ICE 2015 ProRegio Project Overview

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Leon Strickland
6 years ago
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Nikolaos Papakostas Laboratory for Manufacturing Systems

1 ICE 2015 ProRegio Project Overview Innovative Product Service design using manufacturing intelligence Dr. Nikolaos Papakostas Laboratory for Manufacturing Systems and Automation (LMS) Director: Prof. G. Chryssolouris University of Patras

2 Motivation Challenges in production Customers in more established markets are demanding more variety and faster product cycles Locations of production facilities are following markets taking advantage of competitive input factors Growth opportunities in the domestic market decrease while demand in emerging economies rapidly increases Increasing specialisation of locations regarding markets, products or processes New consumers often require very different products to meet their needs, with different features, quality and price points New forms of intelligence, such as big data and the use of data-gathering sensors in production machinery and in logistics (the so-called Internet of Things) offer new production potentials Additional and adapted production capacity distributed over the whole production network is needed to fulfill increasing and varying customer demand 2

3 Partners - Function Aeronautics Machinery Domestic Appliances Manufacturing Industry ICT-Enabler Research Institution 3

4 Partners - Origin Germany France KIT Airbus Flexis Texxmo ECN Audros Karlsruhe Hamburg Stuttgart Boeblingen Nantes Lyon Italy POLIMI Comau ES Milan Grugliasco Trento Greece LMS Grobo Rio Patras Athina Turkey Arcelik Istanbul 4

5 Research questions and objectives Research questions How can customers be integrated in the innovation process? What kind of interdependencies exist between product structure and production capabilities? How can production systems efficiently be adapted to regionally differing products? What is the optimal customer-oriented design of production systems and of production networks? How can cyber-physical systems enable the ad-hoc (re-) scheduling of orders in production networks? Objectives Enable globally operating companies to efficiently deliver innovative, customized products by using their globally distributed production network to meet strongly differing regional requirements regarding product design and functionality of their globally distributed customers Integration of customer in the product development process allowing for an efficient incorporation of strongly differing customer requirements Development of integrated product and production adaptions regarding site-specific conditions and technology options Innovative product-service design by incorporating customers in the order-fulfilment processes Optimal design of production systems and allocation of production processes to production sites including a decision support for ad-hoc (re-) scheduling of customer orders Customer-driven design of product-services and production networks to adapt to regional market requirements 5

6 Benefits and impact Proposed benefits Improvements in production performance Reduction of production costs Shortening of throughput times Improvement of delivery reliability through more transparent production processes Shorten time-to-market of customized products/ services Increasing the attractiveness of companies by offering new added value services that make their products more attractive (e.g. more individualized products and shorter time to market) to different customers segments especially for emerging regions by increasing customer satisfaction by providing more power to the customer comparable to effects of social media by increasing supplier loyalty by even stronger integration into the order fulfilment process by increasing ability to export into emerging countries all around the world and in doing so the project will help to stabilize EU s exports Proposed benefits of ProRegio are expected to increase the attractiveness of European companies for customers from all around the world 6

7 Overall concept Production Network Cyber-physical systems E n a b l e r Strategic planning of production networks and systems Production system Methodology to embed direct customer involvement in the orderfulfilment process Re-design of production networks and systems Methodology for integrative design of product and production systems Customer Design of customer-oriented products for frugal 1 innovation Product 1) Frugal innovation can be defined as the process of reducing the complexity and cost of a good and its production. 7

8 ProRegio Approaches, Methods & Tools

9 ProRegio Platform

10 Tools, usages and interaction Software primary relationship to use cases Design and Simulation Influence Execution Influence Use Case 1 main application Use Case 2 main application Use Case 3 main application Customers Suppliers Knowledge System Conf/Opt (Polimi) Knowledge Virtual Factory (Polimi) Knowledge Rule Stream (Polimi) Knowledge Modfrontier (Engin Soft) Knowledge Production network support tool (LMS) Knowledge Prod. Network Design (KIT) Knowledge Prod. Planning (flexis) Knowledge Artificial / human CPS (Texxmo) Portal Portal Connector Connector Connector Connector Connector Connector Connector Connector PLM Platform (Audros) Customer data Design data Manufacturing data Documents Technical data Network data Plant data & Orders MES data Production Process data

Product-Service aspects and business & financial models Maintenance Expert Adds annotations/ pictures and voice content on the realtime video image Machine Breakdown in Factory s Production Line

11 Product-Service aspects and business & financial models Maintenance Expert Adds annotations/ pictures and voice content on the realtime video image Machine Breakdown in Factory s Production Line (Arcelik) Provides info of the broken down machine and transmits the video captured from the AR system ProRegio Platform Operator wears AR glasses and informs about the problem. Operator Guidance through ProRegio Platform s Integrated Augmented Reality System All the content is being integrated and displayed to the operator s screen Operator

Cyber Physical Systems, Internet of Things Potential Solution Clusters for Digital Shopfloor Management (Airbus) Track location (with RFID, GPS,.

12 Cyber Physical Systems, Internet of Things Potential Solution Clusters for Digital Shopfloor Management (Airbus) Track location (with RFID, GPS,...) of components, material delivery unit (MDU), tools, aircrafts Extract status information from IT systems (Ground test instructions, takt orders, planned and acknowledged work orders, ) Monitor tool usage (detect usage, count drilling/riveting, measure paint consumption, ) Image processing (installation of cabin, vertical/horizontal tail plain, ) Note: extra benefit is generated by linking the different solutions into a single network

Arcelik Use Case Design of a Refrigerator following Frugal Innovation Approaches and

Multiobjective & Automated Design and the Prompt Reconfigurationof the Network in case of

Finally Remote Maintenace Approaches will be utilized faciliated by Augmented Reality.

electronics and components 25,000 employees Consolidated net sales in 2014 : 4,307 million

13 Arcelik Use Case Design of a Refrigerator following Frugal Innovation Approaches and Augmented Reality Tools for Receiving Customer s Feedback followed by Supplier s Network Multiobjective & Automated Design and the Prompt Reconfigurationof the Network in case of Supplier s Failure. Finally Remote Maintenace Approaches will be utilized faciliated by Augmented Reality. Production, marketing and after-sales services of consumer durable goods, consumer electronics and components 25,000 employees Consolidated net sales in 2014 : 4,307 million Euros 10 brands Operating in 26 countries 15 production plants in 6 countries* (China, Romania, Russia, South Africa and Turkey) Products and services in more than 130 countries 13

14 Airbus Use Case Production network: Optimization of type allocation and order allocation to different FALs by specializing local production processes with respect to aircraft configuration utilizing differing local production capabilities (e.g. lead time, cost, ) in terms of standardizing/ specializing production lines where beneficial balancing of workload and lead time through a/c sequencing Customer link: Improve IT link between customer and production to increase customer integration into the production process Digital shop floor management: Enhance real time acknowledgement of work order status and disturbances in the production process Improve real time visibility of parts Enhance real time quality control 144,000+ Total workforce 690billion Order book 59billion Annual revenue

shared tool among design engineers Lack of explicit technical knowledge skill gap Highly integrated design

15 Comau Use Case System Integrator and Manufacturing Equipment Provider Engineering-to-Order of Automotive Production Equipment Need to manage global operations with growing demand in emerging markets Lack of a shared tool among design engineers Lack of explicit technical knowledge skill gap Highly integrated design tool for better decision making Improve knowledge sharing and reuse across departments Reduce Time, Cost and Errors

16 Cross Collaboration with other Projects Development of common digital models of customers, suppliers, product, process, resources employing semantic modelling approaches (ICP4Life) Investigation of novel business models for product services in the context of remote maintenance (Sense&React) Increase visibility at shopfloor employing IoT with real time asset tracking tools and embedded sensors (Sense&React) Joint Dissemination, Exploitation and Innovation activities

17 THANK YOU! ProRegio Customer driven design of product services and production networks to adapt to regional market requirements

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