changes and trends advanced manufacturing...• diagnosis-on demand • disposable device the size...

GE Global Research

Changes and TrendsAdvanced ManufacturingChristine FurstossOctober 9, 2013

© 2013, General Electric Company

“I find out what the world needs,then I proceed to invent it.”-Thomas Edison

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Date appears here© 2013, General Electric Company

GE today

Oil & Gas Power & Water

Energy Management

Transportation

Healthcare

Aviation

Home & Business Solutions GE Capital

Technology fueled by GE Global Research

GE Global ResearchThe technology development arm for GE

• First U.S. industrial lab

• Market-focused R&D for all products

• One of the world’s most diversified industrial research organizations

• 8 global sites


Global environment

Must innovate differently

Materials … rising costs & supply constraints

Labor … increasing costs in thedeveloping world

Product development … shorter cycle times, more price points

Production … overcapacity in most industries

+


Forces changing manufacturing

Supply chain is being redefined

Hardware meets software new class of innovators, entrepreneurs emerging →

3D printing, desktop design, virtual manufacturing

Moonshot v. incremental thinking capacity to innovate is much greater→

faster prototypingmore creative collaborations raising expectations

Democratization of global and distributed manufacturing engaging more innovators →

showing average folks what’s manufacturablebuilding products earlier


Reponse…3rd Industrial Revolution

3D printing is changing business models- 1st paradigm change in 30 years … and 30 years in the making

Industrial internet meets manufacturing

Anyone can be a manufacturer … Maker movement, GE Garages and growing

Manufacturing as a Service ….companies such as Plethora, Panoko, and growing

Digital thread makes all of this possible

Brilliant Factory

Virtual Product Design

Virtual Manufacturing

The “Brilliant” Factory

Service/Repair Shop

Supply Chain Network

A “digital thread” forms the 21st Century Assembly Line for Smart Manufacturing


Brilliant Machines…

Condition Based Maintenance

Prognostic&

health

Big Data&

Analytics

Dynamic Factory

…Towards a more Predictable Future

Process Informatics… Quality, FTY

Adaptive machining… Speed, Flexibility

Real Time Communication… Productivity

Real Time Factory Opt… Throughput

… Through Sensor Enabled Automation…


Smart Manufacturing at workDurathon Battery Plant

• 10,000+ sensors measure temperature, humidity, air pressure and machine operating data.

• The swipe of a finger can prevent machine malfunctions and adjust processes.

The result? Continuously improving efficiency & quality at speed


Smart Manufacturing at workDurathon Battery Plant

Powered by data, reimagined battery manufacturing

……. be traced back to batches of powder …..

….. and analyzed at every step in between.

Battery performance can…..


Distributed manufacturingCross continents digitally, produce and deliver locally

CustomerService Shop

Digital data transmissionPhysical production & delivery of parts

Local production Local delivery


Additive … the next Assembly Line?

• Enables smart and distributed manufacturing

• A complete transformation in how products are made

• Not just a set of tools for big industry

*CFM’s LEAP Engine …1st jet engine with 3D printed parts

* A 50/50 joint company between Snecma and GE

GE Aviation (Morris Technologies)Additive Manufacturing Facility in Cincinnati, Ohio


“Complexity is free”

South African carpenter and designer develop affordable 3D Printed artificial hand

Photo credit: AP

Photo credit: Robohand

Who manufactures and where they do itcan be almost anyone, anywhere


Specialty materials driving manufacturing needs

Specialty automation

Printed sensors

Materials sustainability

Specialty castings

Ceramic matrix composites (CMCs)

Silicon carbide (SiC)

Size, weight, durability, performance


Material Sustainability…a driving force

Manufacturing efficiency … reduced waste, recycled waste, advanced manufacturing (e.g., additive)

Recycle … manufacturing shrinkage and end-of-life products, repair, re-manufacturing

• Advanced materials used to optimize product performance

• Material crises - more frequent, costly, and distracting

• Supply and price risk driving change in behaviors

Partnerships likely to meet these needs

Y, Ce, TbLa, Eu

Nd, Dy, Tb


Specialty processes

Electrochemical processes

Learning the value of finer and finer features

Advanced lasers (machining, welding,

joining)

Water jet machining In process sensing and inspection

3D painting/cold spray+ Surface engineering


Healthcare … changing footprint

• Diagnosis-on demand

• Disposable device the size of playing cards

• Remote use in the field to detect infectious diseases

Network becoming more highly distributed

• 3D printed ultrasound probe – cost, accessibility

• Equipment for rural, remote settings

• Flexible electronics the next wave

• The next frontier in pharmaceuticals

• Drug production on demand

• Sensors and infrastructure


GE pursuing more open innovation approach


Manufacturing ecosystem


What the industrial R&D ecosystem needs to accomplish …

Make a step change in efficiency of innovationMake a step change in efficiency of innovation

Rebuild talent pipelineRebuild talent pipeline

1

2

• Ability of innovators and entrepreneurs (small + medium-sized companies) to integrate into the complexity of the supply chain

• Visibility to and easier way to assess and guide the development of creative ideas

• Making manufacturing and material science cool & exciting for students & faculty

• Funding of applied research in manufacturing & materials

Must address both: Innovation efficiency Now Talent pipeline in 5-6 years


Speed to competitiveness and jobsNeed to drive manufacturing R&D ecosystem approach

Provide U.S. semiconductor industry with capability for world

leadership in manufacturing

Government and industry consortium for basic and

applied research

Competitive U.S. industry Moved from Government

funding; still vibrant

Goal

Outcome

Approach

Industrial R&D ecosystem approaches

SEMATECH Global Models


What we’ve learned …Don’t fear the democratization of manufacturing, help shape and define it

Evolutions in materials and processes will define future needs

Find strength in numbers … become more connected into manufacturing ecosystems

Edison - take the system view


changes and trends advanced manufacturing...• diagnosis-on demand • disposable device the size...

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