AWEA 2014 Conference
• DOE Project: U.S. Wind Energy Manufacturing and Supply
Chain: A Competitiveness Analysis
• Offshore Supply Chain Opportunities
Patrick Fullenkamp
GLWN, Global Wind Network
pfullenkamp@glwn.org
216.920.1956
© Copyright 2013 GLWN™
A WIRE-Net Initiative
Manufacturing Competitiveness:
US vs. Europe vs. Asia
Limited Snap Shot Study - 2013
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A WIRE-Net Initiative
Key Components
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A WIRE-Net Initiative
Unique GLWN process
 Standardized
component
specifications & drawings

Onsite reviews: Validated cost and
process data from 22 suppliers
Unit of
Measure
Item Description
 Analytics:
Cost Breakdown Analysis,
Value Stream Mapping
Steel Plate 27 mm (1A, 1B, 1C, 1D)
Steel Plate 26 mm (2A, 2B, 2C)
Steel Plate 25 mm (2D, 2E, 2F)
Steel Plate 24 mm (3A, 3B, 3C)
Steel Plate 23 mm (3D, 3E, 3F)
Steel Plate 22 mm (4A, 4B, 4C)
Steel Plate 21 mm (4D, 4E, 4F)
Steel Plate 20 mm (5A, 5B)
Steel Plate 19 mm (5C, 5D)
Steel Plate 80 mm Door Frame (1E)
Manufactured Flange A-A (Sheet 2 of 7) (1F)
Manufactured Flanges B-B (Sheet 3 of 7) (1G, 2G)
Manufactured Flanges C-C (Sheet 4 of 7) (2H, 3G)
Manufactured Flanges D-D (Sheet 5 of 7) (3H, 4G)
Manufactured Flanges E-E (Sheet 6 of 7) (4H, 5E)
Manufactured Flange F-F (Sheet 7 of 7) ( 5F)
HV bolts M80x400 (6A)
HV Washer 80 Dia (6B)
HV Hexagon Nut M80 (6C)
HV Bolts M64x400 (7A)
HV Washer 66 Dia (7B)
HV Hexagon Nut M64 (7C)
HV Bolt M56x300 (8A)
HV Washer 58 Dia. (8B)
HV Hexagon Nut M56 (8C)
HV Bolts M42x300 (9A, 10A)
HV Washer 43 Dia (9B, 10B)
HV Hexagon Nut M42 (9C, 10C)
Weld wire
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
mt
piece
piece
piece
piece
piece
piece
piece
piece
piece
piece
piece
piece
kg
kg
liter
liter
Raw
Material
Detail
A709 Gr50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A709 Gr 50
A572 Gr50
S355NL-Z25
S355NL-Z25
S355NL-Z25
S355NL-Z25
S355NL-Z25
S355NL-Z25
Total
Weight
39.6
35.3
34.7
29.5
28.2
24.3
23
19.3
11.7
1.57
7.23
14.18
7.739
6.78
6.43
4.46
HDG
HDG
HDG
HDG
HDG
HDG
HDG
HDG
HDG
HDG
HDG
HDG
Quantity
4
3
4
3
4
3
4
3
3
1
1
2
2
2
2
1
92
184
92
100
200
100
120
240
120
200
400
200
1
1
985
1046
Unit Cost
960.00
960.00
960.00
960.00
960.00
960.00
960.00
960.00
960.00
3942.00
1400.00
1400.00
1400.00
1400.00
1400.00
1400.00
92.07
8.18
18.73
75.01
7.25
14.63
55.21
6.27
26.19
35.35
1.25
4.86
4.90
9.60
13.75
13.75
Material
Total
38016.00
33888.00
33312.00
28320.00
27072.00
23328.00
22080.00
18528.00
11232.00
3942.00
10122.00
19852.00
10834.60
9492.00
9002.00
6244.00
8470.44
1505.12
1723.16
7501.00
1450.00
1463.00
6625.20
1504.80
3142.80
7070.00
500.00
972.00
4841.20
292.80
13543.75
14382.50
© Copyright 2013 GLWN™
A WIRE-Net Initiative
Epoxy Zinc Carboline 656 Coating - (equivalent utilized)
Epoxy HB Carboline 890 Coating - (equivalent utilized)
Polyurethane Carboline 134 Coating - (equivalent utilized)
material cert
material cert
material cert
material cert
988
30.5
Supplier
Name
Country
of Mfg
Nucor
Nucor
Nucor
Nucor
Nucor
Nucor
Nucor
Nucor
Nucor
Millerbernd
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
Dokka
Dokka
Dokka
Dokka
Dokka
Dokka
Dokka
Dokka
Dokka
Lincoln
International
International
International
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
Asia
Asia
Asia
Asia
Asia
Asia
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
USA
Handling
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
5615.00
11230.00
11230.00
11230.00
11230.00
5615.00
225.00
225.00
225.00
24.50
24.50
24.50
24.50
24.50
24.50
24.50
24.50
24.50
0.00
0.00
0.00
0.00
Global Competitiveness Scoring,
based on limited snap shot data in 2013
Process Technology
Overall Competitiveness
3
3
1
1
0
0
US: Towers, Blades, Generators
China: Towers, Generators, Foundations
Germany: Foundations
US: Blades
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A WIRE-Net Initiative
U.S. Manufacturers: Towers, Blades,
Foundations, PM Generators
© Copyright 2013 GLWN™
A WIRE-Net Initiative
Observation




U.S. has a good foundation – more
to improve
Lessons learned from auto, 30-50%
process savings potential observed
If you don’t make it, you can’t
innovate it (Castings & Forgings –
23%) Policy & Investment support
Educate Manufacturers and
Regional, State, National Leaders
on risk of manufacturing sector loss
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A WIRE-Net Initiative
U.S. Manufacturing Scorecard
Scorecard Legend
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Germany Offshore Wind
Total Value Add - 5.9B as of 2011
Grid
Connection,
0.64
Operations /
Maintenance,
0.25
Project Planning
/ Development,
0.9
Financing /
Insurance, 0.05
Transport /
Assembly, 0.47
Manufacturing
3.61
In Billion Euro's
Source: wab, windenergie agentur
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A WIRE-Net Initiative
Offshore Supply Chain Opportunities
Large Parts in Coastal Regions: Foundations,
Towers, Blades, Nacelles, Export Cable
 Vessels, Substations, Transformers
 Fabrications, Castings & Forgings Machined,
Electrical, Composites
 Service Providers, Equipment Providers,
Material Providers

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A WIRE-Net Initiative
How can you add value
to this new offshore
industry?
.
© Copyright 2013 GLWN™
A WIRE-Net Initiative