Manufacturing Strategies for Next Generation Manufacturing

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1 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

2 Share of Manufacturing of the national BIP 40 Years of de-industrialisation in US and Europe MANUFUTURE next generation Globalization Migration of Production and Consumption to lower developed areas Page 2

3 Innovative Regions in Europe Regional Innovation Scoreboard (2009) See: Page 3

4 Manufuture Activities Growth Manufuture Strategic Orientation Manufuture SRA + Road EFFRA Road 2013 ICT for Manufacturing Factory of the Future Innovative Products Innovative Processes New Business Models Efficient Infrastructure Education for Future Time Page 4

5 Megatrends with Impact on Manufacturing MANUFUTURE next generation 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 Page 5

6 Megatrends and fields of Actions Globalization Politics Urbanization Population Sustainability Education Ageing Resources Customization Infrastructure Individualism Finance Technologies Manufacturing 2030 Research Public debt Knowledge & ICT Page 6

7 Manufacturing technologies are the key enabler for adding value MANUFUTURE next generation Key enabling technologies Product Development Manufacturing Engineering Life cycle knowledge Product requirements Engineering Production Control Systemintegration Production Adapt/Reuse Emergent technologies and methods for the Factories of the Future Factory Networks Manufacturing plants/systems Manufacturing Equipment Modules/components Product sales and aftersales Page 7 Slide 7

8 Industrial Sectors of Manufacturing MANUFUTURE next generation Materials and semi-finished goods - Recycling Industries Capital Intensive Goods Technical and Mechatronic Components Systems, Machines and Equipment (tools, etc.) for Manufacturing Equipment and Systems for Transport and Logistics Manufacturing Systems for Food, Pharma, and Biochemical Manufacturing Systems for Consumer products ICT for Manufacturing Automobile and Suppliers Aerospace, Shipbuilding, Trains Agriculture, Furniture, Food, Pharma, and Bio-chemical Products Electric and House-Products Consumer Products Textile, Leather, Sports, Consumer Goods Services along the product life cycle Page 8

9 Strategic Objectives Strengthen Customization Leadership in Sustainable Manufacturing Global Standards Factories of the Future 4 Major Factories E f f i c i e n c y Competitive & Sustainable Development European 2 Infrastructure Adding Value and Growth Technical, economic, ecologic and social Standards Page 9

10 Topics of the Strategic Innovation Agenda MANUFUTURE next generation Innovative Products & Processes Competitive & Sustainable Development New Business Models in the Life Cycle of Products Factory as good neighbor Manufacturg in urban Environment Factory and Nature Lean, Clean, Green Factories Volume production back to Europe Next Generation ICT for Factories Knowledge based Manufacturing Engineering Infrastructure & Education Innovative Technologies for Manufacturing Page 10

11 Manufacturing in the Urban Environment MANUFUTURE next generation Customers / Markets Universities Higher Education Research Institutes High Adding Value Transport Logistics Environmental Services Local Energy system Communication Services Advantages from public Infrastructure? IPA 000_0088 Entertainment Arts Sports Homes Schools Basic Education Financial Services Health Factories of emotions? Page 11

12 Masnufacturing in the Value Chain Manufacturer User Low Cost High Profit Customer Relation Adding Value by Services High Quality High Performance High Utilization Reconfigurability Design Engineering Assembly Usage / Service Disassembly Recyling As Requested As Designed As should Build As Build As Is As Maintained As Recycled Page 12

13 Manufacturing in the value chain High Adding Value & Competition Natural Sources Material Parts Components Mechatronics Assembly Efficiency Usage Maintenance Services Waste Recycling Remanufacturing Dis- Assembly Retrieval & Reobtain Environment and Value Page 13

14 Factory and Nature - The Green Factory: Lean, Clean, Green Total Energy- Efficiency Management Technical Intelligence - Mechatronics Product Life Cycle LCA Zero Emissions Noise, Air,... No Waste Process. Sustainable Processes Dematerialization Management of Hazardous Substances Remanufacturing and Recycling Green Logistics Carbon Footprint Page 14 Slide 14

15 Technologies beyond Borders 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 Processtechnologies Intelligent Mechatronic Design & Systems Engineering & Manufacturing & Management Cognition Based ICT Advanced Materials Nano-Scale Technologies Implementation in intelligent manufacturing systems in all sectors of manufacturing Page 15

16 New Age: digital real manufacturing Benefits in early Phases MANUFUTURE next generation modelling simulation expenses per piece Conventional Manufacturing Empirical learning Digital Production Real Production engineering production Cum. production Page 16

17 Manufacturing in the digital Age MANUFUTURE next generation Threats: ICT-Security, gap digital-real world, ICT costs, bureaucracy Engineering in a digital Environment with Soft- Machines Engineering Apps Digital Products Digital Factories Administrati on in a digital Environment with changeable, individual Workflows Global ICT - Networks Product Life-Cycle Management real time IT Opportunities: Tools for Engineers (soft Machines), IT-Services, Efficiency of Engineers Page 17

18 Phänomena Models pysical basics Natural Science Fundamental Research Feasibility Technical Realization Limits Engineering Science Basic Research and Analysis Innovative Engineering Precompetitive Application Research and Development Engineering Products Production Systems Product Support IPA 000_0596 Visions and Applications in Mind Optimization Usage Recycling Page 18

19 Strategies for global Markets Synergies of Regional Cooperation Export Efficient Engineering European Economy Competitive & Sustainable Manufacturing Sustainable Solutions Manufacturing Standards ICT based Services Global Economy Market driven Innovation Import Page 19

20 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 Page 20

21 Volume Production (back) to Europe Page 21 MANUFUTURE next generation 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

22 Back Up Page 22

23 Knowledge based Manufacturing Engineering MANUFUTURE next generation Increasing the quality and efficiency of manufacturing engineering Scientific based Process Models Flexibility for turbulent Markets Intelligent Machines Customised Manufacturing Solutions Manufacturing Engineering Digital and virtual Product Engineering, Process planning and Process control with learning elements and In situ-process-simulation Process Technologies beyond limits Remote Manufacturing Flexibility and High Performance High energetic efficiency Variancy Zero-Defects Page 23

24 πάντα ῥεῖ - Panta rhei - Everything is flowing MANUFUTURE next generation Products Markets Order Trends Global Competition Staff - Qualification - Motivation Organization Management Methods ICT-Systems Permanent Adaption of the System Production Law, Guidelines, Standards Pay Scale Agreement Company Agreements Slide 24 Page 24 Innovation Products Processes Location Buildings Machines Equipment Shareholding Financing Capital Markets

25 Grand Challenge: Dematerialisation of Products Reduction of the material-consumption by: Page 25 - 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

26 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 Page 26

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