Lecture 15 : Smart Design and Engineering

[Music] good afternoon everyone welcome to yet another lecture of the NP Ms course titled carbon accounting and sustainable design for product life cycle management I am Dr DEA FIP I'm from I kpur and along with me uh Dr amand sing obro and Dr PR pradap Singh are called teaching this course and we have been going through major topics uh like uh productivity then sustainability what's carbon footprint what is greenhouse gases global warming potential uh how do we do emission reduction what is carbon sequestration uh what is VCS CDM all those kind of aspects we have gone through and we also seen how the sustainability and uh the carbon footprint of different activities how to calculate what is the carbon dioxide equivalence from uh cars especially burning petrol uh electric appliances flights Etc we have seen that as well and then we went into something called as the green manufacturing specifically we took a focus on the uh automobile industry because that is one of the champions of so far being the champions of uh um sustainability or especially sustainable manufacturer and we have seen through what he call as the pngv partnership for the uh futuristic vehicle green vehicle and then we talked about what you call us alab which is ultral light steel Auto Body enclosure that uh uh future vehicle that we discussed how Toyota achieved that and the so us and the Toyota are two aspects we discussed and today if you look into what we are going to do today we are going to talk about smart car which is the Europe's vision smart car is something that was championed by Mercedes in Europe and then we talking about what it is okay so smart actually stands for Swatch Swatch is a company that make watches Swatch Mercedes art that became the smart so this car car was the brainchild of nicholo H child of Nicholas he who is the CE of Swatch okay so his aim was what do is that it's a produce a car that would be fun car that would be fun cheap and simple okay yet environmentally sound then with electric or Hybrid Power Hybrid Power so the interesting part was that the Swatch Mercedes art or the Smart Car Nicholas hay the then CEO of Swatch it was his brainchild so his aim was to produce a car that will be fun cheap and simple but yet it will be environmentally sound and it will either use electric or Hybrid Power then what we also say is paid particular attention attention particular attention for or towards design for assembly okay DFA designed for assembly so it was paid particular attention towards design for assembly uh one first thing is almost everything everything was outsourced and uh assembly time is 4.5 hours around 4 it's now reduced but it's about 4.5 hours when it was started then another aspect of it is car designed to be highly modular to be highly modular okay which means modules or parts attached to a in attached to a rigid integral rigid integral Trion body frame Tri diione body frame so the modules and parts are attached this a highly modular car but it is attached to a rigid integral Tri body frame so what is Trion is it's a trie steel safety shell okay it's a steel safety shell but this body frame this this ston safety shell on which different parts are attached to it and some important aspects of it is the size of the vehicle if you think about it it is 8.21 by 5 by 5 so that's the size of the trade ion then weight it's very lightweight okay it is 682 kg or500 lbs okay pounds and fuel types that is either diesel leaded or unleaded petrol biofuels and electric so these are the fuel types okay and then cost starting at Dollar 25,000 so at 25,000 that's a cost effective thing whether with the system of having either diesel or unloaded leaded petrol biofuels and electric weight of 682 kg and size of 8.21 in by 8.21 ft by 5 5 ft by 5 ft not in just feet it's in feets okay so that kind of a size is what was envisioned in this and the car is designed to be highly modular and on the all these modules are attached to a Trion body frame so with this now let us look at how the design and Engineering of smart actually happened so as we said earlier this is uh almost everything is outsourced design for assembly so main points is it was DFA car with almost almost everything outsourced so then the main system suppliers main system suppliers so who are the main system suppliers the space frame which is also known as the tridion frame okay they that was supplied by Magna the doors was uh Magna uniport okay Yos they did that then the paint or the paint shop that was sorta sorta as men as men then uh the power train the front power train brakes and lights okay this was supplied by Bosch then the cockpit or the driver side they call it cockpit in this one uh Manus man video okay and then the plastic body panels okay there are two suppliers for this Dynamic noble noble or cross MAF is the cross MAF and the rear power train because remember this was a hybrid system this is the crup Automotive Systems it's part of the thean CB group you might have heard about this company called the sunr the same thing okay now so these are the main things Magna supplied the space frame Magna uniport supplied the doors the paint shop the paint job was done by Suman the power train brakes lights was supplied by Bosch manman video supplied the cockpit cross MAF or Dynamite Noble depending upon the type they supplied the plastic body parts and the rear power train was done by crup Automotive Systems which is part of the subsidary of the en crup then also you should understand that almost no inventory on hand okay there was never any inventory as part of this one the company assembles and rolls out cars so unlike other Automotive manufacturers like Toyota and all who manufactur their own engines Honda also manufactured their own engines and stuff they did not do anything they just assembled and rolled the car out that's all so they in because they could do this because no inventory was because everything was coming from other suppliers and they were the Swatch was just basically assembling and supplying this okay so their focus where on what did they focus on number one was Logistics number two was testing and number three was Transportation so these three were the in addition to assembly that add to assembling the car they focused on Logistics testing and Transportation uh otherwise they had no inventory in hand so then what did smart ended up achieving and what were the savings of the smart Okay so the major thing was 95% recyclable that is 3 R of sustainability so they were very much able to achieve 95% uh recycle level and fuel efficiency that is about 60 miles per gallon okay that time industry bust was 30 miles per gallon so remember if you remember the pngv the pngv go pngv gold was 80 MPG miles per gallon remember we said that the partnership for the global vehicle it actually had a goal of 80 m per gallon thing smart came very close to it about 60 m per gallon that they achieved by the time the compact cars in Us and other places were giving 30 m per gall then it is very modular I told you this was all done very modular okay that means easy to assemble and disassemble assemble and disassemble okay so that is the second part easy to assemble and disassemble then they have also very specialized production line I told told you that they uh were focusing only on the assembly uh in addition to Transportation testing and Logistics so because they had a very specialized production line they could do less emissions and reduced production waste so they could do less emissions and reduce the production waste so this this is another 3r reduce okay and reduce emissions reduce waste then another one is parking okay needs very little space so compared to other cars or other typical compact cars it only requires very little space to parking and uh this is Europe's main challenge parking space that's a big challenge in Europe and then the last part is the materials and what they have done is efficient and eco-friendly materials were used so efficient and eof friendly materials were used in this part of this so that's what it turned out to be so if you look into this they were able to achieve recycle which is 95% recyclable which is the three R of sustainability they improved the fuel efficiency okay so this is the uh reduce okay uh also so like for example is it's uh a fuel efficiency was reduce the need of fossil fuel that was part of this and then very modular assemble and disassemble so the reduce assembly time and specialized production I told you again 3 hour reduction happened there parking reduces need for the parking space and efficient and eco-friendly materials so that would allow you for reuse kind of a thing so they were focusing mostly on the three hours of the uh sustainability so with this much we would come across we will come to the conclusion of this uh green manufacturing site and we are in week four but uh what we now done is we have gone through a lot of those topics our next topic will be more about uh how do we do product life cycle management and the importance of it in which we will cover in the coming uh session so thank you very much and uh for your patient uh listening please go through the lecture notes and also uh please read the materials that is given to you uh for better preparation thank you very much [Music] [Music] [Music]