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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
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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
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MANUFUTURE next generation
Innovative Regions in Europe
Regional Innovation Scoreboard (2009)
See: http://www.proinno-europe.eu/page/regional-innovation-scoreboard
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MANUFUTURE next generation
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
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MANUFUTURE next generation
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
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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
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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
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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
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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
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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
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MANUFUTURE next generation
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?
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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
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MANUFUTURE next generation
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
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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
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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
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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
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MANUFUTURE next generation
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
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• 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
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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
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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
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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
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Back Up
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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
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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
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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
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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