“Flexibility” in materials processing -...

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“Flexibility” in materials processing

PROMETIA 4th Scientific Seminar, Barcelona, November 28-29 2017

Maurits Van Camp

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Who we areA global materials technology and recycling group


One of three global

leaders in emission control

catalysts for light-duty and

heavy-duty vehicles and

for all fuel types

A leading supplier of key

materials for rechargeable

batteries used in portable

electronics and hybrid &

electric cars

The world’s leading

recycler of complex waste

streams containing

precious and other

valuable metals

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Unique business

model

Industry leader in

sustainability


Our foundations

more

stringent

emission

control

electrification

of the

automobile

resource

scarcity

Supportive

megatrends

Industry leader in

sustainability

metalsmaterial

solutions

recycling

application

know-how

Chemistry

material

science

metallurgy

Unique business

model

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By 2020 we have…

clear leadership in

clean mobility

materials and recycling

turned sustainability

into a greater

competitive edge


Our strategy

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Unique positionin clean mobility materials

ICEEmission control

catalysts

BEVBattery cathode

materials

(p)HEVBattery cathode

materials and

emission control

catalysts

Fuel cellsElectro-catalyst

and battery

cathode materials


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SHORT

LOOPRecycling services

for customer

production scrap

and residues

LONG

LOOP

Unique technologies

for treating complex

residues and

by-products

Unique position in recycling


Further leverage Umicore’s leadership

in closed loop solutions for customers

Leverage the profitable

expansion to 500kt in Hoboken

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“Flexibility” in materials processingTransition to a knowledge economy

and innovation economy


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“Flexibility” in materials processingTransition to a knowledge economy

The Minimalist Approach


99

Why Minimalist approach?


We live in a risk VUCA world(Volatile Uncertain Complex Ambiguous)

Safety, QEHS Recycling as a “prime” service Sustainability Challenges and its stakeholders Environmental legislation (EU directives, Reach, CMR and local legislation), License to operate, License to market… Value chain, Customers, EBIT, budgets, Metal prices, Currencies,

Globalization…. Quality, ISO 9001, ISO 14001, QEHS, EFQM, 5S, priorities, control,

Corporate demands…. Strategic Roadmaps, R&D, Transition to knowledge and innovation economy, IP, Security, fake news… IT, SAP, communication collaboration Artificial Intelligence.. Maintenance, risk and risk cover, disturbances… HR, Competence management, L&D.

Murphy’s Law Anything that can go wrong, will go wrong

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Some answers


Roger E. Bohn

How to learn fast...

How to avoid fire fighting...

How to involve people in learning...

What are the stages of knowledge...

From Art to Science...

How to control complex systems...

How to organise workforce...

How to reduce problems...

Ramchandran Jaikumar

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Information management

• Problem reduction

• Focus on disruptions

Knowledge management

• Learning cycle

• Knowledge base

• Managing the learning speed

Injecting Life into Information through modeling

• Physical models

• Control models

• Statistical models


The Minimalist Approach

1313PROMETIA 4th Scientific Seminar, Barcelona, November 28-29 2017

The Learning Cycle

Save knowledge Learning process

Automatic and stable

running processInput Output

New knowledge

Improvements

Production Data

Experiments• control models

• physical models

• statistical models

• process team, operators, experts, ...

• experimental design, statistics, ...


Stages of Knowledge

1. We do know nothing.

2. We have an idea but can’t measure it

3. We have an idea and can measure some variables.

4. We can measure the main variables and can control some

5. Recipe level: measurement and control of main variables

6. First order effects

7. Interactions

8. Know it all


From Art to Science

Knowledge at stage 1 2 3 4 5 6 7 8

Nature of production Expertise based Procedure based

Role of workers Everything Problem solving Learning and improving

Location of knowledge Workers´head Written and Oral In database or software

Nature of learning Artistic Natural experiments Controlled experiments

simulations

Nature of problem solving Trial and error Scientific method Table look up

Method of training new workers Apprenticeship Classroom

coaching Teaching

Natural type of organization Organic Mechanistic Learning oriented

Suitability of automation None high

Ease of transfer to another site Low high

Feasible product variety High Low high

Quality control approach Sorting Statistical Feed forward


Procedures and Knowledge

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

1 2 3 4 5 6 7 8

Sstage of knowledge

Deg

ree o

f p

roce

du

re

Zone of inefficiency

Zone of ineffefectiveness


Managing the Speed of Learning

Requires managing:

• Signal noise ratio• Information cycle time• Fidelity• People, people, people


Injecting life into informationModeling

• Control models

• Physical models

• Statistical models

¨Modeling makes integration of knowledge

possible¨

http://kuma.um.be/livelink/livelink.exe/fetch/2000/3986273/5256699/20902466/Thermo?func=ll&objId=22971281&objAction=Open

http://kuma.um.be/livelink/livelink.exe/fetch/2000/3986273/5256699/20902466/Thermo?func=ll&objId=22971281&objAction=Open

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“Flexibility” in materials processingTransition to an innovation economy


2020

Transition to the knowledge economy


inputautomatic & stable running process

output

production

data

learning process

experiments

knowledge integration

improvements

Industrial

economy

knowledge

economy

Innovation

economy

Controllable

knowledge

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Transition to an innovation economy


Industrial

economy

knowledge

economy

Innovation

economy

Competitive

research

Pre-

competitive

collaborations

Controllable

knowledge

Enablers:

• multi-stakeholder collaborations

• people with innovation and

entrepreneurship skills

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Chosen path: Triple helix model

•Triple helix consists of 3 components

• Industry - Academia - Government

• All are taking up Societal challenges

• Interaction drives transitions as it generates

a discussion of innovation in innovation

• Transition:

industrial economy → knowledge

economy → innovation economy


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• Third mission Next to Education and

Research:

• Providing students with new skills, ideas

and entrepreneurial thinking

• Becoming a source of technology

generation and transfer

Game changer: New role for Universities:

Social-Economic Development

Entrepreneurial University


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Precompetitive

collaboration and innovation

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Collaboration and innovation

COMPETITIVE RESEARCH

& DEVELOPMENT

Bilateral agreements

R&D projects with BUs

PRE-COMPETITIVE

COLLABORATION

Networks: CR3, EIT RM

Joint projects: H2020, SIM

PhDs and education

…

STRATEGY

US-EU-Japan trilateral

UNEP resource panel

European Innovation Platform

…


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EIT RawMaterialsAn impressive partnership

Network of 120 active partners in 22 EU member states

6 co-location centers in Lulea, Espoo, Wroclaw, Leuven, Metz, Rome

Headquarters in Berlin


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Remade InstituteUS Department of Energy

Mission:

accelerating manufacturing

innovation and scale-up

technologies that enable the

recycling, reuse and

remanufacturing of

plastics, e-waste, fibers

and metals to cost-

effectively recover end-of-life

(EOL) and waste materials

Institute hosted on Rochester Institute of Technology, campus with leading national labs and universities

Officially launched by DOE on 9 May 2017


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Center for resource recovery and recyclingNSF funded industry-university cooperation


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Copper, Lead and refractory consortiaLeveraging pre-competitive research in our own competitive field

PRE-COMPETITIVE COLLABORATION

Setting up and feeding thedatabases with shared costs

COMPETITIVE RESEARCH & DEVELOPMENT

Creating new insights usingFactage within competitive

projects


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Take Home messages


• “Flexibility” in materials is knowledge and innovation driven

• The minimalist approach is for us the accelerator model for

knowledge generation in a transition to the knowledge

economy

• Multi-stakeholder collaborations and people with

innovation and entrepreneurship skills are the enablers for a

transition to the innovation economy.

Game changer = new role for universities:

Next to Research and education

Provide students with new skills, ideas and entrepreneurial thinking


Thank you for your attention

“Flexibility” in materials processing -...

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