCA). The result of the paper is the quantification of raw materials and energy consumption. The outcomes shows that AM has higher efficiency in terms of materials usage, as a higher proportion of materials ending up in the final product. Injection Molding (IM), on the other hand, wastes a significant proportion of raw materials in components that are not part of the final product. If the same or similar raw materials are used in both manufacturing methods, the advantage is clearly with AM. However, AM has higher energy consumption in comparison to the injection molding technique (IM). In terms of energy consumption, AM only has an advantage in this area when working with a very low production volume. The analysis of the energy consumption shows that most of the energy used in AM is to create the final product, while IM only uses a fraction of the total energy to produce the final product. AM technologies are still very new but have the potential for development and reduction of energy consumption in the future. Added to this potential is the higher materials usage efficiency of AM, which reduce the waste of materials and the energy, embedded in them. These two factors are likely to position AM as cleaner manufacturing alternative.
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| 5. |
- Kianian, Babak, et al.
(författare)
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Analysis of manufacturing costs for conventional gear manufacturing processes: a case study of a spur engine gear
- 2018
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Ingår i: International Gear Conference 2018. ; 1, s. 393-402
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Bokkapitel (övrigt vetenskapligt/konstnärligt)abstract
- This paper presents an in-depth manufacturing cost analysis of conventional wrought steel gear manufacturing and a case study of a spur engine gear is evaluated by real usage data, including a benchmark in gear manufacturing cost calculations between the participating company cost calculation method and the model used and developed in this research. The applicability of the developed manufacturing cost model to serve as a backbone of decision-making support system for adoption of new technologies is tested. The results show that both cost models give a relatively similar result but the proposed cost model provides more granularity and strategic prioritisation of possible future optimization strategies through scenario testing.
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| 6. |
- Kianian, Babak, et al.
(författare)
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Analysis of manufacturing costs for powder metallurgy (pm) gear manufacturing processes : a case study of a helical drive gear
- 2020
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Ingår i: EcoDesign and Sustainability I : Products, Services, and Business Models - Products, Services, and Business Models. - Singapore : Springer Singapore. - 2194-055X .- 2194-0541. - 9789811567780 - 9789811567797 ; , s. 471-487
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Bokkapitel (refereegranskat)abstract
- This paper presents a thorough manufacturing cost analysis for a powder metallurgy (PM) manufactured gear (using press and sintering technique—P/S), through a case study of a R&D 4th drive gear (a helical gearwheel) utilizing both real usage data from six companies and some estimated data from literatures. The chosen costs calculation method, performance part costing (PPC), is comprehensive and designed to follow the manufacturing process routes. The result is an excel based cost calculation tool for analysis of performance driven manufacturing costs for use by practitioners with the capability of serving as a decision support system (DSS) in production development issues. The impacts of three scenarios of (1) gear rolling process automation, (2) overall equipment effectiveness (OEE) parameters improvement and (3) increase in energy price on the total PM gear manufacturing costs are simulated, results are presented and discussed, sensitivity analyses are performed, and outcomes are further discussed.
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| 7. |
- Kianian, Babak
(författare)
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Comparing acquisition and operation life cycle costs of powder metallurgy and conventional wrought steel gear manufacturing techniques
- 2019
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Ingår i: 52nd CIRP Conference on Manufacturing Systems (CMS), Ljubljana, Slovenia, June 12-14, 2019. - : Elsevier BV. - 2212-8271. ; 81, s. 1101-1106
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Konferensbidrag (refereegranskat)abstract
- The automotive industry has striven for fuel economy and resource efficiency through the deployment of powder metallurgy (PM) manufacturing processes for few decades. However, PM technology for transmission gears is currently only used at a small scale within the automotive industry. This is mainly due to: its shortcomings in material properties and performance gaps for final parts; lack of advancement in pressing technologies (dimensional limitation); lack of data availability (e.g. on materials, load capacity calculations; gear design experimental confirmation); premature failed attempts on PM gears; economics of scale and large initial capital investments. This article reviews the current state of the art of PM gear manufacturing technology highlighting an important gap in technical and financial data availability for PM gear economic analysis. Thus, this study seeks to give some empirical evidence of the economic aspects of PM gear manufacturing. Data availability is still the major challenge with respect to PM cost calculations thus further studies are needed to quantify both the economic and non-economic benefits e.g., sustainability, noise vibration harshness (NVH) of PM adoption.
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| 8. |
- Kianian, Babak, et al.
(författare)
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Comparing life cycle costing and performance part costing in assessing acquisition and operational cost of new manufacturing technologies
- 2019
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Ingår i: Procedia CIRP. - : Elsevier BV. - 2212-8271. ; 80, s. 428-433
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Konferensbidrag (refereegranskat)abstract
- Even if practitioners want to adopt new manufacturing technologies, there is a lack of comprehensive tools to support their decisions, regarding both cost and sustainability. This paper reviews and compares the practical use of Life Cycle Costing (LCC) with a performance part costing (PPC) model, chosen based upon the criteria of providing in-depth analysis capabilities and the prospect of integrating cost and sustainability assessment. A case study of a Swedish gear manufacturer is selected, where the company investigates adoption of a new manufacturing technology. Since, this type of decision requires heavy investments e.g. in new machines, tools, linking performance with costs would be a prerequisite for performing well-informed decisions. Based on interviews, the level of detail requirements e.g., performance indicators, when acquiring new technologies are identified. LCC model cost parameters are compared with the PPC cost drivers and the data availability and estimation are discussed.
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| 9. |
- Kianian, Babak, et al.
(författare)
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Manufacturing Renaissance : Return of manufacturing to western countries
- 2013
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Konferensbidrag (refereegranskat)abstract
- Manufacturing Renaissance, i.e. return of manufacturing to west, has been recently observed. This paper analyzes the patterns observed within each of the four main drivers behind this new phenomenon and delves more deeply into the driver that centers on the new manufacturing technologies such as Additive Manufacturing (AM) and 3D Printing. Next, this paper will make the case that the location of manufacturing will be in west, relying on the established theory that has been able to explain the location of manufacturing, i.e. Product Life Cycle Model (PLC).
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| 10. |
- Kianian, Babak, et al.
(författare)
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Sustainability-Conscious Powder Metallurgy Gear Manufacturing: an analysis of current manufacturing challenges
- 2017
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Ingår i: VDI-Verlag GmbH. - 0083-5560. - 9783180922942 ; , s. 1251-1264
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Bokkapitel (refereegranskat)abstract
- This paper aims at mapping the challenges of the state of the art of conventional and powder metallurgy (PM) gear manufacture in order to provide knowledge on what parameters need to be considered when modelling the cost and benefit analysis relating to sustainability. An exploratory case study was designed where a series of interviews aimed to identify the complete set of operational steps for both conventional and powder manufacturing of gears in depth, as well as challenges experienced by practitioners aligned to both manufacturing principles. The interview results identified three technical and four non-technical barriers to adoption of PM manufacturing technology for gears. Some of the existing strategies and solutions to the identified hurdles are presented. A gap is identified in the existing strategies and some suggestions in order to tackle the challenges and bridge the gap are put forward.
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