Vigo SMART Factories Keynote STN AN v5 · 3. Smart factory of the future 1. Smarter products 2. Smarter value adding 3. Smarter materials 4. Smarter usage of energy 5. Smarter machines

Advanced Manufacturing Processes & SystemsDepartment of Mechanical Engineering

University of Bath, Bath, UKJAI 2014, Vigo, 6/11/2014

Smart Factories

Stephen T Newman and Aydin Nassehi

Presentation Contents

1. Introduction

2. State-of-the-art in Manufacturing

3. Smart factory of the future

4. Smarter factories of 2030

5. Conclusions

1.1. Introduction: Manufacturing in a single diagram

(Adapted from Westkämper / Constantinescu, 2010)

Products

By-Products(Waste, Emissions)

Machines People Knowledge

Standards

Value

Time

Transformation

ManufacturingMaterial

Energy

1.2. Introduction: The changing faces of manufacturing

Adapted from Jovane et al. CIRP, Annals, 2003

1.3. Introduction: Mass production

Paradigm Craft Production

Mass Production

Paradigm started

~1850 1913

SocietyNeeds

Customized products

Low cost products

MarketVery small volume per

product

Demand > SupplySteady demand

Business Model

Pullsell-design

make-Assemble

Pushdesign-make-assemble-sell

Technology Enabler

Electricity Interchangeable parts

Process Enabler

Machine Tools

Moving Assembly

Line & DML

Adapted from Jovane et al., CIRP Annals 2003

1.4. Introduction: Flexible production

Paradigm Flexible Production

Paradigm started

~1980

SocietyNeeds

Variety of Products

MarketSupply > Demand

Smaller volume per product

Business Model

Push-Pulldesign-make-sell-assemble

Technology Enabler

Computers

Process Enabler

FMS Robots

Adapted from Jovane et al., CIRP Annals 2003

LOAD / UNLOAD PARTS

TOOL STORE

OPERATORSPART

STORAGE

TOOL TRANSPORTATION

MACHINING CENTRES

RGV

1.5. Introduction: Mass customisation & personalisation


Mass Customization

and Personalization

Paradigm started

~1850 2000

SocietyNeeds

Customized products

Customized Products


product

GlobalizationFluctuating

demand

Business Model

Pullsell-design-

make-assemble

Pulldesign-sell-

make-assemble

Technology Enabler

Electricity Information Technology

Process Enabler

Machine Tools Reconfigurable Manufacturing

Systems

® ITIA-CNR

1.6. Introduction: Evolution of production paradigms

Moving Assembly

Line & DML

Reconfigurable Manufacturing

Systems


Mass Production

Flexible Production

Mass Customization & Personalization

Sustainable Production

Paradigm started

~1850 1913 ~1980 2000 2020

SocietyNeeds

Customized products

Low cost products

Variety of Products

Customized Products

Clean Products


product

Demand > SupplySteady demand

Supply > Demand

Smaller volume per product

GlobalizationFluctuating

demandEnvironment

Business Model

Pullsell-design-

make-assemble

Pushdesign-make-assemble-sell

Push-Pulldesign-make-sell-assemble

Pulldesign-sell-

make-assemble

Pull Design for environment-sell-make-assemble

Technology Enabler

Electricity Interchangeable parts

Computers Information Technology

Nano/Bio/Material Technology

Process Enabler

Machine Tools

FMS Robots Innovative Manufacturing

Jovane et al., CIRP Annals 2003

1.7. Introduction : The Transparent Factory

• Insert VW film here. Originally from : Megaworld Germany, TV programme.

1.8. Introduction: Manufacturing drivers for the future

1. Cost efficiency, with extensive adoption of standards in resources and controls.

2. Optimised consumption of resources through the use of energy and material efficient processes and machinery, renewable power sources, and smart energy management with extensive recovery of heat and dissipated energy.

3. Short time-to-market, enabled by ICT applications, which will increasingly be relevant in manufacturing industries.

4. Increased focus on high added value components/goods through the use of enabling processing technologies and enhanced materials.

5. Adaptability/re-configurability through a modular approach in production systems, in order to maximise autonomy and interaction capability of machinery and continuous re-use of existing infrastructures.

(EU FoF PPP Strategic Multi-annual Roadmap)

1.9. Introduction: Manufacturing drivers for the future cont.

6. Higher and more stable product quality through increased processrobustness and accuracy, while ensuring an easy processmaintainability;

7. Higher productivity under enhanced safety and ergonomics conditions,through an upstream integration in factory design of workplaceoptimisation for human well-being;

8. Increased reusability of production systems towards globalinteroperable factories, which are able to provide services and developproducts anytime and anywhere, independently of the technologies,culture or language in different production sites;

9. New Products, requiring new manufacturing technologies adapted tonew features.

(EU FoF PPP Strategic Multi-annual Roadmap)

1.10. Introduction: Challenges in manufacturing


1

24

Standards

Value

Time

Transformation

Manufacturing Products

By-Products(Waste, Emissions)

Machines People Knowledge

Material

Energy

3

5 6 7

8

9

2. State-of-the-Art (SOA) in manufacturing

• Reconfigurable Manufacturing

• Interoperable Manufacturing

• Sustainable Manufacturing

• Personalised Manufacturing

• Digital Manufacturing

• Virtual Manufacturing

• Ubiquitous Manufacturing

2.1. SOA: Reconfigurable manufacturing



Operation 1 Operation 2 Operation 3 Operation 4 Operation 5

Operation 1 Operation 2 Operation 3 Operation 4 Operation 5

Mc 1a

Mc 1b

Mc 1c

Mc 1d

Mc 1e

Mc 1f

Mc 2a

Mc 2b

Mc 2c

Mc 2d

Mc 3b

Mc 3a

Mc 3c

Mc 3d

Mc 3e

Mc 3f

Mc 4a

Mc 4c

Mc 4d

Mc 4b Mc 5b

Mc 5a

Mc 5c

Mc 5d

Work Out

Work In

2.2. SOA: Interoperable manufacturing : The Drivers!

Boeing 787 part and sub-assembly manufacturers (Source: Adapted from the Seattle Times)

2.2. SOA: Interoperable manufacturing : The Drivers!

Global Enterprises want to seamlessly transfer part information to production venues regardless of location or resource specification.

2.2. SOA: Interoperable manufacturing: The Drivers!

Representation of Range of Manufacturing Resources

in a Typical Sub-Contract SME.

2.2. SOA: Interoperable manufacturing : AS IS and TO BE

Total Interoperability in a CAx Network

2.2. SOA: Interoperable manufacturing: platforms

Interoperability platforms rely on:

-Internal representations for modelling manufacturing data.

-Translators for reformatting existing data to the syntax used internally by the platform and vice versa.

-Communication entities to allow data to be saved and loaded by various manufacturing systems.

Adapted from Newman and Nassehi 2007

2.3. SOA: Sustainable Manufacturing



2.4. SOA: Personalised manufacturing

CAD/CAM for Mass Produced Sole & Mould

Injection Moulding

Mass Produced

Soles

Machine Mould

CAD/CAM for aCustomised Sole

FreezeBillet

Material

CryogenicCooled Fixture

PersonalisedSoles

MachineSoles

Ortho Plan


• Scan User DefinedProduct Data at Source

• Generate Personalised Product Design

• Create Machine Cryogenic Process Plan

• Interpret Cryogenic Process Plan for targeted machine (at Source)

• Manufacture masspersonalised product (at Source)


• Scan User DefinedProduct Data at Source

• Generate perosnalised Product Design

• Create Machine Cryogenic Process Plan

• Interpret Cryogenic Process Plan for targeted machine (at Source)

• Manufacture masspersonalised product (atSource)

2.5. Digital Manufacturing

Digital Manufacturing:

The use of digital technologiesin:-

• Design, • Planning and • Management activities in

manufacturing.

2.6. Virtual Manufacturing

Virtual Manufacturing: The use of virtual reality in various aspects of manufacturing.

2.7. Ubiquitous Manufacturing (UbiDM )

UbiDM: combining ubiquitous computing & manufacturing. (S-H Suh,POSTech)Ubiquitous computing is defined as "machines that fit the human environment instead of forcing humans to enter theirs.“(York & Pendharkar)

2.7. Ubiquitous Manufacturing (UbiDM )

UbiDM: combining ubiquitous computing & manufacturing. (S-H Suh,POSTech)

2.8 State of the Art in Manufacturing

• Reconfigurable Manufacturing

• Interoperable Manufacturing


• Personalised Manufacturing

• Digital Manufacturing

• Virtual Manufacturing

• Ubiquitous Manufacturing

These approaches focus on a subset of challenges.

SMART manufacturing of the future should focus an ALL!


SMART • Clever: showing intelligence and mental alertness

• Keen: shrewd and calculating in business and other dealings

• Well-groomed: having a neat and well-cared-for appearance

Albert Einstein, Scientist


SMART • Clever: showing intelligenceand mental alertness

• Keen: shrewd and calculatingin business and other dealings

• Well-groomed: having a neatand well-cared-for appearance

Ana Patricia Botín, Business woman


SMART • Clever: showing intelligenceand mental alertness

• Keen: shrewd and calculatingin business and other dealings

• Well-groomed: having a neatand well-cared-for appearance

Rafael Nadal, Tennis Player


SMART • Clever: showing intelligence and mental alertness

• Keen: shrewd and calculating in business and other dealings

• Well-groomed: having a neat and well-cared-for appearance

Steve Jobs, CEO Apple



1. Smarter products

2. Smarter value adding

3. Smarter materials

4. Smarter usage of energy

5. Smarter machines and tools

6. Smarter integration of people

7. Smarter management of knowledge

8. Smarter re-use and recycling

9. Smarter standards

The factories of the future should be alert and show intelligence in business processes as well as technical processes while creating a pleasant environment to foster creativity for humans who interact with them.

3.1. Smart factory of the future: Products

• Products Need to be reused easily !!

3.2. Smart factory of the future: Added value

Westkamper / Constantinescu, 2010

3.3. Smart factory of the future: Materials

• Smart materials are materials that have one or more properties that can be significantly changed in a controlled fashion by external stimuli, such as stress, temperature, moisture, pH, electric or magnetic fields.

• Self-healing materials are a class of smart materials that have the structurally incorporated ability to repair damage caused by mechanical usage over time. (shape memory alloys)

• Materials that can be Eco-Friendy (Cradle to Cradle)• New processes enable new materials to be manufactured

economically (i.e. cryogenics).

3.4. Smart factory of the future: Energy

Vijayaraghavan and Dornfeld 2010

3.5. Smart factory of the future: Machines and tools

3.5. Smart factory of the future: Machines and tools

"Intelligent machines are capable of adapting their goal-oriented behaviourby sensing and interpreting their environment, making decisions and plans, and then carrying out those plans using physical actions“

Source : The Center for Intelligent Machines (CIM), at McGill University

An intelligent machine tool should display some of the same characteristics as human intelligence:

• Adaptation to changing conditions, i.e. the ability to learn from experience and use different processes in the future• Integration of sensory input with stored models. Our eyes, ears etc. provide input, which is interpreted, based on a stored world model• Extensive information processing capability• A sophisticated storing knowledge system

Source : IPROMS NoE – PAC Roadmap by Fatronik

3.6. Smart factory of the future: People

Smarter integration with people.

IPA, Westkämper Constantinescu 2010

3.7. Smart factory of the future: Knowledge

Westkämper & Constantinescu, 2010

3.8. Smart factory of the future: Re-use and recycling

Yoshikawa, 2008

3.9. Smart factory of the future: Standards

• New standards for environmentally efficient manufacturing resources

• New standards for the design of the Digital factory including emissions

• Standards for Cradle to Cradle Products • ECO labels for processes & factories

4.1. Smarter factories of 2030

• Self-Diagnosing: The factory has the ability to diagnose itself and determine what is wrong.

• Self-Healing: Building on Self-Diagnostics the factory can take preventive measures or affect repairs.

• Social and communal: The factory is capable of exchanging information with similar factories.

• Self-Replicating: The factory can manufacture a copy of itself, either on its own or through the help of “society”

• Self-Improving: The factory can make decisions to improve its abilities.

• Self-Aware: The factory becomes aware of its own existence.

4.2. Smarter factories of 2030

If the machines become “smart”, will they be friendly with us?

For me science fiction is a way of thinking, a way of logic that bypasses a lot

of nonsense. It allows people to look directly at important subjects.

- Gene Roddenberry, creator of "Star Trek"

5. Conclusions

• Need to design factories as products• Factories need to be Self Aware

– Resource Awareness– Production Context Awareness– User Awareness

• Factories need to use technologiesto support people

• Factories need which areGreen, Knowledge Intensiveand Smart!

Questions

Documents

Vigo SMART Factories Keynote STN AN v5 · 3. Smart factory of the future 1. Smarter products 2. Smarter value adding 3. Smarter materials 4. Smarter usage of energy 5. Smarter machines