The RobustPlaNet project

Transcription

1 RobustPlaNet Shock-robust Design of Plants and their Supply Chain Networks Project acronym: Call and Contract: RobustPlaNet FP NMP-ICT-FOF(RTD) Grant agreement no.: Project Duration: The RobustPlaNet project Coordinator: Dr. Botond Kadar, Sztaki, Hungary Presenter: Dr. Juan Jauregui Becker, UTWENTE, The Netherlands Industrial Technologies, Amsterdam, The Netherlands,

2 RobustPlaNet Approach Shock-robust Design of Plants and their Supply-Chain-Networks Challenges Project Goals Goals Approach Volatile business environment and increasing globalization Robust Production Systems Propagation of disturbances and risks Robust Plants and Production Networks Hierarchical supply chain and productbased business models Collaborative and robustness Production Network Industrial Partners Consortium Academic Partners

3 Motivation: Make supply chain and Production Systems more robust Internal and external Disturbances, e.g.: - Drastic changes in demand - Natural disasters - Machine failure German automotive industry Number of natural disasters worldwide

4 Rational of the project Use Case 2 manage interrelations Use Case 3 manage interrelations Cockpit tool to manage interrelations Use Case 4 manage interrelations Use Case 1 manage interrelations 4

5 Link Application Domains to Use Cases Use Case 1 Use Case 2 Use Case 3 Opportunistic Maintenance Robust Planning and Scheduling Remanufacturing Reconfiguration OMA, ITC, FESTO, MAR, MCM, KIT, POLIMI KNORR, ITC, MAR, MCM, SZTAKI, POLIMI VPN, MCM, FESTO, ITC SZTAKI, POLIMI, TWENTE Use Case 4 Supply Chain SZTAKI, KIT, POLIMI, DAI, FESTO, MAR, MCM, TWENTE, VPN, SZTAKI, KNORR, ITC

6 Use Cases Use Case 1 Use Case 2 Use Case 3 Opportunistic Maintenance Robust Planning and Scheduling Remanufacturing Reconfiguration OMA, ITC, FESTO, MAR, MCM, KIT, POLIMI KNORR, ITC, MAR, MCM, SZTAKI, POLIMI VPN, MCM, FESTO, ITC SZTAKI, POLIMI, TWENTE Use Case 4 Supply Chain SZTAKI, KIT, POLIMI, DAI, FESTO, MAR, MCM, TWENTE, VPN, SZTAKI, KNORR, ITC

7 OMA Use Case: Manufacturing of complex aeronautics parts. Product features: Critical structural titanium parts. Small lots, large variability parts. Complex shape. System and process features: 3 cutting tools storage units (400 tools each) cutting hours. 80% of material is removed. Specific Challenges: Service level strongly affected by corrective maintenance operations. Conservative and expensive tool management policy (no condition monitoring)

8 RobustPlaNet opportunistic maintenance solution and architecture State-based production and opportunistic maintenance planning (+ 20% service level). Production plan Machine degradation monitoring by fingerprint cycles (identification of 3 degradation modes). Tool condition monitoring by data fusion of process and in-process tool wear data (-70% tool-life planning time, 40 hours)

9 Use Cases Use Case 1 Use Case 2 Use Case 3 Opportunistic Maintenance Robust Planning and Scheduling Remanufacturing Reconfiguration OMA, ITC, FESTO, MAR, MCM, KIT, POLIMI KNORR, ITC, MAR, MCM, SZTAKI, POLIMI VPN, MCM, FESTO, ITC SZTAKI, POLIMI, TWENTE Use Case 4 Supply Chain SZTAKI, KIT, POLIMI, DAI, FESTO, MAR, MCM, TWENTE, VPN, SZTAKI, KNORR, ITC

10 Knorr Bremse remanufacturing use case Remanufacturing of mechatronic parts for the automotive aftermarket as a sustainable circular economy business. Process-chain: Operator Reman decision Final Inspection Input Post consumer part Visual Check by the operator Disassembly Cleaning Scrap Good for reassembly Challenges: Large variability in the condition of the post consumer products. Remanufacturing decisions are taken by the operator based on Standard Operations Sheets SOS. The resulting regeneration rate is

11 RobustPlaNet remanufacturing solution Operator Reman decision supported by DSS Final Inspection Input Core Automatic + Visual inspection Part condition dependent optimal disassembly flow Cleaning Scrap Target regeneration rate > 0.8. Target disassembly time reduction = -15%. Good Solution Decision Support System: 1. Part quality inspection: Quality evaluation of cores. Automatic identification of quality characteristics. 2. Adapt the remanufacturing strategy based on the specific core quality. The solution provides considerable economic and environmental benefits

12 Use Cases Use Case 1 Use Case 2 Use Case 3 Opportunistic Maintenance Robust Planning and Scheduling Remanufacturing Reconfiguration OMA, ITC, FESTO, MAR, MCM, KIT, POLIMI KNORR, ITC, MAR, MCM, SZTAKI, POLIMI VPN, MCM, FESTO, ITC SZTAKI, POLIMI, TWENTE Use Case 4 Supply Chain SZTAKI, KIT, POLIMI, DAI, FESTO, MAR, MCM, TWENTE, VPN, SZTAKI, KNORR, ITC

13 Challenges & objectives of the use case Challenges in assembly Increasing product variety Fragmentation of demand Objectives Production technology concept, suitable for changing demand volumes, entire product lifecycle, smaller production lots; Changing production volumes Limited production space Increasing number of techniques required in the assembly process Design-support software applications to facilitate design and evaluation of alternative production configurations, to determine feasible layouts and reconfiguration strategies, to support production planning in the short term;

14 Summary of developed results Technologic approach Production System of Reconfigurable Production Cells, enabling to adapt the cells to an evolving, turbulent environment; production throughout high- and lowvolume phases of the product lifecycle; Design- & management support Workflow of three integrated software tools Strategic design module Automated design of system configurations Performance evaluation of various production design strategies Tactical reconfiguration module Cell layouts Optimized reconfiguration strategies Operational production planning module Operational planning support Simulation of various production plans

15 1 Designing the systems

16 1 Designing the systems Candidate solution 2 Candidate solution 2 Candidate solution 1 Candidate solution 1

17 Use Cases Use Case 1 Use Case 2 Use Case 3 Opportunistic Maintenance Robust Planning and Scheduling Remanufacturing Reconfiguration OMA, ITC, FESTO, MAR, MCM, KIT, POLIMI KNORR, ITC, MAR, MCM, SZTAKI, POLIMI VPN, MCM, FESTO, ITC SZTAKI, POLIMI, TWENTE Use Case 4 Supply Chain SZTAKI, KIT, POLIMI, DAI, FESTO, MAR, MCM, TWENTE, VPN, SZTAKI, KNORR, ITC

18 Reconfigurable Supply Chain Networks Challenges and Objectives Business environment Fluctutations over time Costs Delivery reliablity Alternatives Sourcing / Production / Distribution Global Local for Local Demand Tariff barriers Global Labor costs Status quo Local for Local Reconfiguration strategy Identification of an optimal reconfiguration strategy of the supply chain network of Festo AG & Co. KG. wbk

19 Reconfigurable Supply Chain Networks Objectives and Domonstration Objective Design support for supply chain configurations Demonstration and Exploitable Result Identification of an optimal (re-) configuration strategy Evaluation of configurations in an agent-based stochastic environment What-if analysis Methods and tools for hierarchical decision support for reconfigurable supply chain networks Festo, ITC, SZTAKI, KIT, TWENTE 19

20 DISSEMINATION & EXPLOITATION wbk

21 RobustPlaNet Relevant Exploitation Stories A list of 8 new exploitable products have been elaborated. The most promising business opportunities are as follows: MARPOSS will include the multi-sensor solution, including the laser pre-setter and data fusion algorithms, as a technology for the direct tool condition monitoring in complex machining operations. MCM will include the sensors and the software for machine signature monitoring as an additional service to the machine tool users for monitoring the state of degradation of critical components. Technology Transfer Ltd. has been established in Hungary by SZTAKI, partially based on RPN results, to bring to the market the RPN cockpit. Teckno, a spin-off of Politecnico di Milano, established in cooperation with MCM, will exploit the technology and the software for the efficient planning of the tool life in complex machining operations. A valorisation workshop was held in Twente to harmonize the development of the business plans and market analyses for these results

22 RobustPlaNet Dissemination Events Industrial dissemination events Constructeurdag 2014, NL Cluster Tecnologico Nazionale Fabbrica Intelligente, Milan, IItaly Important EU industrial fairs: Fastener Fair, INDISTRIE, MSV NIITRA, INTEC Demonstration events: Hanover Fair Industrial Technologies in Amsterdam Project workshop in Italy, September Other activities Regular Newsletter. Linked page. Exploitation and valorization workshop. Important academic events Special track at MIM CIRP General assembly 2015 & Overview of scientific outputs: Academic dissemination Planned in DOW Total by M24 Conference Papers Journal papers 3 5 Successful PhD works 3 6 active RobustPlaNet Workshops, Special Tracks or events. Courses Including RobustPlaNet R&D results

23 Resilient Production Networks Cluster Main objectives: To bring together projects focused on methods, tools, services, applications and platforms for strategic, tactical, operational and process support for Resilient Production Networks. To offer synergies in project exploitation: joint promotional workshops; joint standardisation opportunities. To offer cross-exposure and review of use-cases/demos by endusers from all projects.

24 Colleagues working in RobustPlaNet

25 Thank you for your attention! RobustPlaNet Shock-robust Design of Plants and their Supply Chain Networks Project acronym: Call and Contract: RobustPlaNet Grant agreement no.: FP NMP-ICT-FOF(RTD) Project Duration: Further information: Personal contact: