the european manufacturing industry vision and...

© WZL/Fraunhofer IPT/KU Leuven

The European Manufacturing Industry Vision and challenges

Achieving Growth through Strategic Innovation

Fritz Klocke, Professor in Production Engineering, WZL-RWTH Aachen and Head of the Fraunhofer Institute for Production Technology (Germany)

Bert Lauwers, Professor in Production Engineering KU Leuven (Belgium)

Brussels; October 3rd

Seite 1© WZL/Fraunhofer IPT/KU Leuven

Outline

The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow

Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”

Case studies– Energy– Mobility– Resource efficient Production– Life Science

Conclusion


Outline




Conclusion


Environment, climate, recources

Economy growthwelfare

Individual and collective needs

Overall balance

Source: Acatech, oct. 2007

Industrial society in strained relations

Growth trough sustainable Innovation


Each Improvement inProducts

TechnologiesMachines

OrganisationManagement

which gains Acceptance

on the Market Place

might be called

INNOVATION

Source: J. Schumpeter: Theorie der wirtschaftlichen Entwicklung, 1911Joseph Schumpeter (1883 – 1950)

Innovation - what is it about?


Stratigic Dimension - Manufacturing Matters for Europe

66% of private R&D investment

20% of direct jobs and twice as many indirect jobs

Leading source of private R,D & I funding

Biggest purchaser of ICT in Europe

Part of a complex global economic system


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

Imag

es ©

Fra

unho

fer

Markets beyond tomorrow


Henry Ford"If you always do what you've always done, you'll always get what you've always got.“

Source: Library of Congress , Henry Ford

Einstein “We can never solve problems

by using the same kind of thinking we used when we created them”


Outline


Actions taken – some initiatives – Actions taken – some initiatives – Cluster of excellence on “Integrated Production”


Conclusion


The Public-Private Partnership (PPP)‘Factories of the Future’

European level PPPs in the area of R&D&I are a cooperation by the European Commission and private partners (small, medium & large industrial enterprises, research organisations & universities)

European Commission launched ‘Factories of the Future’ PPP as the biggest initiative of its type.

Aim to strengthen European industrial base, create sustainable industry & secure jobs in Europe

‘Factories of the Future’ promotes research through a Multi-Annual Strategic Roadmap

Roadmap means that research call topics are industry-relevant

61 projects launched to date, over double this will be launched between 2012 & 2013


Present ‘Factories of the Future’ Strategic RoadmapProject Examples

ICT-Enabled Intelligent ManufacturingHigh Productivity Manufacturing

New Materials in ManufacturingSustainable Manufacturing

ActionPlanTActionPlanT aims to develop a vision on the short, medium, and long term role of Information & Communication Technologies (ICTs) in the European manufacturing industry in order to ensure its sustainable competitiveness.

MEGaFiTThe primary goal of MEGaFiT is to develop and integrate all necessary technologies which create the basis to reduce the number of defects in the manufacturing of complex high-precision metal parts.

GrafolDeveloping the first roll-based chemical vapour deposition (CVD) machine for the mass production of few-layer graphene for transparent electrodes for LED and display applications.

EMC2EMC²-Factory will develop a radically new paradigm for cost-effective, highly productive, energy-efficient and sustainable production systems.

The present roadmap sub-domains with project examples:


The European Factories of the Future Research Association (EFFRA)

Industry-driven & 100% private European association

Explaining industry needs to public authorities (partner of the European Commission)

Created by MANUFUTURE ETP and industrial associations

Safeguarding industrial relevance of EU-projects within the ‘Factories of the Future’ programme

Creates consensus on common R&D priorities

Coordinates creation of strategic research roadmap

Working on new roadmap: ‘Factories of the Future 2020’

Promoting ‘Factories of the Future’

www.effra.eu

@EFFRA_Live

EFFRA.Live


Cybernetic perspectiveDeterministic perspective

Interconnected physical and mathematical model chains

Describe and predict complex behaviour

Mechanisms, rules and structures to operate and control complex production systems

Decision-making in an uncertain environment

Modelling

Excellence Cluster Production Technology for High Wage Countries“


Holistic Modelling ApproachModular Product and Modular Manufacturing Portfolio

Process model Hybrid process modeling

F(t)f

xd

Empirical models

FEM-model

Ther

mal

pro

cess

be

havi

our

Coupled multibody simulation

Thermal machine model

Temperature distribution

Process evaluation

Stability

Tolerances

Surfaces

∆total = ∆mech + ∆therm

Mec

h. p

roce

ss

beha

viou

r

Opt

imiz

ed

NC

-pro

gram

CAM Path optimization NC-simulation Default of set-pointsx = ... (t) a = ... (t)y = ... (t) b = ... (t)z = ... (t)

OK

Work piece model

Work piece model

Yes

No

∆therm

∆mech F(t)

T(t)


Multipurpose Technology Platforms

safety housing

robot withlaser heads

high-performancespindle

swivel rotary table

Source: Excellence Cluster, RWTh-Aachen, WZL (Multipurpose Machine) Prof. Brecher

Source: Fraunhofer IPT

Source: Alzmetall, Altenmarkt


KombiMaschWorking Chamber

Laser hardening

toolLaser

welding tool

Optical fiber

Process monitoring

sensorTool revolver

(cutting)

B-axis panning

head

Cutting Laser deposition welding Laser hardening

Source: AWK, Machine Tool Colloquium 2008


Complete Machining of Components with Optimized Surface LayersKombiMasch (Machine Tool Prototype), multipurpose machine

Turning/millingdrilling

Hardmachining

Laser depositionwelding

Laserhardening

Modular design of subsystems

Fully automated machining processes

User friendly appliance

Consistent CAx data in entire process

Award winning machine tool - most innovative product in the category »process combination«


Worldwide Production Networks - Cyber Physical Networks

Vision Fusion of real and virtual environment

Fully electronically integrated business processes, intercompany and across companies

Customer integration

Challenges High performance grits

Appropiate cloud technologies

IP issues

SecurityBildquellen: WZL, Siemens, BMBF

Virtual factory

VirtualCompony networks

VirtualCustomer integration

Cyber Physical Networks

Inter- and across companies

From the shop floorto top level management


Outline


Actions taken – some initiatives – Actions taken – some initiatives – Cluster of excellence on “Integrated Production”


Conclusion


EnergyWhat does the future hold? Existing Challenges

Major change in power generation (conversion)

Major change in energy distribution, networks

Major change in energy use (consumption)

Facing the Challenges through …

Solar power

Wind power

Tidal power (tidal range, water currents, waves,…)

Fossil fuels, biofuels and biomass

Nuclear power

Fuel cellsSource: REpower


Wind Power – Key Technologyfor Reduction of Greenhouse Gases

Source: BMU, ZSW-BW

emis

sion

of g

reen

hous

e ga

ses

[%]

(com

pare

d to

199

0)

year

100

80

60

40

20

1990 2020 2030 2040 2050

targets for reduction of greenhouse gases

-40%

-55%

-70%-80-95%

import of renewable energybiomass

geothermal energy

photovoltaic

wind power

hydro power year҅05 ҅10 ҅15 ҅20 ҅30 ҅40 ҅50

gros

s el

ectr

icity

gen

erat

ion

[100

0 G

Wh/

a] 800

600

400

200

gross electricity from renewable energies

gross consumptionof electricity


Increasing Request for Wind Turbines

10

20

30

40

50

60

2011 2012 2013 2014 2015 20160

new

inst

alla

tion

of w

ind

turb

ines

[GW

]

Area:Europe

Asia

America

Rest of world

+46%

Significant increase of new installations of wind energy plants in the future

Predicted New Installations of Wind Turbines till 2016

Source: BTM Consult


gearless wind turbine

Power Train Concepts

wind turbine with gearbox

Source: Schaeffler AG

mar

ket s

hare

[%]

0

20

40

60

80

100

gearbox

2009

2014

mar

ket s

hare

[%]

0

20

40

60

80

100

gearless

20092014

With gearbox …

High number of error sources due to high number of machine parts

Less electrical components due to gear box

Without gearbox …

Higher mass of housing (high amount of copper)

High amount of rare earths leads to severe increasing wind turbine prices


Definition of Large-Scale Parts

Diameter > 500 mm Weight > 30 kg Value of Part > 1,000 €

1,02,0

Dimensions of Large-Scale Parts

80 mm

Source: Liebherr

Source: Schaeffler Source: Liebherr-Verzahntechnik

3,04,05,06,07,0

0effe

ctiv

e ou

tput

[MW

]

1985 1990 1995 2000 2005 2008

20406080

100120140

0

roto

r dia

met

er [m

]effective outputrotor diameter

1 m1.5 MW

3.6 MW

6 MWsize development of

gears


High Demand on Gears Leads to Process Substitution– Generating Gear Grinding of Wind Turbine Gears

Workpiece Module mn 9.5 mm Number of teeth z 44 Tip diameter da 450 mm Face width b 225 mm Helix angle β 8° Stock ∆s 0.4 mm/flank

Process Time Grinding time: 23,2 min Dressing time per workpiece: 5,2 min Bottom to bottom time: 28,4 min

Source: Reishauer AG

Due to the high demand on gears and the small batch productionnew manufacturing processes are developed


Outline



Case studies– Energy– Mobility– Recource efficient Production– Life Science

Conclusion


MobilityWhat does the future hold? Existing Challenges

Mobility of people and goods

Increasing traffic streams

Traffic technology uses around 30% of primary energy

Facing the Challenges through …

Combustion engines

Hybrid drives

Electric Mobility

Fuel cells

Lightweight concepts

Integrated traffic managementSource: RWE AG


Mobility drives Gear Technology

Quelle: Zukunftsinstitut

Wor

ld p

opul

atio

n[M

rd.]

6

4

2

1960 2000 year19800 C

ars

wor

ldw

ide

[Mrd

. km

]

40

30

20

10

01960 2000 year1980

Mobility

PKM = Passagierkilometer

1960: 3

1960: 3

1987: 5

1987: 5

2011: 7

2011: 7

1960: 5,5

1960: 5,5

1980: 17,4

1980: 17,4

2010: 43

2010: 43

People Growth


Investments in »Electric Mobility«

0

1000

2000

3000

4000

5000

21000

19000

20000

23000

22000in

vest

men

ts in

mill

ion

euro

s

Source: RWE AG, Koordinierungsstelle der Industrie 11/2010


Electric Mobility – Mechanical ComponentsHigh Speed Motor – High Torque Motor - Gear

Source: BMW, ZF; Cost structure: Research WZL of small cars with production costs around € 8.000

100%

Equipment

Propulsion

Body

Chassis

Others

Complete Vehicle

30-37%

22-24%

11-20%

9-12%

15-20%

Gears

Auxiliary Drives

Engine

Others

Propulsion

100%

Exhaust system8-11%

20-27%

18-22%

35-40%

7-9%

Con-rods

Camshaft

Crankshaft Engine block

Piston

Valves

Side shaft incl. synchronism

Differential

Clutch

Catalytic converterExhaust manifold

Muffler Incl. Tail pipe

Belt drive

Intake manifold

Engine electronicInjection system

Generator Cooling systemFuel tank

Oil and water pumps

Cost structure of a conventional vehicle


Innovative rolling process for the production of defined riblet structures on compressor blades

Sägezahn Riblets

Shotpeening

Ribletrolling

Source: Leistritz Turbomaschinen Technik, MTU, ThyssenKrupp

Functionality of riblets

Turbulentvortice

Large-eddy simulation (LES)

Shark skinwith riblets

Ma

Saw tooth riblets

Turbulent vortices are kept away from the enlarged surface of the riblet structure

Riblets can reduce wall friction of a turbulent flow up to 10%

Bulkforming

CastingMilling

Rawmaterial(TI6Al)

ECM

Milling


Reduction in weight – driven by new materials and design concepts

Fuel per passenger: 3.4 l / 100 km (Airbus A380)

Increasing air traffic

Highly efficient jet engines

Structure is load optimized and use of light weight materials

Materials

Source: Flight International, Reed Business Information, 2006

Layer designHoney comb structure

GFK

CFK

Aluminium

Glare (Glass-fibre reinforced Aluminium)

61% Alu20% CFK

3% GLARE2% GFK

10% Ti + Steel2% surface protection 2% miscellaneous


Spanten, Rippen, FußbodenträgerFahrwerksschächte

Share of titanium and composite materials (A350) is increasing

Door part: Titanium

Titanium in combination with CFKdue to chemical and mechanical compatibility

Source: Premium Aerotech

Door segment blue: titaniumgrey: CFPA350

Join the best suited materials together.

Role: Multi material design.

New tooling.

New production platforms.


Outline




Conclusion


Resource Efficiency Dilemma

Pro

duct

ivity

Num

ber o

f Pro

duct

s

Use of Resources

today

objective

More Goods with less Resources


People do need fresh waterfertile soil, clean air and an

intact environment

This requiresClean water technologies

Saving and recycling of water inProduction

Environmentally friendly production

Fresh water for everybody might be the most important requirement

for the future

Water – an eminent resource in production


Quelle: Bundesumweltamt / Statistisches Bundesamt


Coolants in Cutting and Grinding

Cleaning

Solvents

Electrolytes

Dielectrics

Quenching

Heat converter


Waste water free electroplating

Chlorine free lubrication

Biodegradable dielectrics

Biodegradable cutting fluids

Dry cutting

People do need an intact environment


Chlorine free fineblanking

Objective

Development of chlorine free lubricants for shearing and fineblanking processes

Application of environmental friendly/biodegradable lubricants in combination with PVD tool coatings

Coatings

Wear

Model test Industrialapplication

Simulation

Lubricants

Develop-ment

Analysis

Test


Chlorine free fineblanking – Interdisciplinary Research

Results

Complete substitution of chlorine additives in fineblanking lubricants

Reduction of the process friction with the newly developed chlorine free ester lubricants compared to conventional lubricants on mineral oil basis

Enhanced tool life due to chemcal interaction of lubricant and workpiece surface

Coatings

Wear

Model test Industrialapplication

Simulation

Lubricants

Develop-ment

Analysis

Test


Dry cutting

New coatings and tool design

New machine designs

Minimal quantity lubrication (MQL)



Dry cutting in serial production

Source: Kennametal Hertel, Fürth

Work material: Ck45Tool: SE-Drill, two level twist drill

(Ti,Al)N-coatinghole diameter 10.6 / 12.5 mm

Cutting speed: vc = 71.5 m/min (level 1)vc = 89.4 m/min (level 2)

Feed: f = 0.3 mm

12,5

10,6

28,0

6,0

12 holes

0

500

1000

1500

2000

2500

3000

1080

2760

wet dry

Num

ber o

f hol

es


Conventional process chain

Forging

Soft turning,drilling, tappingwith coolinglubricant

Gear cuttingwith

lubricationCase hardening

GrindingWith

cooling lubricantGear lapping Screwing

Forging

Soft turning,drilling, tappingwith coolinglubricant

Gear cuttingwith

lubricationCase hardening

Grinding With

cooling lubricantGear lapping Screwing

Optimisation step1.

Hard turning

2. Optimisation step

Dry gearcutting

Wet machining:Cutting material: HSS Coating: TiN

Dry gearcutting

Eliminationlubrication/ yearca. 25.000 l

Dry machining:Cutting material: VHMCoating: TiAlN

New process parameters:Feed fCutting speed vc

3. Optimisation step 3.

Soft turningwith cooling

lubricantWelding

Soft turningwith cooling

lubricant

Elimination cooling lubricantSystem, consumption/ yearEnergy: 1,15 Mio. kWhMedium: 1052 m³Filter fleece: ca. 45 t

Screwing of crown wheel: - Process drilling and tapping- central cooling lubricant system

Welding of crown wheel: - Process Elimination of drilling and

tapping- Elimination of a central cooling

lubricant system

WeldingHard turning

Source: BMW

Technology Push – Bevel Gear ManufacturingEntire Process Chain – Technological Due Diligence


Component/productGrindingMilling

Anneal-ing Assembly

Support processes

FormingSemi-finishedpart/ material

Residual materialschips, effluent,

sludgeScrap

Emissionsheat, noise, vapours,exhalation, vibrations

Energy

Resource-efficient production – the production chain as a focus

SuppliesTools

Source: IWT Bremen, Kutz + Schulz, ThyssenKrupp, AWK 2008


Examplary forming tools in deep-drawing

Source: AUDI AG

Forming tool for front doors consists of– Upper part– Lower part– Die– Blank holder– Form block

Small additional parts suchs as screws and sliding elements are not part of the balance shell


Modelmaking

Coating

Casting

Fettling

Shot Peening

Quality Check

Machining

Build Up

Tryout

Pressing

Maintenance

End-of-Life

Foun

rdy

proc

esse

sM

achi

ning

and

build

upU

sage

Life Cycle phases of the forming tool The forming tool is formed with a

lost mould– Styrofoam model is milled into final

dimensions– Appliance of refractory coating – Casting

Machining is performed with different machines (small, medium, 5-axis)

During the life cycle a sample body part has been focused:front door of a common vehicle

End-of-life phase bases on predictions and assumptions


Standardization of different energy formsStandardization

…

Pressurized Air

Heating

Electr. Energy

Nm³ / part

kWh / part

kWh / part

t / part

MJ / part

MJ / part

MJ / part

MJ / part

Sha

res

of p

rimar

y E

nerg

y co

nsum

ptio

n /

MJ/

part

Consumption Primary energy


Production of the deep drawing tool

3%

58%

Tryout

19%

Build up

16%

Fettling & Shot peening1%

Casting

Coating

0%

Modelmaking2%

Machining

Main Consumers

Casting– Melting Energy and cradle-to-gate

material are the main consumers

Machining – Significant influence on the energy

consumption due to electrical energy

– Credit for scrap metal is included

Tryout– Tryout parts which are considered

as waste material have a significant influence on the consumption

– Credit for recycling of waste material is includedShares of primary energy consumption


Whole life cycle including usage and recycling

0,3%

Sha

res

of P

rimar

y E

nerg

y C

onsu

mpt

ion

Recycling Total

1,4%0,4%

1,8%

Usage

0,8%0,4%1,1%

Foundry Processes

1,5%100,0%

98,5%

96,7%

Mainte-nance

0,3%0,3% 0,3%

Tool manu-

facturing

96,7%

MaterialEnergy(Electrical, thermal)

No coil material (workpiece) included

The most impact is located during the usage phase

The primary energy consumption during pressing exceeds the primary energy for the manufacturing of the forming tool significantly


Design Optimization of Edge Geometry in Deep-DrawingGeometric Modeling in Tool Design

Structure Optimization

Objective: weight reduction with maximum stiffness

Principle: calculation of an optimized material distribution for preexisting load case

Design Optimization

Objective: homogenizing and reduction of loads

Principle: calculation of design optimization by iterative changing surface shape

Source: TOSCA Structure 7.1 Seminar, FE-Design GmbH


Structure Optimization of Tool SystemDefinition of an Optimization Model and Results

Structure optimization with TOSCA structure software

Definition of upper tool half as design area for structure optimization

Lower tool part was not changed

Optimization Strategy: keep stiffness constant

A stiffness satiation was reached after 14 iteration steps combined with a mass reduction of 40%

upper tool half

design areanot modifiable

not designable

0

1

2

3

0 2 4 6 8 10 12 1401020304050

stra

in e

nger

y U

[MJ]

iteration n [-]

mas

s re

duct

ion

mre

d[%

]

10.50

relative materialkey value vrel [-]

mass reduction

strainenergy

Source: Bäcker, V.: Numerical Tool Optimization in Deep Drawing, Dissertation WZL, RWTH Aachen, 2011


Efficiency Loss in Automobile Gearboxes –Gear Box in Use

3

2

4

1

1

4

4

1

1

3

3

Bearing friction– Type of bearing– Preload force

Oil flow – splashing- /delivering losses

– Body shape– Oil volume– Viscosity

Gear sliding– Sliding speed– Axle offset– Lubricating film– Topography– Surface structure

Friction of gasket– Type of gasket– Material– Surface structure

1

2

3

4

1 1

111

1 1

3 3

2

44

4

axle gear 92-98%

inline-shift gearbox96-99%

input shaft

gear wheel, gear 2 driven

shaft

countershaft, gear 1

reduction gear


Efficiency Loss in Automobile Gearboxes – Gear Box in Use –Power by the hour

3

2

4

1

1

4

4

1

1

3

3

Bearing friction– Type of bearing– Preload force

Oil flow – splashing- /delivering losses

– Body shape– Oil volume– Viscosity

Gear sliding– Sliding speed– Axle offset– Lubricating film– Topography– Surface structure

Friction of gasket– Type of gasket– Material– Surface structure

1

2

3

4

1 1

111

1 1

3 3

2

44

4

axle gear 92-98%

inline-shift gearbox96-99%

input shaft

gear wheel, gear 2 driven

shaft

countershaft, gear 1

reduction gear

Geared turbofanPower: 20 MW

Performance ratio: 98-99%Heat: 200 000 – 400 000 kW


Topics for an Energy Efficient Production Increase in process stability and quality (Zero Scrap

Production)

First part right

Material efficiency in mechanical manufacturing processes and systems

Energy efficiency in thermal und chemical manufacturing processes

Closed Resource loops for all Process chains and systems

Crosslink of resources in production systems

Lossless infrastructure use of productions facilities and fabrics

Development of methods for sustainable resources

Input

Prozess

Output

Inpu

t Process-step n

Information

Material

Energy

Out

putInformation

Material

Energy

Information

Material

Energy

Information

Material

Energy

Source: EFFPRO Study from the German Federal Ministry of Education and Research; Pictures: MEV publishing company


Outline




Conclusion


Live science

Endemic diseases and customized solutions for an aging society are of top priority in national health

care systems

People do needindividual implants and limbs

pharmaceuticals and health care assistance

This requires interdisciplinarywork of biologists, medical doctors

and engineers


Automation of biotechnological processes

Traditional laboratory processes are often characterized by a high degree of manual handling operations

Traditional laboratory processes require trained laboratory personnel

The automation– Increases throughput– Increases reproducibility and process stability– Enables continuous process monitoring

The challenge:– Modification of the established manual and laboratory

procedures for the special requirements of automation– Development of adapted process concepts– Integration of individual solutions into automated systems


Cell isolation from human skin biopsiesRe-engineering of each step included in the laboratory process

Manual processing

fat separation (scalpel)

cutting of biopsy (scalpel)

incubation (dispase)

separation (tweezers)

grinding (scalpel)

incubation (trypsin/collagenase)

centrifugation

cell suspension (media)

Automated processing

filtration of epidermis

fat reduction (optional)

chopping of biopsy

incubation (dispase)

filtration of single cells

cell suspension (media)

incubation (trypsin/collagenase)

Fraunhofer IPT, Fraunhofer IPA, Fraunhofer IGB


Cell isolation module Automated cell isolation from multilayered skin tissue Technical capabilities

– Isolation of keratinocytes and fibroblasts

– Automated handling solutions for tissue and cells

– Prevention of cross contamination

Methodology– Development of a combined

enzymatic and mechanical method for skin tissue dissociation

– Development of a multifunctional filtration pipette for tissue and cell handling

– Processing and validation of prototypes under sterile conditions

– Integration in tissue factory



Integrated metrology Cell proliferationMedia analysis

Cell counting deviceOCT-system

Metrology

Status cell culture Quality assurance

Dissolved oxygen

pH-value of the mediaOptical densityDetection of bacterial contaminations

Proliferation of cells

Cell status and cell concentrations

non-invasive analysis of skin test



Tissue factory 2011

Zellisolationsmodul

Zellexpansions -modul

Gewebe -aufbau -modul

Cell isolationmodule

Cell expansionmodul

Tissue cultivation module

--



Automated biotechnological processes - prerequisite for continous process monitoring

Minimization of rejections

Collection of critical process data

(variable cell growth,..)

early error recognition

(contaminations,..)

Quality control(non destructive)

Processoptimization

Quality, time, costs


Limitations of tissue engineering processes/regenerative medicine High demand for pluripotent stem cells for research applications

Poor availability of appropriate donor tissues for research purpose

Liver tissue Kidney tissue Heart tissue Neuronal tissue …

Not enough (autologous) donor tissue/cell material available to cultivate tissue transplants

Specialized isolated cells are maturing during in vitrocultivation loss of specific cell functions

pluripotent stem cells (like embryonic stem cells) can be differentiated into all cell types and can self-renew to produce more stem cells


Project Highlight » StemCellFactory «Objectives Automated cell isolation of mesenchymal stem cells from bone marrow

and fibroblasts from skin

Automation of a manually established process for the generation of induced pluripotent stem cells iPS

Automated differentiation of iPS into neuronal stem cells (and cardiac cells)

Methodology Re-engineering and optimization of each laboratory process to enable

complete process automation

Choice and integration of all necessary commercially available functional modules

Design and development of specific functional components and handling solutions

Development and integration of metrology for inline monitoring of all cell culture processes

Envisaged outcome Development of an fully automated, modular demonstrator for the

reproducible production of iPS derived cell products

iPS cell clone on feeder cells

CAD model of the StemCellFactory


The problem of malaria infections in the world -Motivation for automated vaccine production

History of malaria infections Beginning of the 19th century: people thought that smelly

marshes are the cause of malaria 1880 researchers identified a parasite - which is transmitted by

infected mosquitos - as a trigger Middle of 20th century: malaria could be eleminated in many

contries

Status quo

Malaria is spreading to new regions of the globe and again in areas where it had been successfully suppressed

3,3 billion people are at risk, particularly in the tropics and sub-tropics

250 million cases of malaria annually

Every 45 sec. a child dies from malaria

Together with HIV/TB, malaria is the biggest hindrance to the development of the poorest countriesSource: World Malaria Report 2008. Geneva, World Health

Organization, 2008; 2006 data

Photo by CDC/James Gathany,http://www.who.int/features/factfiles/malaria/malaria_facts/en/


Info from pathogen

Info from plant virus

Recombined

TransientGeneticVehicle

Sow seedsTreat seedlings Grow in greenhouse Harvest and disrupt leaves

Purify vaccine

Stabilize and package

Vaccines from Plants

Source: Fraunhofer IME


Automated production of vaccines in tabacco plantsInfo from pathogen

Recombined

Sow seeds Treat seedlings Grow in greenhouse Harvest and disrupt leavesSource: Fraunhofer CMI, Fraunhofer IPT, Fraunhofer IME


Lab on a chip for molecular diagnostics

Fluid dynamics

Low cost and manufacture

Integrated functions– Sample input– Mixers– Bacterial lysis– Nucleic acid isolation– PCR (thermal cycling)– Optical detection

Automated instrument

Demonstrated for bacteria

Extending to influenza (RNA virus) in human nasopharyngeal aspirates

Source: Sauer-Budge et al Lab Chip, 2009, 9, 2803 – 2810, Fraunhofer CMI, Boston


Production technologyLab-on-a-Chip

Objective

Integration of PCR and fluorescence end-point detection for complete lab on a chip demonstration

Economic feasibility of end product

Methodology

Optimization of production processes to meet target costs

Design and development of tools for injection molding

Results

Ready-to-use prototype

New low cost lab on a chip technology in plastic has applications in research, point of care clinical diagnostics, food and agriculture industries

Demonstration of integrated lab-on-a-chip technology significantly improves attractiveness of technology to investors

PCR chamber

FluorescenceDetection

Mixers

DNA purification

Bacterialysis

Source: Fraunhofer CMI, Fraunhofer IPT


Project examplesensitive lab-on-a-chip for detecting TB in urine

Rapid diagnostics for TB are sorely needed

Point-of-care in limited-resource settings require automation, sensitivity, low cost

Protein biomarkers– Sensitive point-of-care diagnostic detecting

TB antigen in urine

trDNA– Modified PCR of short fragments of DNA in

urine

Source: Fraunhofer CMI, Fraunhofer IPT


Outline




Conclusion


Wait and hope!

Good things:Easy to be realized

Low budget required

DownsideBreak through inventions

happen rather seldom

Probability of success is low

Reserve the„right to play“

Sufficient investments to preserve the

competitiveness without an early determination of

further activities

Source: Courtney/ Kirkland/ Viguerie (HBR 6/97)

What willyou get?

Approach/ strategy to an innovation process


Reqiurements

Critical brain powerto get the statistics aside

Synergy effects

Different disciplines

Science and industry

Trend analysesVisions and scenarios

define a Budgetinstall change processes

Go for it - change

What willyou get? Active creation

of the futurePlaying a leading role in

determining thecompetition rules in the sector

for example:- determine standards

- generate needs

Source: Courtney/ Kirkland/ Viguerie (HBR 6/97)

Approach/ strategy to an innovation process


In a Nutshell

What is everything going to be about?

Inspiring and Education of the Young Generation.

It is our joint Future!

Everything is about people!


It is not the strongest of the species, nor the most intelligent that survives.

It is the one that is the most adaptable to change.

*Regularly attributed to but not documented. Supposedly in the context of »Origin of Species« (1859)

Charles Robert Darwin* (1809-1882)

Source: academic.ru/pictures/dewiki/67/Charles_Darwin_aged_51.jpg


Future developments have to be received as they evolve!

But we can do something,

that our future evolves as we feel like it!

Acc. to Curt Goetz, German author (1888 – 1960)


Thank You very much for

Your kind attention!

the european manufacturing industry vision and...

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