Toward More Efficient Manufacturing. Henry J. Cialone President and CEO

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1 Toward More Efficient Manufacturing Henry J. Cialone President and CEO

2 Shaping the Future of Manufacturing Through Innovative Technology Solutions

3 About EWI EWI develops manufacturing technologies to improve product performance and reduce cost, works with clients to develop, optimize, qualify, test and implement technologies, collaborates with industry and universities to extend our capabilities, and commercializes technologies to deliver competitive advantage

4 Our Approach to Increasing the Efficiency of Manufacturing Increase the efficiency of the manufacturing process (reduce waste) Increase the productivity of the manufacturing process Develop a completely new process that achieves one or both of the above

5 Energy Use in Automobile Manufacturing Electricity use in vehicle assembly plants 1987: 8.6 TWh 1995: 10 TWh 2011: 9 TWh Average power consumption per vehicle built 1987: 1,000 kwh/car 1995: 860 kwh/car 2011: 670 kwh/car What happened? Nissan Automotive Plant, Canton, MS First vehicle assembly plant to earn EPA s Energy Star rating Energy Efficiency Improvement and Cost Saving Opportunities for the Vehicle Assembly Industry, Galitsky, C and Worrell, E, 2008 US Department of Commerce Annual Survey of Manufacturers:

6 Energy Use in Automobile Manufacturing Building efficiency Heating / cooling of facilities Lighting Behavior improvements Engaged conservation efforts Instituted lean manufacturing principles Technology / process improvements Painting process controls Motor efficiency and controls Reduced or eliminated compressed air (example change from pneumatic to servo-driven spot weld guns for 75% increase in efficiency) Pneumatic Weld Head Servo Weld Head

7 Reducing the Energy of Spot Weld Quality Control Destructive testing In any given auto plant, a perfectly good auto body is destroyed up to one time per week, depending on: Manufacturer Maturity of the design Wasted energy For stamping and welding parts used to build the body, Plus the energy to create the steel itself, form it, ship it, handle it

8 Reducing the Energy of Spot Weld Quality Control Non-Destructive Testing Could eliminate the need to destroy a vehicle to assure weld quality Allows all welds to be assessed Provides quality verification for 100% of production run Increases confidence in the manufacturing process Less than 0.1kWh per hour of operation Potential to eliminate redundant welds as a safety factor EWI SpotSight TM Advanced spot-weld inspection technology

9 EWI DeepTIG TM Proprietary mixture of powders applied to the surface of a base metal Increases weld penetration up to 300% Simplifies joint preparation Reduces number of weld passes Reduces heat input and distortion, reducing energy requirements Without DeepTIG With DeepTIG

10 EWI DeepTIG TM Applied to a Nickel-Based Superalloy No DeepTIG 235 A, 10.1 V, 3 ipm TS 2 passes 4.7 kw arc power With EWIDeepTIG 135 A, 9.4 V, 3 ipm TS 1 pass 1.3 kw arc power (73 % reduction)

11 Reducing Energy Consumption in Thick-Section Arc Welding EWI s narrow-groove tandem GMAW two consumable electrodes in one weld pool Less energy required to melt two smaller-diameter wires than one larger diameter wire at the same deposition (productivity) rate 20 lbs/hr with two in. electrodes: ~16 Watts 20 lbs/hr with one 1/8-in. electrode: ~21 Watts

12 Reducing Energy Consumption in Thick-section Arc Welding Narrow-groove joint preparation allows 57% reduction in joint volume compared to a traditional double V- groove in a 5-inch thick joint Combined with EWI s new process, this reduces energy per foot of thick-section weld by 77%

13 Combining Lasers and Arc Welding for Greater Efficiency Application: Welding of steel panel butt welds at a shipyard. Conventional process: Submerged arc welding Advanced manufacturing process: Hybrid laser / arc welds Benefits: Increase productivity, decrease distortion Apples-to-apples energy consumption comparison: Energy cost, $/ft Total cost, $/ft HLAW SAW *2010 energy cost data Page 13

14 AcousTech Machining TM Application of ultrasonic vibrations to conventional machining processes Dramatically improves performance Much higher productivity Ability to cut hard metals Longer tool life Better surface finish Increased accuracy Improved chip management Reduced coolant Lower tool force

15 AcousTech Machining TM Power Consumption Assessment Conventional AcousTech Monthly power usage for 1 machine 1,872 kwh 1,288 kwh Factory floor (20 machining centers) 37.4 MWh 25.8 MWh 4x productivity (unconstrained) 3.1 kwh / pt 0.5 kwh / pt 2x productivity (downstream constraint) 3.1 kwh / pt 1.1 kwh / pt Conventional PLUS Reduced medical claims due to chip formation! 90% Ultra-Sonics AcousTech Drilling Trial (6061-Al) Force (white) reduced 56% Torque (blue) reduced 38%

16 Additive Manufacturing An Emerging Technology Application stainless steel impeller Benefits unconstrained design, ondemand manufacture Energy consumed 12.2 kw hr/part (to produce part and remove from platform) Doesn t consider powder or industrial gas Energy cost Industrial electricity = $0.0675/(kW hr)) Energy Cost/part = $0.83/part Energy Cost/lb=$2.33/lb Energy per part will decrease as part count increases (full build platform) Energy Cost 2.14 $/lb D=50mm, h=30mm Data from Bauman, et. al., SFF Symposium, 2012

17 EWI s Energy Efficiency Strategy at Home Solar array Three 50 kw arrays AEP rebate made financing feasible positive cash flow EWI owns the array in 7 years kw system = 189, kwh / Cost savings = $12,343.6/ year Arrays rated for 20 years of service Renegotiate power pricing Saving $92K over three years (33% reduction) Demand response Interruptible power program, curtail use on hot days 4 days per year

18 EWI s Energy Efficiency Strategy at Home Lighting Parking lot and high bay area 2,007,600 kwh = $203,640 / year 1115 troffers/lights for rest of building 322,612 kwh = $33,278 / year Big-Ass Fans in high bay area High volume, low wattage Air circulation reduces HVAC demand Facility-wide surge protection For mission critical, sensitive equipment Total annual savings >2.5 GWh

19 EWI Manufacturing Innovations Increase the efficiency of the manufacturing process (reduce waste) Increase the productivity of the manufacturing process Provide completely new processes that achieve one or both of the above Are powered efficiently!

20 Thank You! Henry J. Cialone (614)