vigo smart factories keynote stn an v5 · 3. smart factory of the future 1. smarter products 2....
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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
Paradigm Craft Production
Mass Customization
and Personalization
Paradigm started
~1850 2000
SocietyNeeds
Customized products
Customized Products
MarketVery small volume per
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
Paradigm Craft Production
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
MarketVery small volume per
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
(Adapted from Westkämper / Constantinescu, 2010)
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
2.1. SOA: Reconfigurable 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
• Sustainable Manufacturing
(Adapted from Westkämper / Constantinescu, 2010)
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
2.4. SOA: Personalised manufacturing
• 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)
2.4. SOA: Personalised manufacturing
• 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
• Sustainable 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!
3. Smart factory of the future
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
3. Smart factory of the future
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
3. Smart factory of the future
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
3. Smart factory of the future
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
3. Smart factory of the future
3. Smart factory of the future
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