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Manufacturing 2030

Strategies for Next Generation Manufacturing

Engelbert Westkämper

Prof. Dr.-Ing. Dr.Ing. E.h. Dr.h.c. mult

University Stuttgart, Germany

Fraunhofer IPA

MANUFUTURE next generation

Share of Manufacturing of the national BIP 40 Years of de-industrialisation in US and Europe

Globalization Migration of Production and Consumption to lower developed areas


Innovative Regions in Europe

Regional Innovation Scoreboard (2009)

See: http://www.proinno-europe.eu/page/regional-innovation-scoreboard

http://www.proinno-europe.eu/page/regional-innovation-scoreboard








Manufuture Activities

2008 2009 2010 2011 2020 2030 Time

Growth

Factory of the Future

Manufuture SRA + Road EFFRA Road 2013 ICT for Manufacturing

Manufuture Strategic Orientation

Innovative Products Innovative Processes New Business Models Efficient Infrastructure Education for Future


Megatrends with Impact on Manufacturing

Ageing Future markets and products Human work and organization

Individualism Individual and customized products Relation of human being and work

conditions Knowledge in the global ICT

Knowledge driven Product-Development

Optimization of manufacturing processes

IP and IT security Globalization

Global process-standards in OEMs Products and manufacturing

technologies for the global markets Local conditions and regulations Competition of locations

Urbanization Environment, Mobility, Traffic, … New products for mega-cities Work in mega-cities Factories in urban environment

Sustainability Priorities for economic, ecologic, social

efficiency of manufacturing Finance

Turbulences in finance of investment R&D and long term assets Economic cycles

Public debt Adding value - Resilience Growth for employment Taxes, general conditions


Individualism

Megatrends and fields of Actions

Politics

Education

Infrastructure

Manufacturing 2030

Research

Globalization

Ageing

Sustainability

Finance

Technologies

Urbanization

Public debt

Knowledge & ICT

Population

Resources

Customization


Manufacturing technologies are the key enabler for adding value

Product requirements Engineering Production

Control

Manufacturing Engineering

System- integration

Product sales and aftersales

Product Development

Production

Life cycle knowledge

Adapt/Reuse

Key enabling technologies

Emergent technologies and methods for the Factories of the Future Factory Networks Manufacturing plants/systems Manufacturing Equipment Modules/components

Slide 7


Industrial Sectors of Manufacturing

Con

sum

er G

oods

Cap

ital I

nten

sive

Goo

ds

Systems, Machines and Equipment (tools, etc.) for Manufacturing

Equipment and Systems for Transport and Logistics

Technical and Mechatronic Components

ICT for Manufacturing

Manufacturing Systems for Food, Pharma, and Biochemical

Manufacturing Systems for Consumer products

Aerospace, Shipbuilding, Trains

Electric and House-Products

Automobile and Suppliers

Food, Pharma, and Bio-chemical Products

Consumer Products Textile, Leather, Sports, …

Agriculture, Furniture,

Materials and semi-finished goods - Recycling Industries

Services along the product life cycle


Strategic Objectives

1 3

2 4 1 Strengthen

Customization

3

2

4

Leadership in Sustainable Manufacturing Global Standards Factories of the Future 4 Major Factories Adding Value and Growth

Efficiency

Competitive & Sustainable Development

European Infrastructure

Technical, economic, ecologic and social Standards


Topics of the Strategic Innovation Agenda

Innovative Technologies for Manufacturing

Competitive & Sustainable Development

• Infrastructure

& Education

• New Business Models in the Life Cycle of Products

• Knowledge based Manufacturing Engineering

• Innovative Products & Processes

Factory as good

neighbor Manufacturg

in urban Environment

Volume production

back to Europe

Next Generation

ICT for Factories

Factory

and Nature Lean, Clean, Green

Factories


Manufacturing in the Urban Environment

Research Institutes

Transport Logistics

Financial Services

Local Energy system

Communication Services

Arts Homes

Schools Basic Education Sports

Customers / Markets

Entertainment

IPA

000

_008

8

Universities Environmental

Services

Higher Education

Health

High Adding Value

Advantages from public

Infrastructure ?

Factories of

emotions?


Masnufacturing in the Value Chain

Design Engineering Assembly Usage / Service Disassembly

Recyling As Requested

As Designed As should Build

As Build As Is As Maintained

As Recycled

High Quality High Performance High Utilization Reconfigurability

Low Cost High Profit Customer Relation Adding Value by Services

Manufacturer User


Manufacturing in the value chain

Retrieval & Reobtain Environment and Value

High Adding Value & Competition

MaterialParts

ComponentsMechatronics Assembly

UsageMaintenance

Services

Recycling Re-manufacturing

Dis-Assembly

NaturalSources

Waste

Efficiency


Factory and Nature - The Green Factory: Lean, Clean, Green

Zero Emissions Noise, Air,...

No Waste Process….

Sustainable Processes

Total Energy- Efficiency

Management

Technical Intelligence - Mechatronics

Product Life Cycle

LCA

Dematerialization

Management of Hazardous Substances Remanufacturing

and Recycling

Carbon Footprint

Green Logistics

Slide 14


Technologies beyond Borders

Design & Engineering &

Manufacturing & Management

Process- technologies

Advanced Materials

Intelligent Mechatronic

Systems

Cognition Based

ICT

Nano-Scale Technologies

High Performance cost, time, quality Dimensions micro- and nanoscale Environmental clean, sustainable Generative Processes additive technologies Adadaptive Processes self-organisation Energy Efficiency electric, heat, Material Efficiency material, air, oil,… Management Efficiency organization, optimisation

Implementation in intelligent manufacturing systems in all sectors of manufacturing


Cum. production

Real Production

Digital Production

expenses per piece modelling

simulation Conventional Manufacturing Empirical learning

production engineering

New Age: digital – real manufacturing

Benefits in early Phases


Manufacturing in the digital Age

Digital Products

Digital Factories

Engineering in a digital

Environment

with „Soft-

Machines“ „Engineering

Apps“

Administration in a digital

Environment

with changeable,

individual Workflows

Threats: ICT-Security, gap digital-real world, ICT costs, bureaucracy

Global ICT - Networks – Product Life-Cycle Management – real time IT

Opportunities: Tools for Engineers (soft Machines), IT-Services, Efficiency of Engineers


• Phänomena

• Models

• pysical basics

• Feasibility

• Technical Realization

• Limits

• Innovative Engineering

• Precompetitive Engineering

• Products

• Production Systems

• Product Support

• Recycling

Natural Science Fundamental Research

Engineering Science Basic Research and Analysis

Application Research and Development

Optimization Usage

IPA

000

_059

6

Visions and Applications

in Mind


Strategies for global Markets

European Economy

Competitive & Sustainable

Manufacturing

Global Economy

Export

Import

Sustainable Solutions

Manufacturing Standards

ICT based Services

Synergies of Regional Cooperation

Efficient Engineering

Market driven Innovation


Conclusions

Stopp de-industrialization by increasing manufacturing

Megatrends influence manufacturing ….

….they are a new Chance for Europe

Major Topics for Factories of the Future

Digital age for manufacturing

Research and Education – European Infrastructure

High adding value by competitive and sustainable development


Volume Production (back) to Europe European Trendsetting: design oriented products, customized mass

products

Research focus: basic and low-technologies

Customization: design to manufacturing“ and from „customer order to delivery

Make use of flexible Automation and Technical Intelligence: Lean, clean, green manufacturing Integration of process knowledge in the machine control and monitoring

systems IT- support for technicians and workers, e-learning at work On-line peripheral services: maintenance, process know how

Human oriented interfaces for workers: in-situ simulation and visualization

products and work for low skilled labor, education and training with IT-Support

Regional orientation: work conditions in line with the way of life, flexible time- and wage- systems


Back Up


Knowledge based Manufacturing Engineering

Manufacturing Engineering Digital and virtual

Product Engineering, Process planning

and Process control with learning elements and In situ-Process-Simulation

Variancy Zero-Defects

Customised Manufacturing Solutions

Process Technologies beyond limits

Flexibility for turbulent Markets

Intelligent Machines

Increasing the quality and efficiency of manufacturing engineering

Flexibility and High Performance High energetic efficiency

Remote Manufacturing

Scientific based Process Models


πάντα ῥεῖ - “Panta rhei”- Everything is flowing

Global Competition

Permanent Adaption of the

‚System‘ Production

Products Markets Order Trends

Organization Management Methods ICT-Systems

Innovation Products Processes

Location Buildings Machines Equipment

Law, Guidelines, Standards Pay Scale Agreement Company Agreements

Staff - Qualification - Motivation

Shareholding Financing Capital Markets

Slide 24


Grand Challenge: Dematerialisation of Products Reduction of the material-consumption by:

- Light weight construction, multi-material design, joining technologies

- Miniaturisation of dimensions (parts, components, products)

- Intelligent engineering with specialised materials (function oriented Implementation of new technologies (Nano, Graphene etc.) Integration of functions (adaptronic, sensors, actors)

- Mechatronik components, Embedding electronics, MID

- Reduced process chains (near net technologies)

- Process capability (waste, scrap, defects etc.)

- Recycling technologies, remanufacturing technologies

…is a contribution to reduce energy consumption


Manufacturing in urban environment & mega cities Products: customized technical consumer goods, design oriented

products, configurable/modular construction

Emotional manufacturing Zero Emissions of processes and factories: Noise, Air, Fluids,

Waste…. Short Process chains, integration of processes Desktop Machines: small, medium dimensions Intelligent green logistics Digital products – digital factories Human centered workplaces Tele working

Factory layout: flexible, open, integrated, lowest floor space

Production System: human centered, flexible hours of work, event-driven organization

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