Green Machines - A new approach in machine design - Sjef van Gastel November 11th 2010

Contents Introduction Assembléon LCA analysis of pick & place machines Sustainability at Philips and Assembléon LCA analysis of pick & place machines How to improve sustainability of production machines ? Benefits for the customer and the environment ?

Assembléon: a Philips company Assembléon is a global supplier of Surface Mount Technology (SMT) Pick & Place solutions for the electronics manufacturing industry.

Green Products Philips sustainability strategy Our long-term ambitions reflected in our EcoVision program Green Products Bringing care to more than 500 million people Improving the energy efficiency of our total product portfolio with an average of 50% Doubling our global collection, recycling amounts and recycled materials in products Setting higher standards To deliver on our brand promise of “sense and simplicity” and at the same time provide the company direction for the longer term in this area, we have identified three sustainability Leadership Key Performance Indicators (LKPIs) where we can bring our competencies to bear, ‘care’, ‘energy efficiency’ and ‘materials’ including targets for 2015: • Bringing care to more than 500 million people by 2015. This LKPI is mainly driven by Healthcare. This includes increasing access to healthcare in both mature and emerging markets and providing solutions that improve the quality of people’s lives and reduces health risks. • Improving the energy efficiency of our total product portfolio with an average of 50% by 2015. This will mainly be driven by Lighting with a further roll out of LED lighting, but Healthcare and Consumer Lifestyle products will also continue their efforts to increase energy efficiency. • Doubling our global collection, recycling amounts and recycled materials in products by 2015. Consumer Lifestyle will be the main driver of this LKPI. It will imply improving the recycling performance of our operations and of our supply chain and the recyclability of our own products. We are also committed to strengthening legal frameworks for recycling and minimizing e-waste. 4

‘Six ways to excel’: Philips green products definition The environmental impact of a product over its total life cycle (raw materials, manufacturing, product use and disposal) is calculated by means of LCA (life cycle assessment) analysis and expressed in ‘Eco points’ Philips “Green Products” have a better LCA score and significant improved (> 10%) environmental advantage for customers, users and society (3P) in two or more of the Philips Green focal areas. “Green Products” are identified by a sector on sector-specific criteria Philips Green Focal Areas (GFAs)

Sustainability at Assembléon: Questions How ‘environmental friendly’ are our pick & place machines? LCA modeling of pick & place machine Validation of model LCA and Eco point scoring Analysis of results How can we reduce the ecological footprint of our pick & place machines? Energy consumption reduction Materials selection Improved diagnostics / maintenance & repair / logistics What are the benefits for the customer? Societal benefits Economical benefits

LCA example: pick & place machine Production of fuels Production of fuels Production of electricity Production of electricity Water supply Water supply Waste materials Materials recycling Packaging Production of materials Production of parts Transport Operation of machine Disposal of machine Assembly of machine Every product damages the environment to some extend. Raw materials have to be extracted, the product has to be manufactured, distributed and packaged. Ultimately it must be disposed of. Furthermore, environmental impacts often occur during the use of products because the product consumes energy or material. If we wish to assess a product’s environmental damage all it’s life cycle phases must therefore be studied. An environmental analysis of all the life cycle phases is termed a Life Cycle Assessment, or LCA for short. Auxiliary materials Production of machine Use of machine Disposal of machine Time

Pick & place machine energy usage categories Machine Transport Energy for driving motors & controls Energy for supply of compressed air Energy for machine factory floor occupation Lighting Air conditioning (drying / heating / cooling) Energy for rework Energy for maintenance & repair Transport (service personnel, spare parts) This slide describes different energy usage sources.

Result: Eco indicator for pick & place machine (example: Assembléon AX-501) Largest influence factor: energy usage !

Pick & Place machine energy usage comparison Five different machines were modeled and compared (types: A, B, C, D, E and F) Observations: There are large differences between machine types, relating to machine architecture Machine type A is considerably better than all others Parallel placement  slower movements with multiple (low mass) robots  reduced energy content

Energy consumption versus machine architecture Sequential pick & place concept Pick Place Time “Fast & heavy” Parallel pick & place concept Pick Place Time “Slow & light” 11

How can we reduce the ecological footprint? Energy consumption reduction Parallel placement machine architecture Reduced energy content in moving parts (kinetic energy) Enables integrated pick & place process control  less rework Enables reduced compressed air consumption (less pipettes) Smaller & lighter machines (‘Mass Spiral’) Less fuel consumption for transport Materials selection Eco Design Recyclable materials Reused materials (C2C) Improved diagnostics / maintenance & repair / logistics Remote diagnostics and local repair Less travel Logistics Local repair (less transport) E-freight

Mass spiral Performance ↑ Energy usage ↑ Mass ↑ To increase machine performance a more powerful drive system is needed (more mass). This will negatively influence performance. Hence again a more powerful drive system is needed (more mass). This is called: ‘mass spiral’ (Prof. Ir. H. Soemers, University of Twenthe, Netherlands) Mass spiral break-through? Advanced , light weight, materials Parallel machine concepts instead of sequential No staggering of moving masses Direct drive actuators with high energy density BMW 1600 (1964) Engine: 1600 cc Performance: 63 kW Mass: 1070 kg 0-100 km/h: 14 s. BMW 316i (2009) Engine: 1600 cc Performance: +43% Mass: +33% 0-100 km/h: +21%

Low mass Y-slide for robot demonstrator (single sided component picking) Assembly of robot demonstrator Test set-up Design robot demonstrator Design of robot slide (CFC material) Dynamic analysis (ANSYS) Test model slide (raw)

Optimization of motion profiles Short displacements: Max. velocity not reached Much dissipation in a short period  more heating I [A] Long displacements: Max. velocity will be reached Dissipation over a longer period  less heating I [A]

Output optimization within thermal limits Strategy: Adapt motion parameters such that thermal limits will not be exceeded at max. attainable output This strategy shows to be efficient For an increase in motion time of 1 to 2% related motor energy dissipation will decrease by 10 to 17 % (for board width of 200 mm).

Remote diagnostics architecture Internet VPN 2nd /3rd line Engineer Philips Global Network Customer Network Assembléon server: 1 access point for all systems Fire walls Remote Service Center VPN Tunnel Customer Repair On Site

Economical benefits for green pick & place machines Conventional machine Green machine Investment: 100% Average life time: 100% Energy usage: 100% Compressed air usage: 100% Floor space occupation: 100% Machine weight: 100% Remaining value (end-of-life): 10% Maintenance & repair (% of inv): 3% Result: Integral COO (annual): 100% Investment: 100% Average life time: 140% Energy usage: 70% Compressed air usage: 85% Floor space occupation: 70% Machine weight: 90% Remaining value (end-of-life): 15% Maintenance & repair (% of inv): 2% Result: Integral COO (annual): 70% Green machines can bring considerable cost savings, while contributing to a sustainable world

Relationship with enabling technologies Economic benefits

Summary: Benefits from sustainable electronics manufacturing