PPP InfoDay 11 July 2011, Brussels - European …...PPP InfoDay 11 July 2011, Brussels “Smart...

PPP InfoDay11 July 2011, Brussels

“Smart factories”with next generation of production systems

ICT Objectives 7.1/7.2

Erastos Filos, FoF ICT CoordinatorChristoph Helmrath, Laser Manufacturing & Photonics

Rolf Riemenschneider, FoF Smart & Digital FactoryFoF-ICT-WP2011-12

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Outline

• FoF-ICT: Background & Rationale

• Outcome of first FoF ICT Calls in 2009/2010

• The FoF ICT Call in 2011

• Useful linksFoF-ICT-WP2011-12_InfoDay 11July2011

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Industries’ needs for ICT innovation: Productivity growth & Societal challenges

• more sustainable way of production

• make full use of next generation ICT in the shop floor

• boost labour productivity

• use less resources and new materials

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Recovery Plan Objectives:Industrial Competitiveness

Technology/manufacturing equipment suppliers to gain market share:• Automation/industrial robotics & laser technology solutions for factory environments• Product/production design tools (eg software for modelling, simulation, visualisation)• Enterprise/supply-chain management tools

Technology/manufacturing equipment suppliers to gain market share:• Automation/industrial robotics & laser technology solutions for factory environments• Product/production design tools (eg software for modelling, simulation, visualisation)• Enterprise/supply-chain management tools

European industrial end users: • To integrate latest ICT into their production environments• To develop new competencies (knowledge, organisation, skills, business models)• To use ICT that enable energy-efficient and “waste-less” production

European industrial end users: • To integrate latest ICT into their production environments• To develop new competencies (knowledge, organisation, skills, business models)• To use ICT that enable energy-efficient and “waste-less” production

ICT

Supply side

Demand side

FoF-PPP-InfoDay

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Factories of the FutureMulti-Annual Roadmap 2010-2013

Sub-Domains:

1. Sustainable Manufacturing

2. ICT-enabled intelligent manufacturing

3. High-performance manufacturing

4. Exploiting new materials through manufacturing

http://ec.europa.eu/research/industrial_technologies/pdf/ppp-factories-of-the-future-strategic-multiannual-roadmap-info-day_en.pdf

http://ec.europa.eu/research/industrial_technologies/pdf/ppp-factories-of-the-future-strategic-multiannual-roadmap-info-day_en.pdf

FoF-PPP-InfoDay

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Smart Factories:– Goal:

More automation, better control & optimisation of factory processes

– Means:Software, lasers & intelligent devices embedded in machines & factory infrastructure

Vision: ICT is keyto Factories of the Future

• Less waste• Less energy use• Faster time-to-market• Better quality

Virtual Factories:– Goal:

To manage supply chains; to create value by integrating products & services

– Means:Software to holistically interconnect & manage distributed factory assets; new business models & value propositions

• High-value products• Keep jobs in Europe• Process transparency• IPR security• Lower CO2 footprint

• Reduce design errors • Better & efficient products• Less waste + rework• Faster time-to-market

Sensors,Tags

ProductProduct

PLM agentPLM agent

(reader) (reader)

PLM serverPLM serverdata

data

infoadvice

info Inforequest

Digital Factories:– Goal:

To “see” the product before it is produced– Means:

Software for the digital representation &test of products & processes prior to their manufacture & use

FoF-ICT-WP2011-12

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Factories of the Future & ICT Work Programme

2010 20122011 2013

SmartFactories

Obj. 7.1(35 M€)

FoF Call

70 M€

VirtualFactories

Obj. 7.3(45 M€)

DigitalFactories

Obj. 7.4(35 M€)

SmartFactories

Obj. 7.1(40 M€)

Manuf. solutions

for new ICTproducts

Obj. 7.2(20 M€)

Total ICT245 M€

FoF-ICT-WP2011-12_2011

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Outline

• FoF: Background & Rationale

• Outcome of two FoF ICT Calls in 2009-2010

• The FoF ICT Call in 2011

• Useful links

FoF-ICT-WP2011-12

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Results of first FoFICT Calls

WP2010 WP2011

• Success rate: 24% 22%

(08 funded (18 fundedof 34) of 80)

• Oversubscription 1:5 1:4

• Participation by Org. Type:

- Higher Education: 23% 24%

- Private for Profit: 54% 50%

- Research Org.: 22% 25%

• Participation by SMEs: 26% 31%

FoF-PPP-InfoDay

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Factories of the Future Calls Experience

FoF is:- Attractive to industry- SME-friendly- of shorter term scope

Smart Factories

ICTDigital

FactoriesVirtual

Factories2010 Call• 45 M€• 10 projects

2010 Call• 35 M€• 8 projects

2009 Call• 35 M€• 8 projects

2011 Call• 40 M€• ? projects

7.1

2011 Call• 20 M€• ? projects

7.2

FoF-PPP-InfoDay

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Outline



• The FoF ICT Obj.7.1


• Useful linksFoF-ICT-WP2011-12

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Production with higher value creation

• Respond to larger variance of products– Allow scaling of lot sizes & reconfigurability

in production processes.– Continuously monitor product quality and optimize

production parameters– FoF: Tackle ‘disruptive’ production and process paradigms

• Support Scaling/Customization of production line

• Monitoring and Adaptation of non functional –key performance indicators (KPIs) at shop floor level – like robustness, safety and energy consumption

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Agile Manufacturing & Process Control

High-end Automation/

mass production

RapidPrototyping/

Customization

WP2012WP2012 FoF ICT Call on “Smart Factories”:Production with higher value creation

(a): Process automation& optimisation

(a): Process automation& optimisation

(b): Factory-wide sensor networks

(b): Factory-wide sensor networks

(d): Laser applications(d): Laser applications

(c): Robotics-enabledproduction

(c): Robotics-enabledproduction

ActionPlanT –ROADMAPPING

FoF-ICT-WP2011-12_InfoDay 11July2011

Robotics-enabled production

Laser applications

Sensor networks for

energy efficiency

Architecture

Design and

Advanced Control

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a. Demonstration & Benchmarking of novel process automation & control

–

b. Advanced industrial robotics systems

c. Factory-wide networks of intelligent sensors and new metrology tools

d. Lasers and laser systems for manufacturing and materials processing

Target outcomes

Objective 7.1: Smart FactoriesEnergy-aware, Agile Manufacuring & Customization

Call FoF in 2011 40 M€ IPs/STREPs

IP

STREP

IP

STREP

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Objective 7.1: Smart FactoriesEnergy-aware, agile manufacturing & customisation

a)a) Demonstration & Benchmarking of Demonstration & Benchmarking of novel process automation & controlnovel process automation & control

Research Challenges:

• Benchmarking for discrete, continuous and/or batch industries

• Next generation automation & control with flexibility, autonomy, robustness and energy transparencyin real world environments

• Lean & dynamic – facilitate factory level optimisation of production processes• Data aggregation across existing legacy systems (ERP,

MES, SCADA, DCS)

FoF-PPP-InfoDay

Only IP

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Some hints for Demonstration & Benchmarking of

novel process automation & control

• Benchmarking of novel process automation &control– Achieving operational excellence, integrating planning, operation,

surveillance, ramp up and dispatching• Awareness of key performance indicators

• With emphasis on robustness, safety, energy, sustainability• Benchmarking at international level• Benchmarking based quantitative evaluation targets defined in terms of the

operational and economic benefits.

• Dynamic optimization of factory assets– Decoupling of various tasks in the planning (plant layout, process or

resource planning) is desired– Data aggregation across existing legacy systems (ERP, MES, SCADA,

DCS)– Automated synchronization with planning models– The proposed research should be clearly demonstrated in real environments.

• With increasing degree of functional integration of sub systems– Cope with complexity via advanced ICT architectures like SOA, cloud,

et al.– develop ICT driven approaches and scalable architectures.

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b)b) Advanced industrial robotics systems Advanced industrial robotics systems


• User-friendly interaction / cooperation with robotic systems (human-robot / robot-robot)

• Real world demonstration of large-scale applicability to small batch and craft manufacturing

FoF-PPP-InfoDay

Only STREP

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Objective 7.1 b ( robotics) - aims

• Large-scale validation of advanced industrial robotics systems:– Involving system integrators and manufacturers.– Testing and validating robotic prototypes, paving the way

for large-scale applicability to flexible, small batch and craft manufacturing.

– Focus not so much on classic heavy industry sectors, but particularly in light industry, which are until now "robot-resistant", such as e.g. co-worker robots in the food or packaging industry or “apprentice” robots in SME industries as well as large industries.

JAST FP6 project

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• Attention: ICT-WP2011-12 versus PPP-FOF-ICT– the ICT WP2011-12 (Challenge 2 – Cognitive Systems and

Robotics) has a different scope. PPP focuses on downstream testing and validation, not on “upstream” R&D.

• The proposed research should be clearly supported by application scenarios.

• Application domains are not predetermined, but should be traditionally “robot-resistant”.

• The robots can have any shape or size as appropriate.• Robotics components development is not main aim.• End-user participation is encouraged.• Benchmarking is strongly encouraged.

Some hints for robotics proposals

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c)c) FactoryFactory--wide networks of intelligent sensors wide networks of intelligent sensors and new metrology toolsand new metrology tools


• Real-time data collection, storage and knowledge creation of process and product data on shop floor (incl. planning, scheduling, dispatching)

• Focus on Discrete/batch industry including semiconductor manufacturing

FoF-PPP-InfoDay

Only IP

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Smart Factory:Factory-wide Sensor Networs

• Sensor-based solutions for Digital Process Representation in real time of automation and processes.– Factory-wide networks of intelligent sensors

• Contribute to full digital representation of processes with realtime monitoring and modelling.

– New metrology tools and methods for Lean data management and data aggregation

• Holistic approach for data management and storage

– Linking real process data to real-time simulation/modelling

– Supporting Discrete Manufacturing with high variance (down to lot size 1) with emphasis on product quality control and parts handling.

• Results should support international standardisation

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d) Lasers & laser systems for manufacturing & Lasers & laser systems for manufacturing & materials processingmaterials processing

i) High-brilliance active fibre and diode lasers (laser arrays) with nearly diffraction limited beam quality:

Simultaneous targets:

• multi kW continuous wave output power• efficiency ≥ 40% • coupling into small diameter fibres (≤100µm for fibre lasers

and ≤ 300µm diode lasers)

FoF-PPP-InfoDay

Only STREP

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ii) New wavelengths /on-line adaptation of beam properties

Aim : opening-up new process windows and/or contributing tooptimised process efficiencies

Includes:• widely tuneable lasers• ultra-short pulse lasers• versatile frequency conversion systems & photonic

components enabling the on-line adaptation of essentialbeam parametersstable beams of sufficient power and quality for theintended process.

FoF-PPP-InfoDay

Only STREP

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Projects under both topics i) and ii) :industry-driven, strong validation element with quantifiable

targets

Expected Impact:

Reinforced European leadership and industrial competitivenessof laser component and system producers and users and substantial improvement of manufacturing processes

FoF-PPP-InfoDay

Only STREP

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a. Demonstration & Benchmarking of novel process automation & control– Benchmarking for discrete, continuous and/or batch industries– Next Generation automation & control with flexibility, autonomy, robustness and energy

transparency in real world environments

– Lean – easy supervision, management and deployment

b. Advanced industrial robotics systems– User-friendly interaction / cooperation with robotic systems (human-robot / robot-robot)– Real world demonstration of large-scale applicability to small batch and craft manufacturing

c. Factory-wide networks of intelligent sensors and new metrology tools– Real-time data collection, storage and knowledge creation of process and product data on

shop floor (incl. planning, scheduling, dispatching)

d. Lasers and laser systems for manufacturing and materials processing – (i) High-brilliance diode lasers / laser arrrays (ii) New wavelengths & online adaptation of

beam properties

Target outcomes

Objective 7.1: Smart FactoriesEnergy-aware, Agile Manufacuring & Customization

Call FoF in 2011 40 M€ IPs/STREPsmin 50% to IPs and 30% to STREPs

IP

STREP

IP

STREP

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Expected Impactas stated in the work programme

• Strengthened global position of European manufacturing industry through – the introduction of advanced automation into mainstream

manufacturing and

– contributions to international standardisation

• Larger European market for advanced technologies such as electronic devices, control systems, new assistiveautomation and robots.

• Intelligent management of manufacturing information for customisation and environmental friendliness.

• Reinforced European leadership and industrial competitiveness of laser component and system producers and users and substantial improvement of manufacturing processes.

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Outline





• Useful linksFoF-ICT-WP2011-12_ICT2010_29Sep10

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“ManufacturingSolutions for

new ICT“

Obj. 7.2

ICT Work Programme 2011-12:Objective 7.2

Smart FactoriesObj. 7.1

Digital FactoriesObj. 7.4

Virtual FactoriesObj. 7.3

ICTfor Manufacturing

Manufacturing of

Towards Future ICT Factories …

Factories of theFuture

FoF-ICT-WP2011-12_ICT2010_29Sep10

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Objective 7.2Manufacturing Solutions for new ICT products,

focused on Organic & Large-area electronics (OLAE) / Photonics

• New area: fast moving, huge growth potential

• Highly multi-disciplinarydisruptive activity; emerging value chains…

• Opportunity for Europe to gain grounds in manufacturing

• Industrial-scale manufacturing in Europe not yet systematically addressed

• Industrial-scalemanufacturing essential to exploit technologyleadership

• Ease transfer of conventional printing & packaging know-ho to new areas

• Key: low cost, high volume & high trhoughputmanufacturingtechnologies

Where do we stand? What do we want to achieve & why?


Make it happen:<< From Lab to Fab >>

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Objective 7.2 Manufacturing solutions for new ICT products

FoF-PPP-InfoDay

■ Organic Large Area Electronics and Photonics

■ Target Outcomes: From Lab to Fab ! – Feasibility demonstrators for low cost, high volume, high throughput manufacturing

technologies.

– Emphasis on roll-to roll printing, but also evaporation, hot-embossing, laser processing, other low T processes could be addressed

– Address the main road blocks (e.g. patterning processes, resolution & registration accuracy, process stability, multilayer

lamination, automation, in-line quality control, and architectures to cut production costs)

– Address standardisation and end-of-life/disposal/recyclability issues

– OLAE applications: range from OLED lighting, organic photovoltaics, printed batterries, to signage

and displays, organic large area sensor arrays, organic and printed electronics, flex/foil-based

integrated smart systems

Only IP

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Objective 7.2 Manufacturing solutions for new ICT products

FoF-PPP-InfoDay

IndustryIndustry--driven projectsdriven projects including strong elements on quality control, testing and validation to demonstrate manufacturing feasibility at industrial scaleat industrial scale

■ Expected Impact:– New market opportunities for EU’s manufacturing industry in new low cost, high

volume and high throughput OLAE manufacturing processes

– Extended range of applications of « conventional » industries into the OLAE field

– European-produced OLAE products tailored to meet key societal and economic needs

Call ICT-FoF, opens 20 July 2011, closes 01 Dec 2011, 20 M€

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Outline



• The FoF ICT Call 2012, Obj.7.1/7.2

• Useful hintsFoF-ICT-WP2011-12_ICT2010_29Sep10

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FoF ICT Objectives 7.1 & 7.2Must Have

• “Smart Factories” (7.1) focus: – Benchmarking of Advanced Process Automation & Control– Validation of industrial robotics– Application of ‘Factory-wide sensor networks’ and Lasers for

manufacturing

• “New ICT Products” (7.2) focus:– Manufacturing solutions for new (disruptive) ICT,

such as organic & large/area electronics (OLAE) & Photonics

• Proposals must:– be industry-driven– have a strong validation element with quantifiable targets

• “Downstream research”: – Industrial implementation horizon 2016-2020

• Obj.7.1 - Proposals should complement Call 2009- use advanced ICT-based technologies in production


Call ICT-FoF, opens 20 July 2011, closes 01 Dec 2011, 20 M€

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Thank you

FoF on the web:http://ec.europa.eu/research/industrial_technologies/factories-of-the-future_en.html

FoF ICT Web Page:http://cordis.europa.eu/fp7/ict/micro-nanosystems/ict-for-fof_en.html

FoF call & contacts: http://cordis.europa.eu/fp7/dc/index.cfm?fuseaction=UserSite.CooperationDetailsCallPage&call_id=339

7.1 Objective: [email protected]@[email protected]@ec.europa.eu

7.2 Objective: [email protected]

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