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

2. 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 ?

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

4. 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 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 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 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

5. ‘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)

6. 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

7. 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

8. 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.

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

10. 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

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

12. 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

13. 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%

14. 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)

15. 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]

16. 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).

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

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

19. Relationship with enabling technologies
Economic benefits

20. Summary: Benefits from sustainable electronics manufacturing