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The European Manufacturing Scenario Factories of the Future
Speaker: Paolo Calefati
Who We Are European Factories of the Future Research Association (EFFRA)
Industry-led association representing private side in the ‘Factories of the Future’ Public-Private Partnership with European Commission 160+ members from across Europe (growing) Members include large, small & medium industrial enterprises, research organisations, universities, industrial associations and clusters Full time secretariat: Connecting with members, coordinating research agenda & liaising with the European Union
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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 65 % Business R&D Expenditure Manufacturing in Europe remains diverse
Importance of manufacturing now recognised by EU and its member states...
....but also by Europe’s competitors
Realising the potential of 4th industial revolution needs support = ‘Factories of the Future’
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Progress Factories of the Future PPP
1.150 M€ program within Horizon 2020, of those 110 m€ for I4MS (ICT for Manufacturing SMEs) program
200+ projects
1,300+ organisations participating
60% industrial participation
>30% of funding to SMEs
77% of funding to non-EFFRA members
Partnership is addressing all multiple topics to transform manufacturing (from CPS to zero-defect factories)
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Factories of the Future 2020
Strategic Roadmap
One living 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
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Factories of the Future 2020: Priorities to Realise Structural Changes
Strategic Roadmap
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Factories of the Future: I4MS
ICT in ‘Factories of the Future 2020’
Manufacturing for custom-made parts
M2M Cloud connectivity for future manufacturing enterprises
Integrated high-performance computing
Collaborative demand & supply planning, traceability & execution
‘Plug-and-play’ interfaces for factory workers in dynamic work environments
ICT solutions for energy-efficient product life cycles
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FoF 1 – 2014: Process optimisation of manufacturing assets FoF 2 – 2014: Manufacturing processes for complex structures and geometries with efficient use of material FoF 3 – 2014: Global energy and other resources efficiency in manufacturing enterprises FoF 4 – 2014: Developing smart factories that are attractive to workers FoF 5 – 2014: Innovative product-service design using manufacturing intelligence FoF 6 – 2014: Symbiotic human-robot collaborations for safe and dynamic multimodal manufacturing systems FoF 7 – 2014: Support for the enhancement of the impact of FoF PPP projects FoF 8 – 2015: ICT-enabled modelling, simulation, analytics and forecasting technologies FoF 9 – 2015: ICT Innovation for Manufacturing SMEs (I4MS) FoF 10 – 2015: Manufacturing of custom made parts for personalised products FoF 11 – 2015: Flexible production systems based on integrated tools for rapid reconfiguration of machinery and robots FoF 12 – 2015: Industrial technologies for advanced joining and assembly processes of multi-materials FoF 13 – 2015: Re-use and re-manufacturing technologies and equipment for sustainable product lifecycle management FoF 14 – 2015: Integrated design and management of production machinery and processes FoF-01-2016: Novel hybrid approaches for additive and subtractive manufacturing machines FoF-02-2016: Machinery and robot systems in dynamic shop floor environments using novel embedded cognitive functions FoF-03-2016: Zero-defect strategies at system level for multi-stage manufacturing in production lines FoF-04-2016: Continuous adaptation of work environments with changing levels of automation in evolving production systems FoF-05-2016: Support for the further development of Additive Manufacturing technologies in Europe FoF-06-2017: New product functionalities through advanced surface manufacturing processes for mass production FoF-07-2017: Integration of unconventional technologies for multi-material processing into manufacturing systems FoF-08-2017: In-line measurement and control for micro-/nano-enabled 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 FoF-11-2016: Digital automation FoF-12-2017: ICT Innovation for Manufacturing SMEs (I4MS) FoF-13-2016: Photonics Laser-based production
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Factories of the Future & EFFRA
Connecting National & Regional Programmes
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Importance of Investment Investment in R&D is Part of Solution to Recover from Crises
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… new technological challenges are in front of us
Digital Revolution will affect manufacturing in a similar way as it is already happening to communication and consumers markets
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October 2015
(…. but 1202 CPUs to beat Go World Champion)
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90 IBM Power 750 Servers 2880 Power7 Processors cores 16 TeraByte RAM 80 TeraFLOPs Power consumption 200kW vs 20 W of a human brain Won Jeopardy (America’s favorite Quiz show) in 2011
Artificial Intelligent Market growing at a CAGR of 54.56 % between 2015 and 2020 (source: Marketandmarkets) – 8 on 10 key players from the USA
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Product variety
Prod
uct v
olum
es
1850 - Handcraft
1908
1950
Time
2000 - Globalisation
?
Source: PoliMi
Mass Production Mass Customisation “I manufacture what
I need at home”
… and change of business models: Mass Customisation
Source: McKinsley/VDMA
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Factories 4.0 & Beyond Factories of the Future PPP
‘Factories of the Future 2020’ is not the end of the story – EFFRA is preparing complementary agenda to tackle new challenges
Success of the ‘Factories of the Future’ under Horizon 2020 = Highly likely to continue under next programme
Future of industry (e.g. Industry 4.0) requires continuation of successful programme
Factories of the Future is already realising the potential of this next industrial revolution
What might this mean?....
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Factories of the Future: Industrie 4.0 Germany
Source: McKinsley/VDMA
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Factories of the Future: Factories 4.0 - proposal
Innovative SMEs
High-level of customisation & quality
Rapid adaptable production lines
Re-manufacturing
Focused on zero defects
Interconnectivity, communication & data storage via cloud
Factories closer to customers
Energy & resource efficient
Adaptable workplaces for changing worker demographic
Continous skills improvements: multi-skilled jobs
Courtesy TNO
Courtesy Prima Power
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From classical manufacturing/supplier to brand owners and regional eco systems
Innovation 4.0 Industry 4.0 Economy 4.0
+
Courtesy Brainport Industries
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Our European ambition
Factories 4.0 = Innovation 4.0 + Industry 4.0 + Economy 4.0
IoT/Big Data/Cyber Security/Cloud/Blockchain
Innovation 4.0: you can’t innovate alone, you need a networked innovation eco-system – smart specialization of a region Industry 4.0: automate to lower the costs of manufacturing on the shopfloor Economy 4.0: create a Digital Marketplace to automate and lower the cost of transactions
Single product manufacturing for the price of mass produced, in town/region in Europa personal(consumer)/(B2B), series size N=1, zero defect, short delivery, close to customer new manufacturing paradigm: economy of networking, not scale
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Today’s manufacturing with economy of scale (yesterday in Europe, today in China)
design delivery production
design delivery production
design delivery production
Customer
OEM/Brand D OEM/Brand F
OEM/Brand E
B2B: OEM B2C: Brand D
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Future of manufacturing: Factories 4.0 in metropolitan area (smaller factory, close to the customer)
location A
design production D
E
design production F
location C
location B
purchaser X
purchaser Z
A C
B
Customer ordering at web
Customer
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15 & 16 September 2016 (Brussels)
Major conference centred on future of manufacturing in Europe.
Bring together Europe’s leading experts in industrial research and innovation to debate major priorities for the future of manufacturing in Europe.
Showcase the success of ‘Factories of the Future’ projects (including those participating in I4MS)
Two pitching sessions. In these sessions participants in 'Factories of the Future' projects will have the opportunity to present briefly their results to potential business and innovation partners.
conference2016.effra.eu
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15 & 16 September 2016 (Brussels)
conference2016.effra.eu
Topics:
Digital Technologies & the Factory Floor Energy & Material Efficiency Digital Technologies & Networked Factories Human-Centred Manufacturing Data Security, Liability & Integrity in Connected Factories Product Life-Cycle Management & Business Models in a
Product-Service Economy Lightweight Components & High Precision Manufacturing High-Performance Computing & Simulation Additive Manufacturing & Advanced Joining Technologies Next Generation Robotics & Mechatronics in Manufacturing
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Successful case: Prima Industrie, over 35 sparkling years
Long tradition in mechatronics and photonics
1979 - Zac
1985 - Optimo
1990 - Rapido 2001 - Laserdyne
1997 - Platino 2003 - Agilaser
2005 - Syncrono
2008 – Fiber Today –
Green&Smart
2011 - PPPLab
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PRIMA Strategic Innovation Projects
Laser sources and optics
Additive Manufacturing
Industry 4.0
Laser additive manufacturing
Solid state laser sources Mechatronic solutions with integrated optics
The Internet of Things, Cybersecurity, The cloud, Big data analytics, Simulation, Augmented reality, Robots, Horizontal and vertical system integration
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Laser in Material processing: Laser cutting Laser welding Laser cladding Additive manufacturing Laser texturing Laser ablation
Photonics as key enabling technologies for a sustainable manufacturing
Laser: … and for many different applications
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Additive manufacturing, the third industrial revolution
Additive manufacturing represents the third industrial revolution It is the first industrial revolution leaded by societal needs, but expectations exceed the available industrial solutions AM should become more industrial: High productivity for large parts with flexible and industrial machines
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Trebuchet MS, 10 Black
INDUSTRY 4.0
OPTIMIZATION
SERVICE DATA COLLECTION (PROCESS, MACHINE)
DATA MINING IN CLOUD
ADDED VALUE 27
Strategic Innovation Projects: since 2010, participation in collaborative European programs/platform
Laser sources and optics
Additive Manufacturing
Industry 4.0
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Funded Projects and collaborative research programs
Companies involve in collaborative programs: 1. To look for new and future technologies 2. To explore new applications 3. To learn from other sectors 4. To approach problem in different ways 5. To improve resources 6. To get networks and connections 7. To stimulate efforts and for change
management 8. To reduce the time to market 9. … in general to be more competitive in the
future…
New external/extra resources could provide extra value to R&D activities: a. they could improve core business in terms of quality and performances b. they could indicate new potential adjacent businesses close the company core
activities c. they accelerate innovation
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0,0%
5,0%
10,0%
15,0%
20,0%
2010 2011 2012 2013 2014 2015
EBITDA
R&D Investment
R&D Collaborativeprograms
€ -
€ 20.000
€ 40.000
€ 60.000
€ 80.000
€ 100.000
€ 120.000
2010 2011 2012 2013 2014 2015
0,0%2,0%4,0%
6,0%8,0%
10,0%
2010 2011 2012 2013 2014 2015
EBITDA
R&D Investment
R&D collaborativeprograms
Employement
0100200300400
2010 2011 2012 2013 2014 2015
Employement
IMPACT
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€ 0€ 10.000€ 20.000
€ 30.000€ 40.000€ 50.000
2010 2011 2012 2013 2014 2015
Employement
170180190200210
2010 2011 2012 2013 2014 2015
Employement
Conclusion
Innovation is fast, faster than in the past! Today, market condition are oppressive and are forcing companies to seek new profit opportunities. Innovation is the only way to escape this pressure The involvement in technology clusters for a company is crucial. Collaborative programs create a innovation ecosystem where the “best” companies launch profitable open innovation R&D strategies. In this way it is possible to integrate marketing into innovation process since the beginning
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Pope elections in 2005 and 2013
The impact of the innovation activity results maximized and research became an investment to be capitalized on our own company products or versus third parties (technology clusters)
If you want to go fast go alone,
If you want to go far go together
Thank you for your attention
[email protected] www.effra.eu
EFFRA.EU
@EFFRA_Live
EFFRA.Live
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