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»Best practices of research in Manufacturing«

Hans F. Jacobi

Conference »Amplifying Competitiveness in Manufacturing in Malta«

ERDF083 – Manufacturing Research Platform

23rd November 2011

Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA, Stuttgartwww.ipa.fhg.de

Graduate School of excellence for adv. Manufacturing Engineering GSaME, Universität Stuttgart

www.gsame.uni-stuttgart.de

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»Best practices of research in Manufacturing«Table of contents

1 Definition »Best practice «

2 Fraunhofer-Gesellschaft 2.1 Fraunhofer- Gesellschaft taken as a whole2.2 Fraunhofer Innovation Cluster

3 Graduate School of Excellence advanced Manufacturing Engineering (GSaME)

4 Summary

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Definition of Best Practice

»Best Practice is the most effective and efficient, thus, the optimal method, to achieve a goal or to fulfill a task.

Benchmarking is a way to determine the specifics of Best Practices.

An organization can approach Best Practice either as a whole or in a specific field

only. Continuous improvements are performed for that.

World-Class-Manufacturing is related to Best Practice in producing companies.

In general, a market leader can be characterized as Best-in-Class«

On the basis of: http://www.onpulson.de/lexikon/466/best-practice/

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Definition of Best Practice

Best Practice

Best Practice

Bench-markingBench-

marking

Intercompany

comparisons

Intercompany

comparisonsPublic

RelationsPublic

Relations

Performance Indicators

Performance Indicators

DantotsuDantotsu

Good Governance

Good Governance

PRGFPRGFNew world

finance structure

New world finance

structure

Global Governance

Global Governance

BudgetBudget

PRGF: The Poverty Reduction and Growth Facility - IMF

On the basis of: http://www.onpulson.de/lexikon/466/best-practice/

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»Best practices of research in Manufacturing«Table of contents

1 Definition »Best practice «

2 Fraunhofer-Gesellschaft 2.1 Fraunhofer-Gesellschaft taken as a whole2.2 Fraunhofer Innovationscluster

3 Graduate School of Excellence advanced Manufacturing Engineering (GSaME)

4 Summary

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The German Research Landscape

Applied Research

Fundamental Research

predominently institutional predominantly private

Characteristics of Research

Funding

Federal/German Länder Institutes0,9

HGF*2,63

WGL*1,3

Univer-sities9,2

Industry (internal and external expenditures)

55,41AiF~ 0,25

Fraunhofer* 1,63

MPG*1,662

*overall budget in billion euros

HGF Hermann von Helmholtz-GemeinschaftWGL Wissenschaftsgemeinschaft Gottfried Wilhelm LeibnizAiF Arbeitsgemeinschaft industrieller ForschungsvereinigungenMPG Max-Planck-Gesellschaft Source:

Stifterverband für die Deutsche Wissenschaft, Destatis

1 estimation Wissenschaftsstatistik 2008, Stifterverband2 20083 2009

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Joseph von Fraunhofer (1787-1826)

Director and partner in a glassworks

Discovery of the “Fraunhofer lines” in the solar spectrum

New methods for processing lenses

Research volume: approx. €1.66 billion annually

Research and development on behalf of industry and state

mp3 music format, white LED, high-resolution thermal camera

Researcher

Inventor

Entrepreneur

The Fraunhofer-Gesellschaft(since 1949)

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The Fraunhofer-Gesellschaft in Germany 60 Institutes more than 18,000 employees An annual research volume of €1.66

billion, of which €1.4 billion is generated through contract research.

2/3 of this research revenue derives from contracts with industry and from publicly financed research projects.

1/3 is contributed by the German federal government and the Länder governments in the form of institutional financing.

International collaboration through representative offices in Europe, the US, Asia and the Middle East

München

Holzkirchen

Freiburg

Efringen-Kirchen

FreisingStuttgart

PfinztalKarlsruheSaarbrücken

St. IngbertKaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

EuskirchenAachenSt. AugustinSchmallenberg

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

CottbusMagdeburg

Halle

Fürth

Wachtberg

Ettlingen

Kandern

Oldenburg

Freiberg

Paderborn

Kassel

GießenErfurt

Augsburg

Oberpfaffenhofen

Garching

Straubing

Bayreuth

Bronnbach

Prien

Hamburg

Leuna

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Subsidiary Center

Representative Office Senior Advisor

Project Center / Strategic Cooperation

Dubai

Bangalore

Jakarta

Beijing SeoulTokyo

BostonPlymouth

East LansingSan José

NewarkMaryland Cairo

Selangor

Santiago de Chile

Singapore

Cambridge

Brusselsl

Porto

Vienna

Bolzano Graz

Paris

Budapest

Wrocław

Gothenburg

Thessaloniki

Sydney

London

Fraunhofer worldwide

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The Fraunhofer-Gesellschaft Research and development

Application-oriented research of direct use to businesses and for the benefit to society Application-oriented basic research Departmental research for the German Federal Ministry of Defense

Business community Institutes work as profit centers One-third of the budget consists of income from industrial projects Spinoffs by Fraunhofer researchers are encouraged

Contracting partners/clients Industrial and service companies Public sector

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7 Groups:

Information and Communication Technology

Life Sciences

Microelectronics

Light & Surfaces

Production

Materials and Components – MATERIALS

Defense and Security

60 Institutes

more than 18,000 employees

The Profile of the Fraunhofer-Gesellschaft

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Materials and Components - MATERIALS (founded 1997) EMI, Freiburg IAP, Potsdam IBP, Stuttgart ICT, Pfinztal IFAM, Bremen IKTS, Dresden ISC, Würzburg ISE, Freiburg

ISI, Karlsruhe IWM, Freiburg IZFP, Saarbrücken LBF, Darmstadt WKI, Braunschweigguests: ITWM, Kaiserslautern IGB, Stuttgart

Production (founded 1998) IFF, Magdeburg IML, Dortmund IPA, Stuttgart IPK, Berlin

IPT, Aachen IWU, Chemnitz UMSICHT, Oberhausen

Light & Surfaces (founded 1998) FEP, Dresden ILT, Aachen

IOF, Jena IPM, Freiburg

IST, Braunschweig IWS, Dresden

Life Sciences (founded 2000) IBMT, St. Ingbert IGB, Stuttgart IME, Schmallenberg,

Aachen

ITEM, Hannover IVV, Freising IZI, Leipzig EMB, Lübeck

ICT Group (founded 2001) FIRST, Berlin FIT, St. Augustin FOKUS, Berlin IAIS, St. Augustin IAO, Stuttgart IDMT, Ilmenau IESE, Kaiserslautern IGD, Darmstadt IOSB, Karlsruhe ISST, Berlin

ITWM, Kaiserslautern MEVIS, Bremen SCAI, St. Augustin SIT, Darmstadt FKIE, Wachtbergguests: ESK, München HHI, Berlin IIS, Erlangen

Microelectronics (founded 1996) CNT, Dresden EMFT, München ENAS, Chemnitz ESK, München HHI, Berlin IAF, Freiburg IIS, Erlangen IISB, Erlangen IMS, Duisburg

IPMS, Dresden ISIT, Itzehoe IZM, Berlin FHR, Wachtbergguests: Fokus, Berlin IDMT, Ilmenau IZFP, Saarbrücken

Defense and Security (founded in 2002)

EMI, Freiburg IAF, Freiburg ICT, Pfinztal

INT, Euskirchen FHR, Wachtberg FKIE, Wachtberg IOSB, Karlsruhe

guests: IIS, Erlangen HHI, Berlin ISI, Karlsruhe

Fraunhofer Groups147

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1475

1753

1753

939939

464464

482482

1506

1506

Total scientific staff 2010

Total scientific staff 2010

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Materials and Components - MATERIALS (founded 1997) EMI, Freiburg IAP, Potsdam IBP, Stuttgart ICT, Pfinztal IFAM, Bremen IKTS, Dresden ISC, Würzburg ISE, Freiburg

ISI, Karlsruhe IWM, Freiburg IZFP, Saarbrücken LBF, Darmstadt WKI, Braunschweigguests: ITWM, Kaiserslautern IGB, Stuttgart

Production (founded 1998) IFF, Magdeburg IML, Dortmund IPA, Stuttgart IPK, Berlin

IPT, Aachen IWU, Chemnitz UMSICHT, Oberhausen

Light & Surfaces (founded 1998) FEP, Dresden ILT, Aachen

IOF, Jena IPM, Freiburg

IST, Braunschweig IWS, Dresden

Life Sciences (founded 2000) IBMT, St. Ingbert IGB, Stuttgart IME, Schmallenberg,

Aachen

ITEM, Hannover IVV, Freising IZI, Leipzig EMB, Lübeck

ICT Group (founded 2001) FIRST, Berlin FIT, St. Augustin FOKUS, Berlin IAIS, St. Augustin IAO, Stuttgart IDMT, Ilmenau IESE, Kaiserslautern IGD, Darmstadt IOSB, Karlsruhe ISST, Berlin

ITWM, Kaiserslautern MEVIS, Bremen SCAI, St. Augustin SIT, Darmstadt FKIE, Wachtbergguests: ESK, München HHI, Berlin IIS, Erlangen

Microelectronics (founded 1996) CNT, Dresden EMFT, München ENAS, Chemnitz ESK, München HHI, Berlin IAF, Freiburg IIS, Erlangen IISB, Erlangen IMS, Duisburg

IPMS, Dresden ISIT, Itzehoe IZM, Berlin FHR, Wachtbergguests: Fokus, Berlin IDMT, Ilmenau IZFP, Saarbrücken

Defense and Security (founded in 2002)

EMI, Freiburg IAF, Freiburg ICT, Pfinztal

INT, Euskirchen FHR, Wachtberg FKIE, Wachtberg IOSB, Karlsruhe

guests: IIS, Erlangen HHI, Berlin ISI, Karlsruhe

Fraunhofer Groups147

5

1475

1753

1753

939939

464464

482482

1506

1506

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Adaptronics

Ambient Assisted Living AAL

Building Innovation

Digital Cinema

E-Government

Energy

Food Chain ManagementAdditive Manufacturing

Cloud Computing

AdvanCer

Nanotechnology

Simulation

Optic Surfaces

Photocatalysis

Polymer Surfaces POLOCleaning Technology

Water Systems (SysWasser)

Traffic and Transportation

Vision

Automobile Production

Lightweight Structures

Embedded Systems

Fraunhofer Alliances

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PRODUCTION AND ENVIRONMENTAdditive manufacturing: tailor-made products

The Fraunhofer Additive Manufacturing Alliance develops new manufacturing techniques which companies can use to launch products quickly and efficiently.

Components are created directly from the design data – they are constructed layer by layer from powder

Ten institutes cover the entire process chain

Areas of activity: engineering, materials, technologies and quality

Example: High-tech helper for industrial applications – a bionic handling assistant that mimics an elephant's trunk (winner of the 2010 German Future Prize)

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Health and nutrition Affordable healthcare

Challenges – ”The Markets Beyond Tomorrow”

Safety and security Disaster prediction and management

Information and communication

Mobility and transportation Low-emission, reliable mobility in urban areas

Energy and living Low-loss generation, distribution and use of electricity

Production and environment Life-cycle production

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Fraunhofer electromobility systems researchFocusing on the following main areas

Funding from the Federal Ministry of Education and Research as part of Germany’s second economic stimulus program

Total budget: EUR 34.5 million Project leader: Prof. Dr. Ulrich Buller (Senior Vice President of Research

Planning at the Fraunhofer-Gesellschaft) General coordinator: Prof. Dr. Holger Hanselka (Director, Fraunhofer LBF)

Secretariat: Dr. Michael Jöckel (Fraunhofer LBF) Duration: until June 30, 2011

Energy storage technology

Technical system integration / socio-

political issues

Function, reliability, testing and

implementation

Energy generation, distribution and

conversionVehicle

concepts

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PRODUCTION AND ENVIRONMENT

We conduct research in the following areas:

Production that saves energy & raw materials

Product development

Manufacturing technologies/methods

Measurement and test engineering

Automobile and plant engineering, robotics

Production processes

Materials and surfaces

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BEYOND TOMORROW PROJECTS Life-cycle production

Resource scarcity in Germany

Global conflicts over access to rare earths

Reuse offers enormous potential for savings

Clean tech is gaining ground

Production and plant engineering are the backbones of German industry

Demand for raw materials

Production technology

Efficiency and productivity

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Goals

To establish new fields of technology

To secure technological leadership through networked collaboration among the institutes

Principles

Supplemental project-related basic financing andcommitment of additional business income of the institutes

Project funding in internal competition pursuant to transparent rules and procedures

Including funding for high-risk projects

Funding

15% of institutional funding from German federal and Länder governments

Internal programs

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Economically Oriented Strategic Alliances (WISA)

Joint strategic internal research projects with the goal of achieving leadership in a specific field of technology/market segment

Market-Driven Prospective Research (MAVO)

Scientifically demanding, long-term prospective research by several institutes, aimed at certain markets

Internal SME-Oriented Research (MEF)

Acquisition of expertise in new and existing fields of activity relevant to SMEs

ATTRACTTargeted recruitment of outstanding external researchers with innovative ideas

Overview of internal programs

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Designed for immediate application

Project size € (million)

Attract

R&D character

1

2

3

4

Program size

MEF

MAVO

WISA

Forerunner, high risk

Positioning of the internal programs

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Recruiting program “Fraunhofer Attract”

What is “Fraunhofer Attract”? € 2.5 million Budget over 5 years to establish a new research group at a Fraunhofer Institute in Germany

Freedom to develop fundamental ideas and findings towards industrial application at Fraunhofer

Superior equipment and infrastructure for the research group embedded in a suitable Fraunhofer Institute

500

T€

250

t0 1 2 3 4 5

Funding central grant

Funding Fraunhofer Institute

Start Establishment Growth

revenue of group

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Spinoffs as a third path for utilization to activate and maximize commercialization potential

Returns through spinoffs (R&D orders, licensing proceeds, dividends and exit income)

Creating cooperative networks between Fraunhofer institutes and spinoffs

Promoting entrepreneurial thinking and a culture of founders

Contractresearch for

industry

Creating businesses/spinoffs

Licensing

Goals of Fraunhofer Venture

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Spin-off

Sponsoring the spinoff

Optimizing the business plan

Access to innovations

Capital procurement

Cooperation arrangements with industry and research

Fraunhofer Institute

Utilization of institute technologies

Networks to high-tech companies

Investment/exit/license/R&D income

Prospects for employees

Market expertise

Fraunhofer-Gesellschaft

Promoting Germany as a technology location

Creating jobs

Innovation transfer

Maintaining the Fraunhofer image

A bundling of interests brokered by Fraunhofer Venture

Win-win situation

Groups with an interest in founding a spin-off company

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From a small association to the leading organization for applied research in Europe

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MP3 – A data format conquers the internetToday, MP3 is the common abbreviation for the ISO/IEC standard for compressing of digital audio signals.

MPEG Audio Layer-3 (abbr: MP3) allows the compression of music signals to to 8% of the usually needed data volume with almost no audible changes to the original signal.

Deutscher Zukunftspreis 2000

Development of sound recordingDevelopment of sound recording

http://www.sxc.hu/http://informationquickfind.com/

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The Federal President’s prize for achievements in technology and innovation in 2010

cooperation of Festo and Fraunhofer IPA

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The Federal President’s prize for achievements in technology and innovation in 2010

Bionic Handling Assistant

Joint triple actuator structures and movable hand axis

High number of virtual degrees of freedom

Deflection by air ducts (compressed air)

Flexible structural elements of plastic material

Adaptive gripping

low moving mass due to lightweight construction

Safe assistance system

Ideal for human-machine-interaction

Modeled on an Elephant’s Trunk – A High-tech Helper for Industry and the Home

cooperation of Festo and Fraunhofer IPA

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The Federal President’s prize for achievements in technology and innovation in 2010

cooperation of Festo and Fraunhofer IPA

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The most active patent applicants 2010Applicant Patent Apps.* HQ

1. Robert Bosch GmbH 3477 D

2. Daimler AG 1917 D

3. Siemens AG 1654 D

4. GM Global Technology Operations Inc. 1540 USA

5. Schaeffler Technologies GmbH & Co. KG 1249 D

6. BSH Bosch und Siemens Hausgeräte GmbH 931 D

7. Volkswagen AG 664 D

8. ZF Friedrichshafen AG 629 D

9. Bayerische Motoren Werke AG 602 D

10. Audi AG 597 D

11. Denso Corp. 489 JP

12. Porsche AG 443 D

13. LuK Lamellen und Kupplungsbau Beteiligungs KG 392 D

14. Continental Automotive GmbH 375 D

15. Fraunhofer-Gesellschaft 368 DQuelle: Deutsches Patent- und Markenamt, Stand April 2011* Anzahl der im Jahr 2010 eingereichten Patentanmeldungen ohne Berücksichtigung evtl. Konzernverbundenheiten

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Inventions disclosed by and patents issued to the Fraunhofer-Gesellschaft

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Fraunhofer as a Harvard Business School Case StudySince April 2011, the innovation model Fraunhofer is taught as a case study in the standard MBA Program of Harvard Business School.

Fraunhofer: Innovation in GermanyDiego Comin, Gunnar Trumbull, Kerry YangHarvard Business School Revised: September 8, 2011

Learning Objective:Teach about how to organize research, in particular applied research…

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»Best practices of research in Manufacturing«Table of contents

1 Definition »Best practice «

2 Fraunhofer-Gesellschaft 2.1 Fraunhofer-Gesellschaft taken as a whole2.2 Fraunhofer Innovationscluster

3 Graduate School of Excellence advanced Manufacturing Engineering (GSaME)

4 Summary

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Accelerating innovation by creating regional focuses: Reinforcing strengths Creating beacons of research

UniversityBasic Research

IndustryR&D for

Products and Services

FraunhoferApplied

Research

Teamwork

Research Area – Region – Fraunhofer

Fraunhofer innovation clusters

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Successful and visible engagement in research areas by Fraunhofer A forum for effectively showcasing technologies that have made the transition from

research to industry

The inclusion of Germany’s Länder in the appraisal process reinforces the bond Fraunhofer has with each Land

19 approved Fraunhofer innovation clusters to date

Funding distributed within the framework of Pact II (Pact for research and innovation): 50 percent to industry, 25 percent to the Land, and 25 percent to Fraunhofer

Max. EUR 2 million funding when one Fraunhofer institute takes part, max. EUR 3 million when more than one Fraunhofer institute takes part

Fraunhofer innovation clustersExperiences with existing innovation clusters to date

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Fraunhofer innovation clusters Distribution of Fraunhofer funds between Groups

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Digital Production …… comprises the implementation, connection and operation of product- and production-related strategic und operational processes of industrial enterprises by means of information technologies. Objective is to accelerate processes that result in cost-effective products with a higher quality.

Innovation Cluster: »Digital Production«

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1. Intelligent Productsproduction systems for theindividualization of products

2. Production in Digital Productionadaptive technologies for high-quality high-performance production

3. Adaptable Corporate Networksintelligent business processes for cooperative development and production

4. IT as Enabler of Digital Production

systems and technologies for the implementation and the support of Digital Production

5. Managing Digital Productionstrategies and methods for best-in-class production

Five themes:

Innovation Cluster: »Digital Production« - Structure

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Research and Development

New and advance development of functional modules of Digital Production

Increasing performance of Digital Production Integration of individual sub-disciplines Adoption and development of application tools

Knowledge Transfer and Services

Sector- and enterprise-specific design of Digital Productions

Accompaniment of introduction processes Methods and tools training Apprenticeships and lectures

Innovation Cluster: »Digital Production« - Results

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Lenkungskreis

Industriepartner

Fo

rsch

ung

spar

tne

rGeschäftsstelle

Einzelprojekte

QuerschnittsprojekteVerbundprojekte

Structure of the Innovationcluster »Digital Production«

Companies

Researc

h P

art

ners

Joint Projects

Specific Projects

Working Committees

Office

Steering Committee

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Software Providers

Machinery and equipment Optics and precision engineering ...

User Companies

Fraunhofer Institutes Universities Universities for applied sciences Universities of cooperative education

Knowledge Transfer and Multipliers

Automotive OEMs and suppliers Machinery and equipment Electrical industry ...

Research Institutions

Technology Providers

Open Partner Structure

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Quality of location for industry through intelligent products, efficient processes and excellent resources

A close cooperation between the government ofBaden-Württemberg, the Fraunhofer-Gesellschaft,and Industry:

Innovation Cluster »Digital Production«

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»Best practices of research in Manufacturing«Table of contents

1 Definition »Best practice «

2 Fraunhofer-Gesellschaft 2.1 Fraunhofer taken as a whole2.2 Fraunhofer Innovationscluster

3 Graduate School of Excellence advanced Manufacturing Engineering (GSaME)

4 Summary

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Participating institutions

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Research clusters in the 1st period

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Core orientation in the 1st and 2nd funding period

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Improved framework and procedure of the doctoral program

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Success of the „experiment“ GSaME

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»Best practices of research in Manufacturing«Table of contents

1 Definition »Best practice «

2 Fraunhofer-Gesellschaft 2.1 Fraunhofer taken as a whole2.2 Fraunhofer Innovationscluster

3 Graduate School of Excellence advanced Manufacturing Engineering (GSaME)

4 Summary

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»Best practices of research in Manufacturing« Definition »Best practice«

Fraunhofer-Gesellschaft is an organization, which approaches Best Practice as a whole (Research organization) and in specific research fields. - Confirmation by the positive development of the budgets, by winning prizes, by the number of patents, by authorization of Harvard University (U.S.A.) as a case study etc.

Fraunhofer-GesellschaftGroups of institutes, research alliances, internal programs, recruitment of outside scientists to join the Fraunhofer-Gesellschaft, spin-off companies ect.

Fraunhofer Innovation ClusterA regional approach: R&D in German States (Länder), strong collaboration between industry, universities and Fraunhofer institutes to put the results of research into practice

Graduate School of Excellence advanced Manufacturing Engineering (GSaME)GSaME has the status of a faculty of the University of Stuttgart with the right to confer doctorates, scheduled dissertations in four years

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Fraunhofer IPA / IFF University of Stuttgart / GSaME

Research ApplicationHigher Education Development Implementation

Experience from industry

R&D

Industry

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»Best practices of research in Manufacturing«

Thank you very much for your attention

Contact:Hans F. JacobiRepresentative Advisor to the Institute DirectorsFraunhofer Institut for Manufacturing Engineering and Automation

Cluster Co-ordinator A – Stuttgart Enterprise ModelGraduate School of Excellence advanced Manufacturing EngineeringPhone: +49 (711) 970-1231Fax: +49 (711) 970-1012hfj@ipa.fraunhofer.dewww.ipa.fraunhofer.dewww.gsame.uni-stuttgart.de