Factories of the Future Industry 4.0 The European Perspective Luis Carneiro INESC TEC, on behalf of EFFRA
Agenda The importance of the manufacturing industry EFFRA The European Factories of the Future Research Association EFFRA Strategic Roadmap 2020 EFFRA Roadmap 2020 and Industry 4.0 Examples of FOF projects Future calls for proposals
Background Manufacturing & Europe How important is manufacturing? Despite the continued fall-out from crisis, manufacturing means a lot for Europe: 20 % Direct jobs 67 % Exports (673 billion ) 65 % Business R&D Expenditure Manufacturing in Europe remains diverse Importance of manufacturing now recognised by EU and its member states... Positive trade balance in: Machinery Transport equipment (mainly cars, but also trucks, trains etc) Chemicals Processed agricultural products...but also by Europe s competitors Development of more competitive & sustainable industry needs support => Factories of the Future
Realising Industry 4.0 in Europe Factories of the Future The European Union s pre-competitive, collaborative programme for manufacturing research & innovation Launched in 2010 Factories of the Future is a contractual public-private partnership The EU & industry have committed to support European research & innovation Funded through EU s Horizon 2020 research & innovation programme Budget: 1.15 billion Strategic research agenda = Factories of the Future 2020
EFFRA Europe s Factories of the Future Association Representing private side in Factories of the Future PPP 160 members (Large, SME, RTO etc.) from across Europe An experienced, enaged and motivated community www.effra.eu Actively promotes Factories of the Future PPP & projects Collaborates closely with EC to develop strategic research agenda ( roadmap ) Works with national & regional initiatives
Factories of the Future 2020 Strategic Roadmap One document covering 2014-2020 Developed by EFFRA & through broad public consultation Identifies megatrends which drive structural changes in manufacturing sectors Establishes research priorities which will allow industry to meet these challenges Priorities focus on development, application & integration of enablers & technologies Factories of the Future call topics based upon research priorities = industry relevant Not static: we are developing the Roadmap further
Factories of the Future 2020
Factories of the Future cppp: Progress FoF in figures 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 Nr of projects Cumulative total FoF-2010 25 projects post-project impact & investments 25 25 FoF-2011 36 projects post-project impact & investments 36 61 FoF-2012 37 projects post-project impact & investments 37 98 FoF-2013 53 projects post-project impact & investments 53 151 FoF-2014 25 projects post-project impact & investments 29 180 FoF-2015 25 projects post-project impact & investments 28 208 FoF-2016 37 projects post-project impact & investments 37 238 238 Projects to date. > 1,500 organisations participating High involvement of SMEs: 200+ Majority of projects feature demo activities 700+ results have been reported on EFFRA Innovation Portal Close to the market exploitation of project results Project results enhancing existing products
Factories of the Future & EFFRA Connecting National & Regional programmes
From FoF 2020 roadmap to Factories 4.0 & Beyond
Structural Changes Digitalisation Digitalisation will affect manufacturing in a similar way as it is already happening to communication and consumers markets
Structural Changes Increased level of digitalisation Roos, G. (2014). The constantly changing manufacturing context. Chapter 1 in Advanced Manufacturing - Beyond The Production Line. Committee for Economic Development of Australia (CEDA).
Factories of the Future Factories 4.0
Factories of the Future Inspiration? Benchmark?
Additional skin: damping Tactile sensors Capacitive proximity sensors Slow down Stop with seamless continuation of tasks afterwards (Category 2) Full stop (Category 0) MRK-Systeme
The Productive Robot Apprentice Compare robot learning by masterapprentice relationship. Master teaches by demonstration. Apprentice watches actions and effects and stores these in his knowledge base. While applying this new skill, the master corrects the execution by refining the experience. This loop is iterated until satisfied result is obtained. Operation without safeguards : limited velocity -> dual armed robot approach for achieving required productivity Local mobility in the workplace.
SUstainable PREdictive Maintenance for Manufacturing Equipment Industrial end-user (paper mill) : Condat Transfer and Dissemination : Cofely-Endel SME s as solution provider : Orloga (Paper engineering) EC_Systems (CMS provider) Optimitive (Process optimization) Loy&Hutz (CMMS) R&D partners CETIM FhG-IPA Grenoble-INP CVUT ril 2015 FoF impact workshop - Success story: SUPREME
Outcome adapt dynamically maintenance planning to the current condition of critical components an increase in the reliability and availability of the production equipment and a decrease of the maintenance costs, a decrease of the energy consumption with an optimized operation of the machine.
Factories of the Future: Demonstration I-RAMP3
Factories of the Future: Demonstration I-RAMP3 Cyber physical solutions exemplified on an e-vehicle assembly line 50% Decrease of ramp-up time for joining technologies 90% Decrease of ramp-up time for specialized assembly systems
Network-enabled Devices -- NETDEVs NETDEV Device interface Real-time system NETDEV communication Intelligent extension of traditional devices, featured with Self-description Self-connecting Self-awareness and self-adaptation Task driven operation High level communication In the Demonstrators, NETDEVs for Servo-presses, Welding controls, Sensors, Cell orchestration, Data collection, Real-time communication I-RAMP 3 compatible communication
Impacts -- Examples
Virtual Simulation and Training of Assembly and Service Processes in Digital Factories
Project Example FORTISSIMO Enabling manufacturing SMEs to benefit from high performance-computing cloud-based simulations www.fortissimo-project.eu
Project Example MANUTELLIGENCE www.manutelligence.eu
Apps4ame Engineering Apps for advanced Manufacturing Engineering New tools to model, simulate, optimize and monitor planned and existing manufacturing systems necessary to overcome the complexity of demand dictated, personalized, customer-driven and knowledge-based proactive production Digital systems are often Large applications with many functions Difficult to use expensive Not crosslinked Difficult to integrate in Legacy Systems Not mobile Engineering Apps (eapps) are in comparison Small applications with few features, available in many devices (Tablets, phones) Highly specilized Crosslinked Easy to use Consortium:
Apps4ame Hybrid Process Manager Dashboard for holistic view of project status Real time monitoring and control of the ongoing work activities Totally integrated Knowledge and Document Management Technical integration with Windows and MS-Office productivity tools, which are widely used by project teams Integrated communication / Messaging along the process activities Problem solving support - tickets management integrated with all entities Support to individual tasks management
Apps4ame - SmartObjects Rules creation and configuration CLoud platform Smart Object Midlleware Condition monitoring Alarms generation (earlywarnings) Local access to information and technical assistance
Scalable 4.0 Scalable automation for flexible production systems Objective: Develop and demonstrate a Scalable production system framework, where: Robots are considered as a pool of production resources Robots are plug-n-produce production resources Robots integrate seamlessly with the humans and the production system and are a source of flexibility 29
Scalable 4.0 30 Considering sharing of Tasks between humans and robots, health and safety, scalability,
Factories of the Future: Factories 4.0 Recent Developments Factories of the Future Conference 2016 Major gathering of experts to discuss achievements of partnership Opened by Commissioner for Digital Economy & Society, Gunther Oettinger Recognition of importance of industry 4.0 Projects showcased results & progress Conference demonstrated work underway to realise industry 4.0 with factory 4.0 at its heart Factories 4.0 & Beyond working document unveiled Complement existing roadmap 2018, 2019 & 2020 Call Topics will be based upon Factories 4.0 & Beyond
Factories of the Future Call 2017 (Open) 85 million for the following topics: FoF-06-2017: New product functionalities through advanced surface manufacturing processes for mass production FoF-07-2017: Integration of unconventional technologies for multimaterial processing into manufacturing systems FoF-08-2017: In-line measurement and control for micro-/nanoenabled high-volume manufacturing for enhanced reliability FoF-09-2017: Novel design and predictive maintenance technologies for increased operating life of production systems FoF-10-2017: New technologies and life cycle management for reconfigurable and reusable customised products 33 million for the following topic: FoF-12-2017: ICT Innovation for Manufacturing SMEs (I4MS)
Factories of the Future: Call 2017 (Opens in 2016) Online Brokerage Open Online brokerage for Call 2017 is open on EFFRA s Innovation Portal www.effra.eu/portal Upload an expression of interest in a call topic Find potential project partners Innovation Portal includes information on all Factories of the Future projects launched to date including information on project consortia. PPP Info Day on 14 October 2016 in Brussels
Factories of the Future: Key Tool EFFRA Innovation Portal One reference resource for progress monitoring for sharing information among projects for promoting projects, results and demonstrators to the wider community for portfolio management and analysing coverage of FoF 2020 roadmap for supporting the further roadmapping exercises www.effra.eu/portal
Thank You info@effra.eu luis.carneiro@inesctec.pt @EFFRA_Live TM EFFRA.Live TM EFFRA.EU TM