Research project "Resource Efficient Production in Brazil"

Transfer of applied reseach into the industry for resource efficient production

The cooperation between the SENAI network and the Fraunhofer IPT in Germany was established in 2013 and aims at increasing the energy and resource efficiency all over Brazil.

Within the joint project the course for future development in the Brazilian research and the manufacturing sector is set. This includes applied research conducted by the individual SENAI institutes – those results again can be transferred into the industry for innovative and advanced solutions. The practical application of research results will be evaluated in consulting services carried out by SENAI experts carefully chosen regarding their individual core competencies.

SENAI has access to competencies and knowledge throughout the whole network and therefore stands for a strong basis of experience. Projects are conducted methodically: a first problem identification and visualization is followed by a deeper analysis to get to the problem’s root cause. In the end, specific improvement measures are suggested with precise recommended course of action and a detailed cost calculation.

The project

Initial situation

Prices for resources such as raw materials, energy and human resources are increasing constantly due to resource scarcity and the growing demand in production technology and other industrial sectors. This trend will continue in the future decades: according to the International Energy Agency (IEA), prices for coal and gas will almost double until the year 2035.

This circumstance obliges companies as well as institutions such as the SENAI network likewise to face these changes with the development of efficient production processes using approved methods from production technology and quality management. Therefore, SENAI established a strategic partnership with the Fraunhofer Institute for Production Technology IPT, Germany, to carry out joint projects in Brazilian companies to push the thought of energy and resource efficiency into the local industry.

Resource efficient production in Germany

The need of energy as well as resource efficiency in production has already been addressed over the past years in companies, research and politics all over Germany. Companies strive to reduce costs, research aims at relieving the worldwide resource demand to save limited resources, and politics provide the necessary framework including incentive systems. Those circumstances can be perfectly transferred to the structure in Brazil to support manufacturing companies and research simultaneously.

SENAI pursues the adaption of a model to conduct applied research and provides services such as the application of those results in projects for the industry. In this context, on the one hand the companies’ processes and material as well as energy flows can be reduced and on the other hand ideas for new research activities can be found in the industrial environment.

Project targets

The conjoint project of SENAI and the Fraunhofer IPT and its goals are threefold:

  • Concept for setup of technology centers
  • Know-how transfer
  • Pilot project

In the course of the project, several SENAI institutions were visited and core competencies identified. A comparison with the needs of companies, especially those in Brazil, which were extracted from discussions with experts, led to a concept how to improve SENAI’s internal collaboration to combine individual competencies.

The know-how transfer was ensured by several seminars regarding approved as well as innovative methods of quality management for the analysis of processes and technological competencies to develop measures for improvement. Those seminars were conducted at ITA, São José dos Campos, SP and Aachen, Germany.

The pilot project was carried out at Renault do Brasil in São José dos Pinhais, PR. It embraced the analysis of several production lines using an advanced method based on value stream mapping extended by energy and resources. Subsequently, the biggest consumers were chosen and process information as well as load profiles were gathered, which led to a deeper analysis of potentials for technical improvements and recommended courses of actions for their realization. Additionally, further measures regarding the overall production site’s efficiency were considered and validated in a technical and economic feasibility study.

Approach

The main goals of the project include the transmission of knowledge about energy and resource efficiency and suitable, structured and innovative methods to visualize, analyze and improve technical and organizational processes on the shop floor in the manufacturing industry. Furthermore, the project was structured to enable SENAI to carry out consulting services in Brazil by using the transferred methods and approaches by itself. The dedicated "learning by doing"-approach ensures a stand-alone execution of projects in the field of resource and energy efficiency in the Brazilian industry.

Results

Companies all over Brazil working in the manufacturing sector benefit from the support of SENAI due to its professional, competent and independent assessment. SENAI employees first evaluate and afterwards investigate a specific problem to gather information about the actual situation, which leads to a structured and detailed analysis with state-of-the-art knowledge about technologies as well as organizational methods. The application of those instruments delivers manifold results:

  • Transparency regarding processes, both technical as well as organizational
  • Costs of single circumstances influencing the overall process
  • Broad recommended action plan with detailed economic and technical feasibility study

After those evaluations, all the results will be presented to the company’s representatives and transferred. If desired, SENAI also supports the company in the implementation of selected measures for improvement.

Project partners

SENAI

SENAI was established in 1942 and is well-known for its network of professional schools and technological centers to provide education in fields like chemistry, mechanics, construction, etc. It is maintained by the Brazilian Confederation of Industry: with over 2.3 million enrollments each year and about 800 schools it is one of the most important institutions for technological education today and thus supplies the Brazilian industry with qualified activities in over 28 areas of expertise.

In order to support selective Brazilian industry sectors to increase their worldwide competitiveness in the future, the Brazilian Confederation of Industry established the SENAI Institute of Innovation. To promote the development of new technologies and raising the productivity in the production sectors, a two-step plan was developed: Firstly, the awareness must be raised and secondly, a culture of innovation must be adopted according to successful and established research structures. Therefore, the SENAI Technological Institute and the SENAI Innovation Institute were raised to contribute to a higher competitiveness of the Brazilian industry.

Already 22 Innovation Centers were established in diverse fields such as "Production Automation", "Biotechnology" and "Renewable Energy". They aim at using their cross-functional competence in consulting services for the Brazilian industry, e.g. conducting certain projects with the goal of improving the energy and resource efficiency in companies.

Contact regarding the project's organization

Marcos Dias
Unidade de Inovação e Tecnologia - UNITEC
SENAI - Departamento Nacional - Brasília - DF
Phone +55 61 3317 8322
mdias@dn.senai.br

Contact regarding technical questions within the project

Victor Gomes
Instituto SENAI de Tecnologia Metalmecânica
Centro de Inovação e Tecnologia SENAI FIEMG
Phone +55 31 3489-2132
victoreog@fiemg.com.br

Renault

The goal of Renault was the application of an innovative process management method such as the Resource Value Stream Map together with SENAI under supervision of the Fraunhofer IPT to provide solutions for the reduction of energy and resource consumption at Renault’s facility either to save costs as well as the impact of the production’s impact onto the environment. As a large key-player in the automotive industry, Renault fits perfectly into the pattern of requirements for the implementation of such a conjoint project.

Fraunhofer Institute for Production Technology IPT

The Fraunhofer Institute for Production Technology IPT combines knowledge and experience in all fields of production technology. In the areas of process technology, production machines, mechatronics, production metrology and quality as well as technology management, Fraunhofer IPT offers partners and customers tailor-made solutions and immediately actionable results for modern production.

Enterprises in all industries are faced with the challenge of developing a distinctive and unmistakable profile. Unique products that are capable of captivating customers and flawless, efficiently working processes are essential distinguishing marks on the global market. For this reason, the development of a comprehensive quality management system has become one of the most vital tasks for today’s executives. They can only attain their operative and strategic targets once such a system is in place and are well aware that it has a major impact on corporate success. Thus, the Fraunhofer IPT carries out research regarding the efficient use of correct methods, tools, design of processes and technologies to develop an energy and resource efficient production as well as the organization of structural resources.

The Fraunhofer IPT provides a cross-functional team with experts from the "Process Technology" and "Production Quality and Metrology" who are working in the divisions high performance cutting, laser material processing as well as production efficiency in the field of energy and resource efficiency.

Contact

Dipl.-Ing. Eike Permin
Head of Production Quality
Phone +49 241 8904-452
eike.permin@ipt.fraunhofer.de

Dr.-Ing. Kristian Arntz
Head of Laser materials processing
Phone +49 241 8904-121
kristian.arntz@ipt.fraunhofer.de

 

Instituto Tecnológico de Aeronáutica

The Technological Institute of Aeronautics (ITA) is one of the most respected engineering schools and research institutions in Brazil, with the focus on aerospace science and technology. It is a public university and supported by the Brazilian Air Force. It is located in the city of São José dos Campos near São Paulo.

The institution was created in 1950 and has strongly contributed to the development of the aerospace and defense sectors in Brazil. Every year a well-chosen number of students has the chance to receive the highest education in the areas of Aerospace Engineering, Aeronautical Engineering, Mechanical Engineering, Computer Engineering, Civil-Aeronautical Engineering, Electronic Engineering and several more.