Balanced Manufacturing (BaMa)


Support: FFG e!MISSION - P 840 746
Project management: Wolfgang Kastner
Project team: Bernhard Heinzl
Start: 2013-10-01
Finished: 2017-09-30




Balanced Manufacturing verfolgt das Ziel, methodenbasiert zu signifikanten Energieeffizienzsteigerungen in der Produktion zu führen. Die Projektschwerpunkte fokussieren auf die Entwicklung und Implementierung von Lösungen zu energieeffizienten Fertigungssystemen, zum Energie-Monitoring und zur Vorhersage und Optimierung des Energiebedarfs von Produktionsprozessen - unter Berücksichtigung der ökonomischen Erfolgsfaktoren Zeit, Kosten, Qualität.


Traditionally, the manufacturing industry focuses on availability, adaptability and productivity of production systems. The simultaneous increase in energy costs and decrease in availability and security causes manufacturing companies to spotlight resource efficiency. Although a variety of methods and tools for optimization of singular aspects of energy efficiency within production facilities exist, a systemic, comprehensive approach for analysis, evaluation and optimization of energy- and resource-flows within a production facility is lacking.

BaMa will develop a simulation-based method for monitoring, predicting and optimizing energy and resource demands of manufacturing companies under consideration of the economic success factors time, costs and quality. All relevant building blocks of the facility (production, building, energy, logistics and management system) will be modelled.

The project starts with a thorough system analysis and definition of the BaMa Methodology. A modular approach will be chosen and that segments a production facility into "cubes". Cubes have a clearly defined interface and represent a certain physical behavior that contributes to the energy balance of the overall system. For data acquisition, an experimental cube, representing a basic production-unit module will be constructed and used for detailed measurements and analysis of energy and resource flows. Based on cube-related energy and resource flow analysis, a specific product-footprint can be derived. The product footprint represents a product’s expenditures concerning cost, time, energy and the environmental impact such as resulting carbon emissions in the product life cycle phase within the factory.

In a next step, BaMa will be implemented inside a customized tool chain. The tool chain (Balanced Manufacturing Control, BaMaC) allows for energy efficient operation, design and refurbishment of production plants under competitive conditions, with regard to minimal energy and resource consumption. BaMaC will contain three core modules:

  • Monitoring: data on resources consumption will be aggregated and visualized.
  • Prediction: allows forecasting of overall energy demand of the plant based on the product-footprint and the production schedule.
  • Optimization: based on data and numerical simulation-models of the cubes, this part of the tool chain will improve the plant operation with regard to the optimization targets energy, time, costs and quality.

Finally, BaMa will be deployed at production facilities of several project partners in order to demonstrate its functionality for multiple industry sectors and to ensure national and international visibility. In addition, guidelines for change management process based on the ISO 50001 with the objective of efficient energy management and optimization will be developed.


For more information, visit the project website!

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