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    Abstract The paper presents a systematic approach for energy efficient engineering of injection mould design. It supports engineers with analysing design outcomes for an energy efficient operation of injection moulds, while the approach needs to guarantee the appropriate final products’ quality and assure production process performance over several years of usage. An ICT supported systematic approach is presented that enables engineers to monitor manufacturing processes, learn from past designs and elicit knowledge for designing new injection moulds that can be operated with less energy usage. Gained experience and key results are presented that were collected in automotive plastic part production. 24754
     Keywords:  Design for Energy Efficient Manufacturing; Manufacturing Systems Energy Monitoring; Knowledge based Injection Mould Design
     
    1   INTRODUCTION
    Producers of plastic parts are  facing hard global competition.
    Besides high quality and reasonable costs, environmental impact
    has become an important factor, which is closely linked with energy
    consumption. A key element for the  life-cycle of plastic parts in the
    stage of manufacturing is the design of the injection mould. Mould
    design represents a challenging and costly task seeking to fulfil and
    match requirements of the product designer and the production site.
    A huge amount of factors must be taken into consideration for mould
    design. Some main factors are mould size, number of cavities,
    cavity layout, runner and gating systems, shrinkage of the material
    and ejection systems [1].
    Industry and specifically the automotive domain are at the forefront
    of searching for new ways to reduce environmental impact of
    production processes. Besides the EU proposals for reducing CO2
    emissions, automotive companies are targeting at ECO-Innovations
    that are opening a wider field beyond engine and powertrain
    technology. This includes the production of parts for a car [2].
    Injection moulding as the most important and most widespread
    procedure of polymer processing for finished plastic parts [3], can
    address several challenging demands on competitiveness: Plastic
    parts are typically lightweight and offer a great freedom of design for
    the product designer at low cost. 
    The injection moulding process  still offers opportunities for
    improvement considering energy efficiency. Potential energy
    savings for sub-systems are within a range of 10% to 80% [4]. Our
    own work as well as previous other research specifically identify the
    importance of effective collaborative teams [5] and that good
    solutions for innovation problems strongly depend upon the
    designers. Creative designers using powerful design tools will be
    able to solve technical problems rather fast [6]. 
    As Bogdanski, Spiering et. al. point out, a key enabler to facilitate
    energy efficiency in production environments is to monitor energy
    flows and feedback this information addressee oriented [7]. Main
    motivation of our work was to elaborate a systematic approach that
    supports the analysis of injection mould design outcomes
    considering energy efficient mould operation. The key idea was to
    feedback this information to the mould designers so they can exploit
    knowledge on cause-effect type relations, especially facilitating to
    learn from similar problems addressed or solved before.
    In this paper we are presenting the underlying idea for energy
    efficient injection mould design. We will highlight the key factors in
    mould design which have high impact upon energy demand in
    production process and describe the related approach for evaluating
    energy efficiency of moulds in an automotive manufacturing
    environment.
    2   METHODOLOGY 
    2.1   Energy Consumption in Injection Moulding Processes
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