improving production efficiency

www.durr.comwww.durr.com

IMPROVING PRODUCTION EFFICIENCY

PAINT AND FINAL ASSEMBLY SYSTEMS

Barcelona, October 2-3, 2014

WELCOME

Dr. Frederic de Molière

OEM´S COMMITMENT TO SUSTAINABILITY

© Dürr Systems GmbH, Production efficiency, Barcelona, October 2-3, 2014 2

OEM

Sustainability image

Environmental protection

Cost control for sustainability

Governmental regulations


Dürr approach to optimize economy & ecology targets

ECO⊕PAINTSHOP



ECO⊕PAINTSHOP

ECO⊕PAINTSHOP


Stays for short-term and long-term perspectives

Invest

Savings

1,530 yearsoperating life

3 5

Economy & ecology over the whole lifecycle.

25 years ≙5 x invest amount

Time

PRODUCTION EFFICIENCY


Holistic view on the whole Paintshop

EcoDryScrubber

EcoBell 2

General Paintshop settings

Ecopure TAR

EcoEMOSEcopure TAR Suntec

Heat Recovery Wheel

Ecopaint RoDipVariable exhaust aircontrol

Low volume air seal

CIC Oven

Straight Pass Oven

Heat Exchanger

EcoLoopLinked HX System

EcoReBooth

Paint Process

Plant Layout

Shop ventilation concept

EcoDC MACS

EcoMultiCyclone

PT/ED heat recovery

Latent cooling storage

EcoBell 3

EcoLCC

EcoRP E

EcoPump 9

Ecopure TARCOM VEcopure RTO

Ecopure KPR

Eco+Energy CPS Suntec


Achievements: up to…

ECO⊕PAINTSHOP

- 60% Water

- 60% Waste Water

+ 10-20% Throughput- 50 % CO2- 90 % VOC

- 30-50 % Paint

- 50% Energy

- Independence of climate conditions

- Minimized sealer application time

- Minimized paint application time

- Minimized color change time

- Eco+Speed

- Ecopaint RoDip

- Closed quality loops

- Optimized material flow

- Process decoupling

- Short lead time car body

- Ecopaint RoDip

- EcoReBooth

- EcoSmart AC

- EcoDC MACS

- Degrade Mode

- Approved products

- Stand-by equipment

- Splitted capacities

- Manual backup zones

- Decoupling buffer

- Preventive maintenance

- Short meantime to repair

PROCESS EFFICIENCY


Products & Solutions

- Bath maintenance concept

- Dust protection concept


ECO DC MACSModular Anode Control System

11© Dürr Systems GmbH, Production efficiency, Barcelona, October 2-3, 2014

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Gleichrichter 1

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Gleichrichter 3

Operating Szenario

Busbar 1 Busbar 2

Current detection forcoating monitoring

Busbar 3



ECO DC MACS

Breakdown szenario

12© Dürr Systems GmbH, Production efficiency, Barcelona, October 2-3, 2014

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Rectifier 3



ECO DC MACS

Neibourgh anodes compensate failure no loss of car body!!!

13

Fast body transfer & color change

Time reduction for body transfer and color change from 16 to 8 sec

Capacity increase up to 15%

Up to 18m² reduction of polluted surface

Reduction of cleaning time

CPU reduction + higher sustainability

Higher profitability

© Dürr Systems GmbH, Production efficiency, Barcelona, October 2-3, 2014

Eco⊕Speed

ECO SPEED

14

Fast body transfer & color change


EcoLCC2 AB

EcoMCC3 AB

For color changes of 8 sec AB technology is necessary as well as a second dosing pump, a second color channel and a second main needle

EcoBell3 is optimized for this requirement

ECO SPEED

- Ecopure KPR

- Ecopure TAR

- Ecopure TARCOM V

- Ecopure RTO

- Plant layout

- Ecopaint RoDip

- EcoBell 2

- EcoBell 3

- EcoLCC

- Shop Ventilation Concept

- EcoReBooth

- EcoDryScrubber

- Eco+Energy CPS

- Ecopure TAR Suntec

- Heat Recovery Wheel

- Heat exchanger

EMISSION EFFICIENCY



EMISSIONS EFFICIENCYPaintshop References

VOC Emission (examples)

CO2 kg/unit

China141

China291

China208

China268

0

50

100

150

200

250

300

Dürr paint shops recently implemented

China2.3

0

5

10

15

20

25

30

35

Abatement: oven

Abatement: CC, oven Abatement:

primer, BC,CC, oven

China7.3

China30.8

Abatement: oven


VOC g/m2

China17.6

CO2 Emission (examples) VOC Emission (examples)


EMISSION EFFICIENCYRecuperative thermal exhaust air purification system

Integrated purification and energy supply ideal form oven processes

Integrated heat recovery for significant energy savings

Significant flexibility due to adjustable operation points

Highly efficient burner technology

Reduced energy demand due to innovative pre-heating systems with reduced CO2 emissions


- EcoBell 2 - EcoBell 3- EcoLCC- EcoICC- EcoRP E

- Eco+Energy CPS- Ecopure TAR Suntec- Variable exhaust air control- Low volume air seal - CIC Oven- Straight Pass Oven

- Heat Recovery Wheel / Plate- EcoLoopLinked HX System

- EcoReBooth- EcoDryScrubber- EcoSmart AC

- site, product (m²), skid length, jph, working hours/day

- Shop ventilation concept

- Ecopaint RoDip- EcoDC MACS- EcoMultiCyclone- PT/ED Heat Recovery- Latent cooling storage

ENERGY EFFICIENCY



- Ecopure TAR- Ecopure TARCOM V

- EcoEMOS Energy - Paint Process- Plant Layout

ENERGY EFFICIENCYReferences and sensitivities

Hungary790 China

711China551

Russia590

China430

China922

100200300400500600700800900

1000

kWh/unit


Total energy saving potential worldwide for reduction by 400 kWh/car ( 75 Mio cars/year):

- 4 nuclear power plantsChina399

Germany

Brazil

- 59 kWh/unit

- 97 kWh/unit- 59 kWh/unitShenyang

Yantai

100200300400500600

kWh/unit

- 70 kWh/unit

16 h/day 24 h/day


DRY OVERSPRAY SEPARATION

The intentionally simple and robust paintoverspray separation

The exclusive paintoverspray withoutadditives

Fluidized bed furnace –Limestone powderrecycling

Efficiency throughdry separation


21

DRY OVERSPRAY SEPARATION

21

References

Rehau Südafrika TC I+II

HKK Japan

70 paint lines with more than 2.200 EcoDryScrubber modules 70 paint lines with more than 2.200 EcoDryScrubber modules

Yamaha I Japan

Yamaha Indonesia

FAW Audi Changchun CP1BMW Shenyang TC I+II

SGM NorsomChery Dalian

SGM YantaiBBAC Daimler Beijing

SVW Yizheng CP 5SGM Shanghai

SCJLR ChangshuSVW Nanjing CP4 TC I+II

SGM WuhanFAW Chengdu CP 3.2FAW Chengdu CP 3.3

Nissan HuaduSVW Ningbo CP6

Honda East LibertyBMW Spartanburg

VW ChattanoogaFord Kansas

Porsche LeipzigBMW Leipzig

BMW RegensburgRehau Viechtach

SMART HambachWagon Nagold

PSA Sochaux TC I+IIBMW Dingolfing

Audi GyörRehau Györ

Daimler KecskemétFord Otosan Yamaha II Japan

Audi Mexico


0%10%20%30%40%

50%

60%

70%

80%

90%

100%

2010 2011 2012 2013 2014 2015

WetScrubber

EcoDryScrubber

Your advantages:

Reduced energy consumption

Automated process control without manual intervention

Minimized reaction time on rapid climate changes

Short pay-back time < 1 year

Adaptable for green- and brownfields

Product information:

Precise control of temperature and humidity

Coordinated teamwork of modules instead of previous individual control for each module

Measurement of external conditions for optimal selection of target setpoint

Feedforward control for precise setpointcontrol depending on external conditions

Optimal control of air supply

units and recirculation air units

Optimal air supply unit control


ECOSMART AC

Classical air control: Plant startup and disturbance


Booth Temperature

time

Booth Relative Humidity

%

°C

Setpoint

Setpoint

time

0%

100%

Module setpointsSustained oscillations

Increased energy usage

Limit

Limit

Limit

Limit

OptimumOptimum

ECOSMART AC

ECOSMART AC


Plant startup and disturbance

0%

100%

Module setpoints

time

%

°C

Setpoint

Setpoint

time

OptimumOptimum

Small oscillations

Optimal energy usage

Limit

Limit

Limit

Limit

Booth Temperature

Booth Relative Humidity

- EcoDose

- EcoGun Sealing

- EcoRS

- EcoFlow Sealing

- EcoShot Meter

- EcoJet

- EcoTemp / EcoHeat

- Pre-Treatment

- Electro Coating

- EcoReBooth

- EcoDryScrubber

- Ecopaint RoDip

- EcoReBooth

- EcoMultiCyclone

- EcoIon Ex

- EcoFilter-Oil-UF

MATERIAL EFFICIENCY



- Ecopaint RoDip

- EcoBell 2

- EcoBell 3

- EcoLCC

- EcoICC

- EcoPump 9

MATERIAL EFFICIENCY


26

Minimized material consumption - less waste & waste water

Waxing

CC

BCLASD

Benchmark 118,5 € / unit*

Material consumption (excl. water)

Benchmark 397 l / unit

Sealing

others PT

* (excl. water)

EC

INNOVATIONS IN APPLICATION

27

EcoBell3 Ci: Application systems, new high speed atomizer for interior painting


Application area Water based paint 1K, 2Kwith high tension without high tension

Solvent based paint 1K, 2Kwith high tension

Interior paintingSB50%: 50-220 mm

Exterior paintingSB50%: 180-600 mm -

Combined zone (interior & exterior), plastic parts & bumper painting

SB50%: up to 600 mm -

EcoBell3 Ci

EcoBell3 E

EcoBell3 C

EcoBell3

EcoBell3

EcoBell3

EcoBell3

INNOVATIONS IN APPLICATION

28

EcoBell3 Ci: Application systems, new high speed atomizer for interior painting


Lowest self-contaminationReduction of oversprayAutomatically cleaning without production cycle lossHigh productivity Further increase of the transfer efficiency

Highest HT-safety (CE type examination)Compact design

SPACE EFFICIENCY



Ecopaint Oven

Layout concepts

Ecopaint ReBooth

Minimized Footprint

SPACE EFFICIENCY


EcoRP E and EcoRP

Reduced Booth width and length

High Bay Storage

Minimized Footprint


SPACE EFFICIENCY


STORAGE SYSTEMS

Foot Print 970 m²

Floor Conveyor Storage System

Flexible Layout Function to design/LocationFoot print requirement

Compact LayoutHigh functioanlityHigh flexibility

Layout to requirement

Advantages Disadvantages Advantages Disadvantages

Foot Print 170 m²

High Bay Storage System

EFFICIENCY THROUGH FLEXIBILITY


Flexible products & solutions

30 jph 60 jph

30 jph30 jph

30 jph

60 jph30 jph

BC/CC

Oven

BC/CC


Eco Screen 3D-on Site

task bar

program editor

fitting tool

change log

access protection

call of further editors and tools

graphics editor




Solutions

Box Concept Color changer EcoLCC EcoBell 3

Single stations (boxes) arranged in parallel

Bodies fed in/out by adequate conveyors

Painting task is maximized in each box

Stop & go mode

Reduced color change time < 10 sec. with pushout

Exterior and interior painting

High automation level

10 years agoAverage today

New Paintshop Plant Tiexi

Thanks to state-of-the-art technologies, Tiexi plant paint shop ranks the world’s most sustainable paint shops, water consumption, VOC emission and waste water are reduced to 1/3 of average level 10 years ago.

Energy Water VOC Waste Water

Major lever in resource conservation in production is the Paint Shop

41% of Tiexi total energy. 35% of total water usage. 100% of Process waste water: 100% Solvent emissions.

PRODUCTION EFFICIENCYHolistic view on all efficiency criteria – Example: BBA Tiexi paintshop


REMAINING POTENTIALS


Process Efficiency

Emissions Efficiency

Energy Efficiency

Material Efficiency

Space Efficiency

Your Paintshop

Remaining potentials

Efficiency through Flexibility

low high

“Subject to change without prior notice. The information in this presentation contains only general descriptions and performance features. In actual applications they may not be exactly as described here. The desired performance features are only binding if they are agreed explicitly upon completion of contract”.

IMPROVING PRODUCTION EFFICIENCY

www.durr.com

PAINT AND FINAL ASSEMBLY SYSTEMS

Bacelona, October 2-3, 2014

improving production efficiency

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