Project No.: Project acronym: ReBorn. Project title: Programme: FoF.NMP Deliverable 1.2

Transcription

1 Project No.: Project acronym: ReBorn Project title: Innovative Reuse of modular knowledge Based devices and technologies for Old, Renewed and New factories Programme: FoF.NMP.2013 Deliverable 1.2 ReBorn External industrial requirements description Project co-funded by the European Commission within the Seventh Framework Program for Research and Technological Development (FP7)

2 ReBorn External industrial requirements description Start date of project: Duration: 36 months Author: Michael Peschl, HWH Due date of deliverable: Actual submission date: Project co-funded by the European Commission within the Seventh Framework Programme ( ) Dissemination Level PU Public X PP RE CO Restricted to other programme participants (including the Commission Services) Restricted to a group specified by the consortium (including the Commission Services) Confidential, only for members of the consortium (including the Commission Services) ReBorn consortium Page 2

3 CHANGE CONTROL Document History Version Date Change History Author Organisation /03/2014 Document drafted Nicole Vetter HWH /03/2014 Document review; conclusions added Michael Peschl HWH /03/2014 Update of statistics Nicole Vetter HWH /03/2014 Final review Michael Peschl HWH /03/2014 Answers blackened Nicole Vetter HWH /09/2014 Distribution List corrected Nicole Vetter HWH DISTRIBUTION LIST Date Issue Group 26/03/2014 Revision ReBorn Coordinator 26/03/2014 Acceptance ReBorn Coordinator 26/03/2014 Distribution ReBorn Consortium 26/03/2014 Submission European Commission ReBorn consortium Page 3

4 Contents 1. INTRODUCTION THE WHOLE PURPOSE OF THE QUESTIONNAIRE METHODOLOGY TARGET GROUP OF THE QUESTIONNAIRE 7 2. QUESTIONS AND POSSIBLE ANSWERS OF THE QUESTIONNAIRE ON REQUIREMENTS 8 3. EVALUATION OF THE QUESTIONNAIRE OVERALL COMPANY INFORMATION Q1 COMPANY NAME (OPTIONAL) Q2 INDUSTRY SECTOR Q3 PRODUCT PRODUCED Q4 ROLE OF YOUR COMPANY Q5 YOUR POSITION PROGRAM LEVEL Q6 IN WHICH INDUSTRIAL SECTORS DO YOU SEE THE MAIN POTENTIAL OF EQUIPMENT RE-USE? Q7 DO YOU THINK IF EQUIPMENT RE-USE IS IN PARTICULAR INTERESTING FOR THE EUROPEAN INDUSTRY? Q8 HOW DO YOU ESTIMATE THE POTENTIAL OF RE-USED EQUIPMENT AND SOFTWARE IN GENERAL? Q9 HOW WOULD YOU ESTIMATE THE CURRENT LEVEL OF EQUIPMENT RE-USE? Q10 WHAT ARE THE MAIN BLOCKING POINTS FOR RE-USING EQUIPMENT IN YOUR OPINION AT THE MOMENT? Q11 DOES YOUR COMPANY RELY ON RE-USED EQUIPMENT/SOFTWARE? Q12 HOW IS YOUR EXPERIENCE WITH RE-USING EQUIPMENT/SOFTWARE? PROGRAM LEVEL PERSPECTIVE OF EQUIPMENT USER Q13 WHICH ADVANTAGES DO YOU SEE FOR RE-USING EQUIPMENT AND SOFTWARE IN GENERAL? Q14 WHICH ECONOMIC BENEFITS DO YOU SEE FOR RE-USING EQUIPMENT AND SOFTWARE? PROGRAM LEVEL PERSPECTIVE OF EQUIPMENT PRODUCER/SUPPLIER Q15 WHICH ADVANTAGES DO YOU SEE FOR RE-USING EQUIPMENT AND SOFTWARE IN GENERAL? Q16 WHICH ECONOMIC BENEFITS DO YOU SEE FOR RE-USING EQUIPMENT AND SOFTWARE? PROJECT LEVEL Q17 IN YOUR OPINION, WHICH OTHER AREAS ARE WORTHWHILE TO BE CONSIDERED IN THIS CONTEXT? Q18 IN WHICH OF THOSE THREE AREAS (OR ADDITIONAL AREAS) DO YOU SEE THE MAJOR BENEFITS? Q19 IN WHICH AREAS (OR ADDITIONAL AREAS) DO YOU SEE THE NEED FOR THE ESTABLISHMENTS OF (NEW) INDUSTRIAL STANDARDS/CERTIFICATES? Q20 IN WHICH AREA (OR ADDITIONAL AREAS) IS YOUR ENTERPRISE PARTICULAR INTERESTED IN? Q21 REBORN RELIES ON MONITORING AND ANALYZING OF DATA ON THE SHOP FLOOR. WHICH DATA DO YOU MONITOR TODAY? Q22 WHICH DATA SHALL BE MONITORED WHEN APPLYING THE REBORN APPROACH IN THE FUTURE? APPLICATION AREAS Q23 WHICH OF THE CAPABILITIES ARE COVERED BY CURRENT STATE OF THE ART TECHNOLOGIES? Q24 WHICH OF THE CAPABILITIES MENTIONED ABOVE ARE MOST INTERESTING FOR FUTURE DEVICES? Q25 HOW LONG DO YOU ESTIMATE THE LIFE TIME OF TOOLS IN AVERAGE? Q26 HOW LONG DO YOU ESTIMATE THE LIFE TIME OF EQUIPMENT/PRODUCTION IN AVERAGE? Q27 WHICH FEATURES/CAPABILITIES ARE IN YOUR OPINION ADDITIONALLY REQUIRED? Q28 WHERE DO YOU SEE THE MAJOR BLOCKING POINTS FOR USING SELF-MONITORING DEVICES? Q29 IN WHICH OF THESE FEATURES DO YOU SEE THE MAJOR ECONOMIC BENEFITS? Q30 WOULD YOU USE RE-USED EQUIPMENT IN YOUR FACTORY/PLANT? Q31 BESIDES THE TECHNICAL LEVEL, WHICH OTHER REQUIREMENTS NEED TO BE FULFILLED? 52 ReBorn consortium Page 4

5 Q32 COULD YOU IMAGINE THAT TODAY OR IN THE FUTURE YOUR PRODUCT OR APPLIED PRODUCTION TOOLS WOULD BE PRODUCED BY USING AM TECHNOLOGY? Q33 HOW CAN YOU DESCRIBE THE OPERATION AREA OF YOUR AM PRODUCED PART AND WHAT IS THE LOT SIZE OF THE PRODUCT(S) YOU ARE GOING TO PRODUCE USING AM TECHNOLOGY? Q34 WHAT IS THE LIFE TIME OF THIS/THESE PRODUCT(S)? Q35 WHAT IS THE PHYSICAL DIMENSIONS OF THIS/THESE PRODUCT(S)? Q36 HOW CAN YOU DESCRIBE FORCES TRANSFERRED ON YOUR AM PRODUCED PART(S) DURING ITS/THEIR USAGE? Q37 LAYOUT DESIGN IN THE CONTEXT OF THIS DOCUMENT, IS CONSIDERED AS RE-ENGINEERING OR NEW PLANNING PRODUCTION EQUIPMENTS`S, MATERIAL FLOW, HANDLING AND AUTOMATION DEVICES, AND/OR INFRASTRUCTURE FACILITIES. HOW OFTEN DO YOU EXECUTE LAYOUT DESIGNING AND WHAT WOULD BE ITS SCOPE OF PLANNING DUE TO? Q38 IF APPLICABLE, IN WHAT CASES, MENTIONED IN THE PREVIOUS QUESTION, DO YOU USE DATA, INFORMATION OR OTHER IMPLICIT KNOWLEDGE IN THE PROCESS OF LAYOUT PLANNING TO INCREASE THE PROPORTION OF HARDWARE PRODUCTION EQUIPMENT OR SOFTWARE TODAY? Q39 IN WHICH USE CASE WITHIN THE PROCESS OF PLANNING AND EXECUTION OF LAYOUT PLANNING, IF APPLICABLE, DO YOU SEE FURTHER POTENTIALS TO INTEGRATE SELF-DESCRIPTIVE EQUIPMENT INTO THE PROCESS OF LAYOUT PLANNING? Q40 WHICH KNOW-HOW AND/OR RESOURCES WOULD YOU CONSIDER AS NECESSARY TO IMPLEMENT A PROCESS OF LAYOUT DESIGNING WHICH INCLUDES SELF-DESCRIPTIVE EQUIPMENT AND PROCESS INFORMATION? CONCLUSION 65 A1. QUESTIONNAIRE AS FILLABLE FORM 66 A2. EVALUATION LIST SORTED BY RESPONDENTS 67 ReBorn consortium Page 5

6 1. Introduction The internal requirements gathered and analysed within task 1.1 represent the point of view of the partners within the consortium and their self-interest. To extend the requirements and the target group of the ReBorn technology the requirements of different branches and external industrial experts are needed. For this, the industrial advisory group and other related organizations have been interviewed via an online questionnaire. Their feedback will be consolidated and priorised, similar to the process in task 1.1. The result brings a wider range of different aspects on the project course and targets The whole purpose of the questionnaire The key purpose of task 1.2 gains to identify, if the internal requirements of the consortium are in line with external industrial requirements. In order to identify the external industrial requirements, a questionnaire has been conducted. The outcome of task 1.2 gathers and validates the external requirements. After the evaluation, the results of the questionnaire are compared with the results of task 1.1. In this process relevant and irrelevant topics will be identified. The outcome of this comparison supports the standardization procedures of task 1.4. This shall guarantee a smooth takeup of the ReBorn technology beyond the European project. To obtain a proper statistical basis for the process, at least 15 feedbacks coming from at least three different industrial sectors were expected. To ensure a proper acceptance, an anonymization of the questionnaire`s feedback is done Methodology To get the requirements of external partners of different branches an online questionnaire is created. The respondents are informed via and get a weblink to the online questionnaire. The questionnaire is setup by using the online platform Besides the questionnaire itself the platform also provides tools for the analysis the results. The questionnaire is divided into several parts: The first five questions targets on gathering of some company information. This provides information about the background of the respondents. Also this ensures that all major branches are covered. The main part of the questionnaire is divided in three levels: Program level Project level Application areas The program level requests information relevant to the general scope of the application area which corresponds to the target of the program call. Inside the program level different point of views are covered. The respondent is requested to put themselves in different roles. ReBorn consortium Page 6

7 General perspective End-user of old/refurbished equipment Equipment producer/supplier The project level is dedicated to the requirements of the project, in which re-using of equipment is the main focus. Finally, the questions of the third part are tailored to the three specific application areas of ReBORN, namely factory layout planning, controls and devices as well as mechanical systems on shopfloor Target group of the questionnaire The target group of respondents is composed of the Industrial Advisory Group which is established and other related organizations (e.g. partner s customers, business partners etc.). Two institutes, at least two companies and a few organisations are included. Also the background and the job positions of the respondents differ. Included are CEOs, CTOs, R&D, team and project managers, developers and factory planning assemblies. To get a wide range of different aspects, the target group covering different industrial sectors such as: Automotive Aerospace Software development Customer goods Anonymization of the questionnaire`s feedback is important for the respondents to take part of it. ReBorn consortium Page 7

8 2. Questions and possible answers of the questionnaire on requirements This chapter contains screenshots of the questions and the possible answers of the online questionnaire. For the whole questionnaire as fillable form see A1-Questionnaire as fillable form, p. 66. ReBorn consortium Page 8

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22 3. Evaluation of the questionnaire overall 3.4. Company information Q1 Company name (optional) Answered: 14 Skipped: 1 This information is not published, because the anonymization of the questionnaire was assured. ReBorn consortium Page 22

23 Q2 Industry sector Answered: 15 Skipped: 0 #* Answers Date 1 Electrics and electronics :37 2 Video sensor systems :02 3 Various sectors (automotive, semiconductor, ) :37 4 Automation :55 5 Automation components :25 6 Machine building :14 7 Automotive :48 8 Aerospace Industry :23 9 Simulation (different sectors) :16 10 Machine production :39 11 Software development :18 12 Consumer Goods :51 13 Research, mainly factory automation and quality assurance :46 14 Automotive :40 15 Engineering :00 * Order does not necessarily reflect the order of the table Company information. Correlation between the Industry Sector and the company name can be derived from the date column. ReBorn consortium Page 23

24 Q3 Product produced Answered: 15 Skipped: 0 #* Answers Date 1 quality assurance system for resistance welding :37 2 SiteView video sensors :02 3 Manufacturing Execution System (MES) :37 4 Material handling and automation :55 5 Pneumatic + electric drives, valve terminals, control equipment, :25 6 automated production equipment :14 7 Automated production equipment (mostly welding machines) :48 8 Airbus planes :23 9 Engineering service provider :16 10 robotized welding systems :39 11 Software tools :18 12 beauty care, laundry and home care, adhesived :51 13 Optical Measuring and Testing Technologies :46 14 Cars :40 15 Software :00 * Order does not necessarily reflect the order of the table Company information. Correlation between the products and the company name can be derived from the date column. ReBorn consortium Page 24

25 Q4 Role of your company Answered: 15 Skipped: 0 Potential answers Answers Equipment vendor % 4 Software company % 4 Integrator 40 % 6 End user % 2 Engineering % 4 Consultant 6.67 % 1 Other % 2 Respondents overall: 15 ReBorn consortium Page 25

26 Q5 Your position Answered: 15 Skipped: 0 # Answers Date 1 head of development :37 2 CTO :02 3 Managing Director :37 4 Project manager :55 5 Portfolio management :25 6 R&D manager :14 7 R&D Engineer :48 8 Factory planning assembly :23 9 Team Manager :16 10 Project manager :39 11 CEO :18 12 Process consultant IT :51 13 Head of Department :46 14 Manager :40 15 Software developer :00 ReBorn consortium Page 26

27 3.5. Program level Q6 In which industrial sectors do you see the main potential of equipment reuse? Answered: 13 Skipped: 2 # Answers Date 1 all production industry where products change in less than :41 2 Mechanical engineering, automotive, aircraft :09 3 Assembly, Semiconductor, PV :39 4 general assembly of products, testing :26 5 production equipment in automotive :17 6 small series (customized products, prototypes) production :03 7 Automotive industry :25 8 assembling, shop floor manufacturing :16 9 chemical, mechanical and software :41 10 At Henkel: industrial goods for automotive industry (adhesives), in general: machine builders, electronics :54 11 Vehicle Manufacturing (Aircraft, Railway, Automotive etc.) :48 12 Only for specific expensive components like robots :42 13 production :00 ReBorn consortium Page 27

28 Q7 Do you think if equipment re-use is in particular interesting for the European industry? Answered: 15 Skipped: 0 Potential answers Answers Yes 80 % 12 No 20 % 3 Respondents overall: 15 ReBorn consortium Page 28

29 Q8 How do you estimate the potential of re-used equipment and software in general? Answered: 15 Skipped: 0 Potential answers Answers < 10 % % % 40 % 6 25 % 50 % 40 % 6 > 50 % 6.67 % 1 Respondents overall: 15 ReBorn consortium Page 29

30 Q9 How would you estimate the current level of equipment re-use? Answered: 15 Skipped: 0 Potential answers Answers < 10 % % 7 10 % 25 % 40 % 6 25 % 50 % 6.67 % 1 > 50 % 6.67 % 1 Respondents overall: 15 ReBorn consortium Page 30

31 Q10 What are the main blocking points for re-using equipment in your opinion at the moment? Answered: 15 Skipped: 0 Potential answers Answers Economic benefits not clear % 4 Infrastructure/logistics not available % 5 Uncertainty about the technical risks of using old/refurbished equipment 60 % 9 Other (Please specify) % 7 Respondents overall: 15 ReBorn consortium Page 31

32 Q11 Does your company rely on re-used equipment/software? Answered: 15 Skipped: 0 Potential answers Answers Yes % 7 No % 8 Respondents overall: 15 ReBorn consortium Page 32

33 Q12 How is your experience with re-using equipment/software? Answered: 14 Skipped: 1 Potential answers Answers I use old/refurbished equipment regularly with good results % 3 I use old/refurbished equipment regularly with partially good results % 8 I use old/refurbished equipment regularly with poor results 7.14 % 1 I have never used old/refurbished equipment % 2 Respondents overall: 14 ReBorn consortium Page 33

34 3.6. Program level Perspective of equipment user Q13 Which advantages do you see for re-using equipment and software in general? Answered: 14 Skipped: 1 # Answers Date 1 lower development costs; short set-up times; teached personal :51 2 Time savings :13 3 Reduce engineering :40 4 cost saving, faster construction :05 5 Reducing ecologic footprint; reducing lead times; more flexibility in trying out technical approaches :29 6 lower investments :19 7 Cost reduction of new assembly lines :20 8 None, except for economical reasons. New equipment generally performs better, has less problems and standstills (greater reliability), lower energy consumption, etc :12 9 as an end user, I am interested in the cost benefit relation of the product. It should work well and I am happy when I can save costs :16 10 Software : proven in practise :42 11 cost savings, environmental aspects, keep intellectual property :57 12 flexibility; efficient production of low badge sites :51 13 cost savings :43 14 efficiency :01 ReBorn consortium Page 34

35 Q14 Which economic benefits do you see for re-using equipment and software? Answered: 15 Skipped: 0 # Answers Date 1 investment can be decreased; maybe risk reduction;ecological benefit; :51 2 Cost savings :13 3 Save time and money :40 4 cost saving, faster construction :05 5 relatively small :29 6 lower investments :19 7 Extension the life times of the machines :20 8 Production planning can be separated from equipment life time expectance :12 9 as an end user, i want to have a cheaper price for re-used :16 10 Cost reductiion :42 11 Lower purchase cost of software :23 12 lower investment costs :57 13 high :51 14 cost savings :43 15 none :01 ReBorn consortium Page 35

36 3.7. Program level Perspective of equipment producer/supplier Q15 Which advantages do you see for re-using equipment and software in general? Answered: 14 Skipped: 1 # Answers Date 1 focus on service instead of new hardware / software :54 2 Reliable building blocks if modular, quicker ramp-up :14 3 Life time of equipment is longer als USP (sustainable) :42 4 cost saving, faster construction :05 5 As a producer, this is tedious :30 6 lower investments :20 7 Cost reduction :21 8 Can offer services to customers that don't need new equipment :21 9 We are an engineering service provider in the area of technical simulation, r&d partner mainly to the automotive industry. We don not handle equipment, we handle software. Software is always reusable, new versions are based on the previous version. All software development makes use of previous developments. Important is the benchmark of various versions. I see a big potential of reusing equipment in the machine tool industry, where the production takes place on the shop floor. Here individual machines are asse,bled, tailored to the special needs of the customer. Advantage in economical and quality terms :16 10 Development time :43 11 Differentiate from competitors : :52 13 cost savings :43 14 efficiency :01 ReBorn consortium Page 36

37 Q16 Which economic benefits do you see for re-using equipment and software? Answered: 14 Skipped: 1 # Answers Date 1 maybe new customers because lower prices :54 2 Saving efforts :14 3 Longer market presence :42 4 cost saving, faster construction :05 5 Costly; makes only sense if re-using/ re-furbishing occurs many times :30 6 less investments :20 7 Lower initial investments on projects :20 8 avoiding waste of well known and functioning parts :16 9 Cost :43 10 Lower development costs for the new software :23 11 New business models (service-based), long-term contact with end : :52 13 cost savings :43 14 none :01 ReBorn consortium Page 37

38 3.8. Project level Q17 In your opinion, which other areas are worthwhile to be considered in this context? Answered: 6 Skipped: 9 # Answers Date 1 devices open for partial upgrade; using standardized interfaces for new combination of equipment; quick setup after new combination; :08 2 Predictive maintenance Root-cause reasoning :15 3 general assembly assembly of small-series products now done :32 4 shop floor manufacturing and assembling :16 5 model-based planning of assembly steps as well as inspection : :44 ReBorn consortium Page 38

39 Q18 In which of those three areas (or additional areas) do you see the major benefits? Answered: 12 Skipped: 3 Potential answers Answers Self-monitoring devices 50 % 6 Modular mechanical devices and embedding of Additive Manufacturing (AM) technology in production process flow Enhanced factory planning based on old, re-used factory layout designs including the planning with re-used equipment % 7 25 % 3 Other (Please specify) 8.33 % 1 Respondents overall: 12 ReBorn consortium Page 39

40 Q19 In which areas (or additional areas) do you see the need for the establishments of (new) industrial standards/certificates? Answered: 12 Skipped: 3 Potential answers Answers Self-monitoring devices 50 % 6 Modular mechanical devices and embedding of Additive Manufacturing (AM) technology in production process flow Enhanced factory planning based on old, re-used factory layout designs including the planning with re-used equipment 50 % % 2 Other (Please specify) % 2 Respondents overall: 12 ReBorn consortium Page 40

41 Q20 In which area (or additional areas) is your enterprise particular interested in? Answered: 11 Skipped: 4 Potential answers Answers Self-monitoring devices % 6 Modular mechanical devices and embedding of Additive Manufacturing (AM) technology in production process flow Enhanced factory planning based on old, re-used factory layout designs including the planning with re-used equipment % % 2 Other (Please specify) % 2 Respondents overall: 11 ReBorn consortium Page 41

42 Q21 ReBorn relies on monitoring and analyzing of data on the shop floor. Which data do you monitor today? Answered: 13 Skipped: 2 Potential answers Answers Process data % 10 Maintenance data % 5 Data during ramp-up % 5 Data during dismantling 7.69 % 1 Other (Please specify) % 2 Respondents overall: 13 ReBorn consortium Page 42

43 Q22 Which data shall be monitored when applying the ReBorn approach in the future? Answered: 13 Skipped: 2 Potential answers Answers Process data % 10 Maintenance data % 10 Data during ramp-up % 8 Data during dismantling % 7 Other (Please specify) % 4 Respondents overall: 13 ReBorn consortium Page 43

44 3.9. Application areas Q23 Which of the capabilities are covered by current state of the art technologies? Answered: 11 Skipped: Overall Average ranking Self-monitoring % % % % % % Proactive diagnosis % 6 0 % % % % 1 0 % Self-healing 0 % 0 0 % % % % % Refurbishment plan generation 0 % 0 0 % % % % % Online update % % % 2 0 % % % Plug & produce 9.09 % % % % 2 0 % 0 0 % ReBorn consortium Page 44

45 Q24 Which of the capabilities mentioned above are most interesting for future devices? Answered: 11 Skipped: Overall Average ranking Self-monitoring % % % % 1 0 % 0 0 % Proactive diagnosis 9.09 % % % % 4 0 % 0 0 % Self-healing 9.09 % % % % % % Refurbishment plan generation 0 % 0 0 % 0 0 % % % % Online update 9.09 % % % % % % Plug & produce % % % % % % ReBorn consortium Page 45

46 Q25 How long do you estimate the life time of tools in average? Answered: 10 Skipped: 5 # Answers Date 1 Question too diffuse : years : years : : years : years : year : years : years : years :02 ReBorn consortium Page 46

47 Q26 How long do you estimate the life time of equipment/production in average? Answered: 10 Skipped: 5 # Answers Date 1 Question too diffuse: 3 years in our case : years : years : years : years : years : year : years : years : year :02 ReBorn consortium Page 47

48 Q27 Which features/capabilities are in your opinion additionally required? Answered: 7 Skipped: 8 # Answers Date 1 standardized software interfaces for self monitoring; software for summing and concentration of self monitoring data :17 2 Plug&play capabilities in heterogeneous environments :20 3 access to specific documentation :35 4 quality monitoring :44 5 working interfaces between refurbished/reused parts and new parts :16 6 Device monitoring and system wide alarm correlation : :47 ReBorn consortium Page 48

49 Q28 Where do you see the major blocking points for using self-monitoring devices? Answered: 10 Skipped: 5 # Answers Date 1 investment increases :17 2 None. We do that actually :20 3 integration and configuration to get the right data :45 4 awareness of context, where the devices is used, is required :35 5 complexity and felxibility :24 6 Higher component costs (extra sensors, intelligence etc), without reducing the actual wear and tear of the component (instead, it can only signal it) :44 7 monitoring in production is state of the art :16 8 lack of standards :47 9 lack of context information : :47 ReBorn consortium Page 49

50 Q29 In which of these features do you see the major economic benefits? Answered: 11 Skipped: Overall Average ranking Self-monitoring % % % 3 0 % % 2 0 % Proactive diagnosis 0 % % % % 5 0 % 0 0 % Self-healing % % % % % % Refurbishment plan generation 0 % 0 0 % % % % % Online update % % 2 0 % % % % Plug & produce % % % % 2 0 % 0 0 % ReBorn consortium Page 50

51 Q30 Would you use re-used equipment in your factory/plant? Answered: 12 Skipped: 3 Potential answers Answers Yes % 4 I don`t know 50 % 6 No. Why not? % 2 Respondents overall: 12 ReBorn consortium Page 51

52 Q31 Besides the technical level, which other requirements need to be fulfilled? Answered: 12 Skipped: 3 Potential answers Answers Service contracts 75 % 9 Close collaboration between supplier and end % 8 Other (Please specify) % 2 Respondents overall: 12 ReBorn consortium Page 52

53 Q32 Could you imagine that today or in the future your product or applied production tools would be produced by using AM technology? Answered: 10 Skipped: 5 Potential answers Answers Yes 40 % 4 No 60 % 6 Respondents overall: 10 ReBorn consortium Page 53

54 Q33 How can you describe the operation area of your AM produced part and what is the lot size of the product(s) you are going to produce using AM technology? Answered: 3 Skipped: 12 Potential answers Answers No. 1: name product/tool 100 % 3 No. 1: lot size 100 % 3 No. 1: cycle time OR throughput 100 % 3 No. 2: name product/tool % 2 No. 2: lot size % 2 No. 2: cycle time OR throughput % 2 No. 3: name product/tool 0 % 0 No. 3: lot size 0 % 0 No. 3: cycle time OR throughput 0 % 0 ReBorn consortium Page 54

55 # No. 1: name product/tool Date 1 specific connecting parts :38 2 custom-made grippers (product-specific) :54 3 orthopedic implants :21 # No. 1: lot size Date : :54 3 1, tailored for individual patient :21 # No. 1: cycle time OR throughput Date 1 Minutes :38 2 production time < 1 week, maybe 10 individual pieces/year :54 3 don't know in advance :21 # No. 2: name product/tool Date 1 Jig components (product-specific) :54 2 rapid prototype development for automotive industry :21 # No. 2: lot size Date : :21 # No. 2: cycle time OR throughput Date 1 production time < 1 week, maybe 100 individual pieces/year : month :21 # No. 3: name product/tool No. 3: lot size No. 3: cycle time OR throughput There are no replies. Date ReBorn consortium Page 55

56 Q34 What is the life time of this/these product(s)? Answered: 3 Skipped: 12 Potential answers Answers No % 3 No % 2 No. 3 0 % 0 # No. 1 Date years : years : years :21 # No. 2 Date years : month :21 # No. 3 Date There are no replies. ReBorn consortium Page 56

57 Q35 What is the physical dimensions of this/these product(s)? Answered: 3 Skipped: 12 Potential answers Answers X x Y x Z mm % 1 Other (Please specify) % 2 Respondents overall: 3 ReBorn consortium Page 57

58 Q36 How can you describe forces transferred on your AM produced part(s) during its/their usage? Answered: 3 Skipped: 12 Potential answers Answers Expressed in Newtons % 1 Ranking high middle low 0 % 0 Other (Please specify) % 2 Respondents overall: 3 ReBorn consortium Page 58

59 Q37 Layout design in the context of this document, is considered as reengineering or new planning production equipments`s, material flow, handling and automation devices, and/or infrastructure facilities. How often do you execute Layout designing and what would be its scope of planning due to? Answered: 5 Skipped: 10 Potential answers Answers Change of products or product variants 100 % 5 Exchange of tools or modules because of product changes 100 % 5 Exchange of tools or modules because of wear of tools and components or economic inefficiencies 100 % 5 Exchange of production equipment because of product changes 100 % 5 Exchange of production equipment because of wear of tools and components or economic inefficiencies 100 % 5 Optimization of the production line and its segments, e.g. measurements to increase energy efficiency 100 % 5 # Change of products or product variants Date 1 Three years :24 2 5/year :42 3 sometimes. In case of an (unforseen) mid-life product update, sometimes a change of the equipment is needed. Or: a new jig is added to an existing machine which had remaining production capacity left :07 4 every few weeks :25 5 Not known :04 ReBorn consortium Page 59

60 # Exchange of tools or modules because of product changes Date 1 Three years : /year :42 3 sometimes. In case of an (unforseen) mid-life product update, sometimes a change of the equipment is needed :07 4 every few weeks :25 5 Not known :04 # Exchange of tools or modules because of wear of tools and components or economic inefficiencies 1 Three years : /year :42 Date 3 seldom (wear parts: often, but this is expected maintenance). The equipment is designed to last the whole machine lifetime :07 4 depending on the material of the product :25 5 Not known :04 # Exchange of production equipment because of product changes Date 1 Three years : /year :42 3 Often :07 4 Every few weeks :25 5 Not known :04 # Exchange of production equipment because of wear of tools and components or economic inefficiencies 1 On demand : /year :42 Date 3 Often. equipment is designed/chosen to have a lifetime equal to the product (model) lifetime :07 4 Every few weeks :25 5 Not known :04 ReBorn consortium Page 60

61 # Optimization of the production line and its segments, e.g. measurements to increase energy efficiency Date 1 one year :24 2 3/year :42 3 seldom :07 4 Every 2 years :25 5 Not known :04 ReBorn consortium Page 61

62 Q38 If applicable, in what cases, mentioned in the previous question, do you use data, information or other implicit knowledge in the process of layout planning to increase the proportion of hardware production equipment or software today? Answered: 6 Skipped: 9 # Answers Date 1 we do nor do that :33 2 Not sure :35 3 In all cases (changes in existing machines, replacing machines), the current factory layout is used as input data. However, this does not implicate that the new machine will always be based on the same concept :16 4 In all cases :33 5 NA : :48 ReBorn consortium Page 62

63 Q39 In which use case within the process of planning and execution of layout planning, if applicable, do you see further potentials to integrate selfdescriptive equipment into the process of Layout planning? Answered: 6 Skipped: 9 # Answers Date 1 we do nor do that :33 2 ad-hoc planning of small series lines :44 3 In the Concept Engineering phase, floorplanning could benefit from descriptive data for our product portfolio. However, this will only work for 'standard' designs, not for custom-made solutions (specials). 4 layout planning is a very individual and tailored process, depending on the requirements of future production : :33 5 conceptual design phase (cost calculation): model and check : :48 ReBorn consortium Page 63

64 Q40 Which know-how and/or resources would you consider as necessary to implement a process of Layout designing which includes self-descriptive equipment and process information? Answered: 5 Skipped: 10 # Answers Date 1 we do nor do that :33 2 Acually, no special know-how or resources :44 3 mechanical layout (floorspace, accessibility of doors and cabinets, etc), product flow layout, performance figures (cycle times, throughput, batch sizes etc), operating conditions (number of required operators and other resources) 4 - knowlegde about all restrictions, capabilities and requirement (product, proces) : : :48 ReBorn consortium Page 64

65 4. Conclusion The survey on the requirements of external, non-reborn organizations revealed interesting aspects. 15 organizations contributed to the gathering of external requirements. A good distribution of industry sectors is covered with a majority in automotive industry. The company roles are different with a major number of system integrators (40%). By this, as system integrators are serving very different applications areas depending on their end-user, a wide perspective is guaranteed. The major input for the survey came from the decision makers (Project/product management, CEO, etc.) within the organizations. As ReBORN targets on re-using of equipment and tools, one of the first question was on the necessity of reuse as such. The outcome of the analysis of this question clearly revealed the importance of scientific efforts within this sector: For 80% of the organizations, equipment re-use an interesting and important part or their (future) strategy in which high potential is expected. The major drivers for equipment reuse are cost saving aspects. The current state of the art reveals that advanced efforts in approaches for equipment reuse are required. Even if equipment is already reused and about 50% of the organizations rely on reused equipment and so also have quite good experience with this strategy, some critical issues have to be tackled. The major technical blocking point for a further uptake is seen in the uncertainty about the technical risks of using old/refurbished equipment (60%). Major impact is seen in the improvements on shopfloor (devices and mechanical systems) while factory planning issues are to be addressed by only 25% of the involved organizations. The availability of data is seen as a significant issue in order to realize equipment reuse. Nowadays, process monitoring is usually done in order to gain data relevant for equipment reuse. Other data (maintenance, data during dismantling ) is nearly not covered. However, especially the availability of maintenance data of particular interest (Q22 Which data shall be monitored when applying the ReBorn approach in the future? p. 43). The capabilities and features which are expected from the equipment, self-monitoring and proactive diagnosis are seen to be very important. On the other hand, self-healing and refurbishment plan generation are not important in the eyes of the external persons. This is in particular interest as it is in contrast to the internal requirement and also of the scope of several project calls within FP7 and Horizon For that reason, we interpret the result of this particular question rather as a lack of awareness of such features than a clear statement against their need. Besides the technical readiness, service contracts and close collaboration between supplier and end user are important for equipment re-use. This reflects the internal requirements and also the experience of collaborative research and development activities of several partners. ReBorn consortium Page 65