Corner Factory - Revisiting Urban Manufacturing

Corner Factory Revisiting Urban Manufacturing

Simon Nilsson Chalmers Architecture Spring 2016 1

Master's Thesis Chalmers University of Technology Department of Architecture MPARC - Architecture & Urban Design Material Turn studio Spring 2016 Title Corner Factory Revisiting Urban Manufacturing Author Simon Nilsson www.simonnilsson.nu Supervisor Daniel Norell Examiner Jonas Lundberg

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Abstract

This thesis reimagines the form, function and place of the factory. The factory of today is typically a flat, expandable and cheap ‘shed’, almost always placed in a monofunctional industrial zone. Manufacturing is dispersed and obscure, overlooked by a paradigm of ’mixed-use’ densification.

The reasons for this separation seems dubious in a rapidly changing industrial landscape. New fabrication flows, disruptive technologies and a changing workforce looks supportive of revisiting the original factory condition: urban and compact, in close proximity to workers and resources.

Factory architecture has often been a blunt reflection of technological and societal conditions - how could a contemporary urban factory likewise reflect ongoing shifts?

There is a tradition of ‘spectacle’ in factory architecture, where industrial workings are manifested extrovertly. In this vein, what aspects of new vertical production processes could be utilised for visual effect?

On a city-block corner in a central development area of Gothenburg, a high-rise (22x22x49m) factory is conceived.

Tailored towards the high-tech sector on a hotel model and ready to accommodate ‘Industry 4.0’, the facility utilises a smart logistical core for handling the vertical flow problem.

Promoting exposure of automated equipment, constant activity is provided to its surroundings.

Employing this proposal as critical device, the potential of industrial presence to contribute to a cityscape is investigated and further debate hopefully provoked.

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Contents

Abstract 2

Proposal 53 Exhibition 53

Contents 3

Model 54 Views 57

Design 4

Drawings 61

Aim 4

Axonometric 62

Method 4

Detail section 63

Questions 4

Section 65 Elevation 66

Themes 5

Form, place and spectacle

Plans 67

7

Typological evolution chart 11

References 73

Discriminating paradigms 13 The fourth revolution 15 Work and play 17

Process 19 Criteria 19 Conceptual collages 21 Future context 24 Development analysis 27 Logistics 29 Morphology 30 Use 31 Users 32 Program 33 Process flow studies 35 Flow chart 37 Vertical flow problem 38 Direct input/output system 39

Automated storage/retrieval system

40

Machinery 41 Space-making equipment 42 Core placement 43 Core development 45 Structure 47 Facade 51

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Design

Aim The aim of this thesis is to challenge the virtual absence of manufacturing in discussions regarding urban planning, and to explore what current shifts might mean for factory architecture.

Method This is to be achieved by investigating future manufacturing space through a visionary factory proposal that provokes further discussion.

Questions Factory architecture has often been a blunt reflection of technological and societal conditions - how could a contemporary urban factory likewise reflect ongoing shifts?

There is a tradition of ‘spectacle’ in factory architecture, where industrial workings are manifested extrovertly. In this vein, what aspects of new vertical production processes could be utilised for visual effect?

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Themes

Factories, being pragmatic enclosures for the making of things, have perhaps faster than any other building typology adapted to new conditions. Guided by the hand of market capitalism, their architecture has closely followed changing technological, economical and societal conditions. Recurring industrial revolutions have radically transformed the form, function and place of factories over the years. This master’s thesis is exploring several themes found in the growing space between the current state of factories and an ongoing transformation of manufacturing.

OPPOSITE: TAHOE-RENO INDUSTRIAL PARK (BING MAPS 2016) 6

‘Industry, overwhelming us like a flood which rolls on towards its destined ends...’

Le Corbusier, Toward an Architecture (1923)

Form, place and spectacle Manufacturing is today dispersed and global, typically

architecture by the enormous Fiat Lingotto plant in Turin

located in industrial districts sorely lacking in urban

(Giacomo Mattè-Trucco, 1923)

qualities. Found at the outskirts of cities, no matter the

With its crowning rooftop test track, signifying a new

country, these production zones all look similar. They are

age through the symbolism of the car. At the time of its

sprawling fields made up of ‘sheds’ - rudimentary steel

opening, it was something radically new, and was hailed by

halls, cheapy erected and easily expanded, the simplest

Filippo Tommaso Marinetti as the ‘first Futurist constructive

possible shell for sheltering a production process. Or in

invention’

effect, the very antithesis of the vertical city-factory.

impressive sights in industry’ and ‘a guideline for town

Historically, multi-storey factories has often been found

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and by Le Corbusier as ‘one of the most

planning’.

in dense city environments, in proximity of workers and

Apart from this incredible gimmick, the Lingotto plant is

resources. The cotton mills of Victorian England was for all

modelled on the Ford Highland Park factory (Albert Kahn,

their flaws as workplaces a very vital urban phenomenon,

1910). In this facility, Ford was testing out his theories of

and supreme drivers of urbanisation itself. Embracing

utilising gravity through chutes and slides along the vertical

technology and rationalism, the early 20th century factory

production line winding across four floors. In the end,

was an instrumental mover of Modernism itself, through

Highland Park was abandoned as Lingotto opened. The

buildings such as the AEG turbine factory (Behrens,

pragmatic Ford had simply faced up to the supremacy of

1910) or the Fagus Factory (Gropius & Meyer, 1913). A

horizontal flows for mass production . The cotton mills had

few years later, the spectacular was introduced in factory

been compact and multi-storey for reasons of mechanical

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LINGOTTO PLANT IN 1928 (DGTMEDIA - SIMONE. CC 3.0) OPPOSITE: VAN NELLE FABRIEK (ARJANDB. CC-BY-SA-3.0-NL DESATURATED BY AUTHOR)

1. MARINETTI, SOMENZI, MAZZONI. (1934) FUTURIST MANIFESTO OF AERIAL ARCHITECTURE 2. BRUNNSTRÖM, L. (1990) THE RATIONAL FACTORY : ON THE ROOTS OF FUNCTIONALIST ARCHITECTURE (SWEDISH EDITION)

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8

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force transfer, and electrification initially did little to alter

car manufacturers, with the BMW plant in Leipzig being

factory typology. But the advantages of laying out a

especially noteworthy. Through a central section designed

spacious production line on a single floor soon became

by Zaha Hadid, car chassis are conveyed through the

obvious. Opening a virtually self-sufficent car-making

management and administration facilities, blurring the

mini-city at River Rouge, a new template for large-scale

division of labor in a celebration of speed and movement

manufacturing was established.

reminiscent of Lingotto.

‘The most beautiful spectacle of the modern age’, again

With super-block structures such as the Starett-Lehigh

according to Le Corbusier, is the Van Nelle Fabriek

building on Manhattan (Cory & Cory, 1931) urban

(Brinkman & Van der Vlugt, 1931). Designated a world

manufacturing reached an all-time high of density and

heritage in 2014, it brandishes the world’s first pre-

urbanity. However, during the postwar economic boom,

fabricated curtain wall. Through this the factory’s contents

factories started leaving cities according to the economical

was exposed like never before, and the machine aestethic

logic of that era. Cheap energy, transportation and labor

truly came into its own through the constructivist bridges

pushed industry to similarly cheap locations.

transporting goods into a logistics terminal.

Today, as manufacturing conditions are rapidly changing,

This super-transparency has a modern counterpart in the

so are the fundaments of the location and form of certain

Gläserne Manufaktur of Volkswagen in Dresden (Günther

facilities. Complementing the fields of sprawling sheds at

Henn, 2002), which is meant to represent the company’s

our city outskirts, could an urban return of factories be

values (rather ironical in light of the 2015 emissions

plausible? The exuberant wonder of the first machine age

scandal). While a practical, operational facility and not

have faded, but technology is marching on. What could

a showroom, this factory is still the public ‘face’ of VW

these recent advances and following socioeconomic shifts

production, being both building and ongoing PR campaign.

imply for factory architecture?

This communications strategy is common among premium

And what could a contemporary spectacle consist of?

TESLA FREMONT FACILITY (CHRISHMT0423 CC 2.0) OPPOSITE: STARETT-LEHIGH BLDG (AUTHOR 2014) 10

Typological evolution

OPPOSITE: STARETT-LEHIGH BLDG (AUTHOR 2014) (3) 1910, AEG TURBINENFABRIK: THE FACTORY RECOGNIZED AS ARCHITECTURE (2) 1797, MURRAY’S MILLS: URBAN AND COMPACT

(6) 1931, VAN NELLE FABRIEK: SUBLIME MACHINE AESTETHIC

(4) 1910, HIGHLAND PARK: GRAVITATION FLOW EXPERIMENTS BY HENRY FORD

(1) 1400’S, VENICE ARSENALE: CANAL PRODUCTION LINES IN FIRST FACTORY

(5) 1923, FIAT LINGOTTO: FUTURISTIC TEST TRACK MANIFESTING NEW VALUES

Public Relations

1400

URBANISATION

1800

1910

AEG Turbinenfabrik, Berlin (1909)

EXPERIMENTAL FACTORY ARCHITECTURE

5 A EG TURBINENFABRIK

1 Floor loops Floor loops

Gravity flow Gravity flow

Processes and business separated on floors FACTORY Processes and business separated on floors BY BEHRENS:

Chutes and lifts moving material and product Chutes and lifts moving material and product

ELEVATION OF TYPOLOGY

Production line Production line

Linear production throughout building Linear production throughout building

The urban factory as representative branding move

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GRAVITY FLOW

Early 20th century

CHUTES AND SLIDES MOVING MATERIAL Early 20th century

2

3

VERTICAL LINE CONTINUOUS, LINEAR FLOW

Expan dabilit y dabilit y

Expan

Total fl exibilit y exibilit y

Total fl

4

Prod ucti on li CITY-BLOCK neFACTORY c tio W ork ns lih no ep Work flow sho p flo w Prod u

DIRECT INPUT / OUTPUT SYSTEM DIRECT INPUT / OUTPUT SYSTEM

19401940The competition -- flat, straight-forward flows, flexible, expandable , cheap The competition -- flat, straight-forward flows, flexible, expandable , cheap

MODIFIED IMAGE SOURCES: BING MAPS 2016 11

Near future Near future Material flow concept - Central logistics core handling all flows Material flow concept - Central logistics core handling all flows

(11) 2003, VW: CLEAN HIGH-TECH IN TRANSPARENT SHELL ‘ (9) 1934, BRICKEN BLDG: TALL MANUFACTURING LOFTS

(8) 1933, STARETT-LEHIGH BLDG: INTEGRATED LOGISTIC TERMINAL (7) 1933, RIVER ROUGE: FORD MOVES ON TO THE SHED MORPHOLOGY

(10) 1980, FANUC MT FUJI: FULLY AUTOMATED PRODUCTION

AGE OF SHEDS

1940

2000

NEAR FUTURE

FIAT

9

CELEBRATING PRODUCT & PROCESS

Floor loops

Production line

Processes and business separated on floors

Linear production throughout building

ow

terial and product

Floor loops

Production line

Processes and business separated on floors

Linear production throughout building

Gravity flow Chutes and lifts moving material and product

THE BRANDING PR FACTORY

11

Early 20th century

FLOOR LOOPS

tury

8

PROCESSES SEPARATED ACROSS FLOORS

Expand

ability

10

Total fle xibilit

y

Expan

7

dabilit

Total fl

y

Produ ctio n lin e Wor ksho p flo w

DIRECT INPUT / OUTPUT SYSTEM

exibilit

y

THE ‘SHED’ APPEARS 1940HORIZONTAL LINE

The competition -- flat, straight-forward flows, flexible, expandable , cheap

Prod u

FLAT, FLEXIBLE AND EXPANDABLE FLOWS

Work s

ctio

hop

n lin e

Near future Material flow concept - Central logistics core handling all flows

flow

1940-

ward flows, flexible, expandable , cheap

DIRECT INPUT / OUTPUT SYSTEM

Near future Material flow concept - Central logistics core handling all flows

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‘...we are witnessing the end of the machine age - at least on the level of the collective imaginary.’

Vittorio Gregotti, Architecture - Means and Ends (2010)

Discriminating paradigms There seems to exist a paradigm stating that the cities

Richard Florida also argues that “diversity and creativity

of tomorrow needs to be denser, and urban areas more

work together to power innovation and economic growth”.

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mixed in program, or diverse. In effect, this ‘diversity’

As shown by Nina Rappaport in examples from New

typically means combining residential, commercial and

York7, urban clustering of production can allow for industrial

‘public’ space at the scale of the block or building. With

symbiosis through sharing of resources, recycling of goods

‘public’ usually translating to consumtion of goods,

and energy. While the claims to an ‘industrial renaissance’

services or culture, and offices producing information and

in the west seems overblown

ideas - always immaterial - a question might arise: why not

is enjoying an increasing attractiveness. Certain smaller

consider including industry into this paradigm?

businesses employing skilled city-dwellers have no viable

Classic ‘more is more’ notions of urban diversity, such as the ‘ubiquitous principle’ forwarded by Jane Jacobs, seems

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9,10

, the locally manufactured

alternative habitat other than the city, where the flow of people and ideas are at its most intense.

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supportive of this. In later works, Jacobs argues that

The potential of an diverse cityscape for both economical

urban heterogeneity ultimately is the source of economic

and sensory stimulation is well established, but the

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productivity. Along these lines, urban studies theorist

Worker

potential of manufacturing to contribute to this appears

City

Mixed-use qualities Labor division Unskilled labor

Purchasing power

Population boom (Urbanization) Pollution

Increased living standard

Establishment

Early Factory

Zoning codes

GWP boom Fordism

Capitalism Taylorism

Industry

Mass-produced standard product

Policy / market

EXCHANGES, EARLY FACTORY

3. PISKORZ, W., GOULET, R. CITIES OF TOMORROW: CHALLENGES, VISIONS, WAYS FORWARD. BRUSSELS: EC 4. JACOBS, J (1961) DEATH AND LIFE OF GREAT AMERICAN CITIES 5. FAINSTEIN, S. (2005) CITIES AND DIVERSITY. COLUMBIA UNIVERSITY 6. FLORIDA (2002) THE RISE OF THE CREATIVE CLASS-REVISITED: REVISED AND EXPANDED 7. RAPAPORT, N. VERTICAL URBAN FACTORY 8.SIRKIN ET AL. (2011) MADE IN AMERICA, AGAIN: WHY MANUFACTURING WILL RETURN TO THE U.S. 9. NAGER, A, AND ATKINSON, R. (2015) THE MYTH OF AMERICA’S MANUFACTURING RENAISSANCE: THE REAL STATE OF U.S. MANUFACTURING. 10. HEYMANN, R., VETTER, S. (2013) EUROPE’S RE-INDUSTRIALISATION: THE GULF BETWEEN ASPIRATION AND REALITY.

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largely unexplored.

otherness, this thesis argues that the mere addition of

There are of course many causes of the current spatial

another sector to our urban spaces is beneficial through its

organisation of industry. Part of the reasons for the absence

diversifying effect, primarily social and visual. Bringing the

of manufacturing in discussions on densification is likely to

factory worker out of the anemic industrial district and into

be the connotations carried by the word ‘industry’, evoking

the central city would certainly serve to widen the cross-

images of heavy transport, loud and emissive machinery, if

section of people using those urban spaces. Perhaps

not belching chimneys. While this was once often the case,

more interestingly, introducing a prominent factory on

manufacturing has become cleaner, quieter and more

the corner of a shopping street, in a restaurant area or

compact. Final assembly of the Volkswagen Phaeton is

a central business district could provide an unexpected

carried out on wooden floors in what is basically museum

and intriguing break in an all too familiar and predictable

spaces. Certain small-scale manufacturing can be carried

rhythm. In regard to ‘diversity’, it is this potential for visual

out in what is essentially office spaces, completely

spectacle that this thesis focuses on.

inoffensive as neighbours.

Whether or not urban industry is brandishing its

Worker

Local skill & innovation

City

Spectacle

Consumer Awareness

Densification

‘Instant’ delivery

Attractive urban workplace

Future Factory

Relocation

Manufacturing base Reindustrialisation

Network exchanges

Print Job

Industry

Incentives Masscustomised quality product

Policy / market

EXCHANGES, FUTURE FACTORY

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PL EM

INDUSTRIAL OUTPUT INDEX (NAICS) (2012=

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NS EMPLOYED IN U.S MANUFACTURING SECTOR

105

‘The goal of the future is full unemployment, so we can play.’

90

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ANC

AISS

“REN

NOT?

12 Arthur C. Clarke

MASSIVE FISCAL SUPPORT & QE

85

2008

2000

10

2012

U.S industrial output and employed, 2000-2014

The fourth revolution While the very tangible machine age of Le Corbusier’s enthusiastic l’Esprit Nouveau may be over, as argued by

80

Vittorio Gregotti11, today’s machines is busier than ever.

70

But industrial output and employment have ‘decoupled’, in

return on capital outpacing growth, famously observed by

50 40 30

13

Thomas Piketty . Productivity and wages are no longer

20

correlated.

10

14

1900

1850

$1.94 TRILLION

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OIL CRISIS

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will likely 1950

away old manufacturing structures at an accelerating pace.

CRISIS!

1960

12.3 MILLION

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Joseph Schumpeter’s ‘creative destruction’ is sweeping

$1.94 TRILLION

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replace traditional manufacturing as we know it today .

16

2000

19.5 MILLION (1977)

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A widely published study

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UR

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and

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Distribution ofLABOR U.S labor force by sector 1850-2010 DISTRIBUTION OF U.S FORCE

BY SECTOR, 1850-2010

this time is different. There is certainly no shortage of technologies,

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executive summaries on emerging technologies concur: disruptive

RY SIGNIFICANCE?

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since antiquity, with ‘sympathy for the luddites’ . The

potentially

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Economists like Paul Krugman are acknowledging looming long-term technological unemployment, feared

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the words of Erik Brynjolfsson.

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1980

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2000

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U.S industrialPUToutput and employed, 1945-2015 T

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concludes that 47% of U.S jobs

12.3 MILLION

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2016 2016

Gross world product (1990 intl$)

70

15

1770 1770

OTHERS Offshoots OFFSHOOTS (EG. US) EUROPE Others (eg.

US) Europe

INDUSTRIAL OUTPUT INDEX (NAICS) (2012=100)

OUS OF

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liberated by a largely automated infrastructure.

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a system where man is

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MILLIONS EMPLOYED IN U.S MANUFACTURING SECTOR

their manifesto demands ‘fully

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repurposing of technology for socially beneficial and

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transformation and destruction of jobs. Arguing the

2010

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Alex Williams are advocating an improved pace of this

2000

20

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Leftist accelerationists such as Nick Srnicek and

automated luxury communism’,

1980

U.S industrial output and employed, 1945-2015

tended to overshadow the utopian.

17

1970

U.S INDUSTRIAL OUTPUT AND EMPLOYED, 1945-2015

bad about this shift, but the dystopian implications has

emancipatory ends,

1960

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2000 SIGNIFICANCE?

Distribution of U.S labor force by sector 1850-2010

MATERIALS

HOME

MATERIALS

HOME

HOME

HOME PRINT SHOP

HOME HOME

HOME

HOME

HOME

HOME

HOME

HOME

EXECUTIVE MANUFACTURING PRODUCT DISTRIBUTION

HOME HOME

PRINT SHOP EXECUTIVE MANUFACTURING HOME PRODUCT DISTRIBUTION

HOME HOME

HOME HOME

MARKET HOME

Such a system seems to imply centrally organised

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Print shop - decentralized additive manufacturing TOMORROW’S AM Consumer-driven organization CONVENTIONAL MASS PRODUCTION

the ‘long tail’ of demand through mass customization.

Open-source soft- and hardware and decentralization of

SCALE OF PRODUCTION RUN

manufacturing could complement Marx’s ‘owning’ with

Pr

HIGH

production in the hands of the consumers.

EARLY AM

Indeed, consumer-oriented 3D printing service bureaus

LOW PRODUCTIVITY PRODUCTIVITY HIGH

LINE

BREAK-EVEN POINT is CURRENT becoming more and more accessible, and industrial TODAY’S AM

UNIT COST

F

Additive Manufacturing vs conventional Mass Production ECONOMIES SCALE: ADDITIVE VS CONVENTIONAL Economies of OF scale

‘renting’ in a democratizing way, putting the means of

EARLY AM

‘print shops’ are contributing further to the atomisation

FLEXIBLE LINE MANUFACTURING SYSTEM

MATERIAL

CURRENT BREAK-EVEN POINT of the manufacturing supply chain.

This move from TODAY’S AM

UNIT COST

PRODUCTIVITY

TODAY’S AM Print shop - decentralized additive manufacturing Consumer-driven organization

LOW

revolutionary potential of the ‘Maker Movement’ to serve

MARKET

CURRENT BREAK-EVEN POINT

UNIT COST

former Wired editor Chris Anderson stresses the

AM large, self-sufficient enterprises toTOMORROW’S networks of smaller CONVENTIONAL MASS PRODUCTION

actors SCALE is likely to be boosted by autonomous transport, OF PRODUCTION RUN

NATURE

FLEXIBLE JOB SHOP WASTE / AM MATERIAL MANUFACTURING SYSTEM LABOR MANYPRODUCT WORKERPARTS PER SYSTEM MANUFACTURING

FEW

WAGE

Productivity vs Flexiblility

TOMORROW’S AM CONVENTIONAL MASS PRODUCTION

LOW

logistics,

architect SCALE SamOF Jacobs the spatial networks PRODUCTIONreferences RUN

Additive conventional Mass Production of Manufacturing contemporaryvs battlefields, describing the Economies of scale

HOME

EARLY AM

manufacturing. On the other end, praising decentralization,

Additive Manufacturing vs Speculating conventional Mass Production especially by air. on the future of Economies of scale

HOME

HIGH

HOME HOME

FEW

CAPITAL INTEREST

MANY

PARTS PER SYSTEM

FINANCE

Productivity vs Flexiblility

future

CONSUMER

PRICE

JOB SHOP / AM

MONETARY

PRODUCTIVITY VS FLEXIBILITY

‘smart city’ as an ‘automation and regulation of flow’ with ‘devices, machines, buildings, infrastructure in constant

19 information-jabber aimed at optimised efficiency’.

MATERIAL NATURE

Material and monetary processes

During

the fourth industrial revolution, it appears the city itself is

increasingly MATERIAL

turning into manufacturing infrastructure.

NATURE PRODUCT WORKER MANUFACTURING As manufacturers move from specializedCONSUMER equipment LABOR

PRICE

WAGE

COGNITIVE

to

WASTE

MATERIAL WASTE generic platforms, CAPITAL the factory becomes more universal INTEREST

REPAIR

printers and robots are needed, besides the occasional

USE

MANUAL

FINANCE

MONETARY human.

CALCULATION, RECORD-KEEPING PROCESSING CUSTOMER SERVICE PICKING / SORTING REPETITIVE ASSEMBLY SUBSTANTIAL SUBSTITION

MANUAL

FINANCE

conclusion, this would imply that only 3D CAPITAL INTEREST

Factories would be platforms themselves,

SUBSTANTIAL SUBSTITION

OUTSOURCING PICKING / SORTING REPETITIVE ASSEMBLY ASSEMBLY

SUBSTANTIAL SUBSTITION

Material and monetary processes

FORMING / TESTING HYPOTHESES MEDICAL / LEGAL DIAGNOSIS

COMPLEMENTARY

FORMING / TESTING HYPOTHESES ADJUST MEDICAL / LEGAL DIAGNOSIS JANITORIAL SERVICES CHANGING ENVIRONMENTS COMPLEMENTARY

MEASUR

STRONG COMPLEMENTARY

EVALUATE JANITORIAL SERVICES CHANGING ENVIRONMENTS

DESIGN IMPLEMENT

STRONG COMPLEMENTARY

Production calibration

AUTOMATION AL, 2003) Typical andPOTENTIAL desireable(AUTOR productET flows

only distinguished by the scale of equipment. Rapid

ASSESS PROBLEM

NON-ROUTINE

SUBSTANTIAL SUBSTITION

COGNITIVE

WORKER MANUFACTURING CONSUMER and reconfigurable.

In the more distant future, taken to PRICE WAGE MONETARY its ultimate

CALCULATION, RECORD-KEEPING CUSTOMER SERVICE MATERIAL ROUTINE EXTRACTION

END OF LIFE

PRODUCT

LABOR

NON-ROUTINE

ROUTINE

MATERIAL WASTE

changeovers would provide total flexibility and scalability.

Material and monetary processes

Trucks produced one week, helicopters the next. This is MATERIAL EXTRACTION

MATERIALS

ASSESS PROBLEM

PLAN DEPT.

not the scenario for the Corner Factory, set in a much

WASTE

closer END OF LIFEfuture.

PROCESSING WASTE

REPAIR

ADJUST

MATERIAL EXTRACTION

END OF LIFE USE

PROCESSING OUTSOURCING

HOME MARKET

HOME

LOCAL / REGIONAL

DESIGN

EVALUATE

Production calibration

Typical and desireable product flows ASSEMBLY

SUB-CONTRACTOR 1

HOME

CHEAP OCEAN CARGO

WORKER EXECUTES

SUB-S

SUB-CONTRACTOR 2

SUB-S

SUB-S

SUB-CONTRACTOR 3

EXECUTIVE MANUFACTURING TOYOTA LEAN - WORKER-DRIVEN, “KAIZEN” PRODUCT DISTRIBUTION HOME SPOTTING DESIGN POTENTIAL

SUB-SUB-CO

SUB-SUB-CONTRACTOR

SUB-CONTRACTOR 4

Improvement philosophies

HOME

IMPLEMENT

HOME

(FINAL ASSEMBLY) SPOTTING DESIGN QUALITY CONTROL HOME POTENTIAL PROCESSED TAYLORISM - SCIENTIFIC MANAGEMENT, TOP-DOWN PACKAGING ORDER CUSTOMER CARE PRINT SHOP

ORDER / DEMAND

HOME

SUB-SUB-CONTRACTOR

TAYLORISM - SCIENTIFIC MANAGEMENT, TOP-DOWN PLAN PARENT HOME FACILITY

DEPT.

PRODUCT

IMPLEMENT OUTSOURCING

USE

MEASURE

MEASURE DESIGN

ADJUST EVALUATE

ASSEMBLY REPAIR

ASSESS PROBLEM

WORKER EXECUTES

SUB-SUB-CONTRACTOR

HOME TOYOTA LEAN - WORKER-DRIVEN, “KAIZEN” HOME

HOME

Globally outsourced supply chain Production calibration Improvement philosophies

Typical and desireable product flows

MARKET SUB-CONTRACTOR 1 PARENT FACILITY

MARKET

PRODUCT

PARENT FACILITY

LOCAL / REGIONAL

SUB-SUB-CONTRACTOR

VALUE-ADDING

CUTTING

WELDING

DRILLING COATING

PRODUCT ORDER / DEMAND

(FINAL ASSEMBLY) QUALITY CONTROL PACKAGING CUSTOMER CARE

ORDER CHEAP OCEAN CARGO

PROCESSED

ASSEMBLY

SUB-SUB-CONTRACTOR

CHEAP OCEAN

Print shop - decentralized additive manufacturing VALUE-ADDING CUTTING WELDING DRILLING organization

CARGO REVOLUTIONSUB-CONTRACTOR 2 18. ANDERSON, C. (2012)(FINAL MAKERS: THE NEW INDUSTRIAL ASSEMBLY) Consumer-driven SUB-SUB-CONTRACTOR QUALITY CONTROL 19.

JACOBS, S. (2015) MACHINES OF LOVING GRACEPROCESSEDSUB-CONTRACTOR 1 ORDER / DEMAND SUB-SUB-CONTRACTOR PACKAGING CUSTOMER CARE

MARKET

PRINT SHOP MODEL

SUB-SUB-CONTRACTOR

SUB-SUB-CONTRACTOR

SUB-CONTRACTOR 3 SUB-SUB-CONTRACTOR SUB-SUB-CONTRACTOR SUB-CONTRACTOR 2

SUB-CONTRACTOR 4 ORDER

SUB-SUB-CONTRACTOR SUB-SUB-CONTRACTOR

SUB-CONTRACTOR 3 SUB-SUB-CONTRACTOR

WASTE

CHANGEOVER

DOWNTIME

TRANSPORT

COATING

TRANSPORT

ASSEMBLY

16

STORAGE

SUB-SUB-CONTRACTOR GLOBAL SUB-SUB-CONTRACTOR

WASTE

CHANGEOVER

DOWNTIME

TRANSPORT

TRANSPORT

STORAGE

Work and play As a ‘first step’ of the ‘robot replace human’ programme at Changying Precision, producing cell phone components, 20

90% of the human workforce was replaced with robots .

The result was a three-fold productivity increase with far higher accuracy. The remaining people merely control and monitor production. Is this supervisory role the human element in future factories?

As the trend towards shorter product cycles and mass customization continues, the reprogramming of machines is one of the tasks that will require human input for a long time to come. The calibration and configuration of functions is probably the area where most factory work ‘on the floor’ will occur.

This field could be described as ‘robot farming, where workers

instruct

increasingly

dexterous

‘cobots’

-

collaborative robots - like animals on a farm. When numeric, this programming was time-consuming and required a high level of expertise. With a new breed of anthropomorphic machines like ReThink’s Baxter, ABB’s YuMi or KUKA’s IIWA, the input can be haptic, with human instructors physically guiding the robot ‘hand’ to record a motion. These machines are basically harmless and easily moved. It isn’t hard imagining their descendants learning

#1, ~1770

SHIFT TECHNOLOGICAL DISRUPTION

LOCATION LOGIC FACILITY PLACEMENT

OBJECTIVE MAJOR DESIGN CONSIDERATION

FACTORY BUILDING CHARACTERISTICS

a task by watching, or perhaps even being told what to do. Linking the physical factory with a digital environment manipulated by ‘factory workers’ through virtual reality is another possible interface for man through which to ‘farm’ robotic labor.

Fordism is a thing of the past: tomorrow’s factory worker is likely to be well educated, live in a city and want personal self-fulfilment through his or her work. Commuting to a suburban industrial district, far removed from a variety of lunch spots, is unlikely to appeal to this individual. In a future such as the one imagined by Srnicek and Williams, where most dull and monotonous tasks are automated, some of what still classifies as ‘work’ could be highly advanced forms of playful instruction of machines.

This machine ‘teaching’ is anticipated by philosopher Vilém Flusser (1920-1991) in the essay Die Fabrik, where he presents a vision of the replacement of homo faber (making man) with homo ludens (playing man) in 21

post-industrial society.

together with the apparatus, new programs being the outcome of ‘playful’ processes.

#2, ~1890

#3, ~1970

#4, ONGOING

STEAM POWER

ELECTRIFICATION

DIGITALISM

AI, AM, IOT ETC

FORCE MULTIPLIER SUPERCHARGING INDUSTRIAL OUTPUT

MASS PRODUCTION-ENABLING DISPERSION OF WORKSTATIONS

ACCELERATING AUTOMATION BY IT AND ELECTRONICS

AUTOMATION APPROACHING FULL POTENTIAL

CITY

CITY / ZONE

ZONE

CITY / ZONE

CLOSE TO WORKERS AND RESOURCES - IN CITIES

VERTICAL INTEGRATION MAKING SOME INDUSTRY SELF-SUFFICIENT

COMPLEX SUPPLY CHAINS DISPERSING MANUFACTURING

HUMANS MAINLY WORK IN CITIES, ROBOTS ANYWHERE

POWER DISTRIBUTION

MASS PRODUCTION

FLEXIBILITY

INDUSTRY 4.0

MECHANICAL FORCE TRANSFER FAVORING COMPACTNESS

BUILDING TAYLORISM, PROJECTING IMAGE

EASY EXPANSION, SPACIOUS HOUSING OF PRODUCTION LINE

EFFICIENCY, NETWORKING, ADAPTABILITY, PUBLIC RELATIONS

MULTI-STOREY

MIXED

SHED

MIXED

COMPACT BRICK MILLS DRIVING URBANISATION

COMPANY EXPRESSION, VERTICALITY, CONCRETE GRIDS

FLAT FLOWS, EXPANDABLE, CHEAP, SHEET METAL

COMPACT, URBAN FACTORIES ARE FEASIBLE AND DESIREABLE

REVOLUTIONS

21. ECONOMIC TIMES INDIA: CHINA SETS UP FIRST UNMANNED FACTORY; ALL PROCESSES ARE OPERATED BY ROBOTS 22. HARDENS, T. (2010) VILÉM FLUSSER AND TECHNICS − FROM HOMO FABER TO HOMO LUDEN

17

Speculating on the resemblence

of future factories to schools, his factory worker learns

Logistics Spacious assembly line Easy expansion

Modernistic function separation

Theory

“Polluting eye-sores�

Heavy transport

Car-based planning

Taylorism

Self-sufficiency

Preconceptions Globalization

Ocean cargo

Cheap overseas labor

Bulky Fossible Noisy

Rigid

Cheap overseas pollution

Dirty

Technology

Start here

Consumism Fordism Cheap land

Economy

Vertical City-Factory

Sprawling Sheds

Arrive

Theory Consumer Awareness Education

Clean Flexible

Current state

DensiFication

Logistics Renindustrialisation

Wider Diversity Paradigm

Meeting enabling Just-in-time

Maker Movement

Can do better

Close to customer Industrial Symbiosis Drones

Labor cost share drop

Compact R&D

Deep learning User-friendly

Technology

PR Value Mass custom Accessible & democratizing

Manufacturing base value

Recruiting skilled citydwellers

Economy

THESIS / ARGUMENT: RETURN OF THE URBAN FACTORY

18

Process Future factories will of course come in many forms, scales and places. Likewise, the design proposal was naturally

Human Presence

never supposed to be an exhaustive physical summary of

The urban factory cannot be a lights-out robotic

this vast field. Instead, the aim was rather the translating of

operation - it is justified by human presence.

fairly abstract aspects into a specific vehicle for an idea, or thesis: the return of the vertical urban factory.

Evoking images of the local, accessible and urban, the project title chosen for this facility was Corner Factory.

Human Presence The urban factory cannot be a lights-out robotic operation - it is justified by human presence.

Criteria Five points or key issues for this specific future factory

Human Presence Compact & Vertical The urban factory cannot be a lights-out robotic In marked contrast to its sprawling suburban peers, the operation - it is justified by human presence. urban factory increases city density by verticality.

were identified and outlined in the bullet points below.

Human The Corner Factory cannot be a lights-out robotic operation

Human Presence Compact & Vertical The urban factory cannot be a lights-out robotic In marked contrast to its sprawling suburban peers, the operation - it is justified by human presence. urban factory increases city density by verticality.

- it is justified by human presence.

Compact

Human Presence Compact Vertical Clean &&Silent The urban factory cannot be a lights-out robotic In marked contrast to employing its sprawling peers, the Used by light industry thesuburban latest technologies, operation - it is justified by human presence. urban factoryfactory increases density by verticality. the urban is ancity agreeable neighbour.

In marked contrast to its sprawling suburban peers, the Corner Factory increases city density by verticality.

Clean & Silent

Compact & Vertical Clean & Silent In marked contrast to its sprawling suburban peers, the Used by light industry employing the latest technologies, urban factory increases city density by verticality. the urban factory is an agreeable neighbour.

Used by light industry employing the latest technologies, the Corner Factory is an agreeable neighbour.

Accessible

Compact & Vertical Clean & Silent Accessible & empowering In marked contrast to its sprawling suburban peers, the Used by light industry employing the latest technologies, Enabling curious consumers to become fabricators, the urban factory increases city density by verticality. the urban factory is an agreeable neighbour. urban factory manufactures entrepreneurs.

Enabling curious consumers to become fabricators, the Corner Factory manufactures entrepreneurs.

Transparent

Clean & Silent Accessible & empowering Used by light industry employing the latest technologies, Enabling curious consumers to become fabricators, the the urban factory is an agreeable neighbour. urban factory manufactures entrepreneurs.

The Corner Factory celebrates manufacturing itself, advertising its dazzling processes to an general public.

OPPOSITE: STUDY MODELS

Clean & Silent Accessible & empowering Transparent & exciting Used by light industry employing the latest technologies, Enabling curious consumers to become fabricators, the The urban the factory celebrates advertising its urban factory ismanufacturing an agreeable itself, neighbour. urban factory manufactures entrepreneurs. dazzling processes to an general public.

19

Accessible & empowering Transparent & exciting Enabling curious consumers to become fabricators, the The urban factory celebrates manufacturing itself, advertising its

20

Conceptual collages After a lot of research and no design, a few sketchy collages depicting ideas about the athmosphere of the main space types were put together.

LOBBY

21

FACTORY SPACE

22

CORE

23

Future context A city with a rich industrial heritage, Gothenburg was as natural a testing ground as any. The area finally selected was Gullbergsvass, as the riverfront is historically intimately connected with the city’s harbour industry. This district is also set to take on an increasingly strategic position in the long term development of central Gothenburg.

Currently occupied to a large extent by heavy infrastructure, it is planned to be transformed into a dense neighbourhood.

Adjacent to the envisioned RegionCity high-rise development around the central station, featuring skyscrapers of about 23

120 metres , the projected neighbouring building scales is accomodating to a large, vertical factory.

FUTURE CONTEXT MODEL NEXT SPREAD: GULLBERGSVASS, CURRENT (BING MAPS 2016) AND FUTURE SITUATION 23. WSP., WHAT!. (2015) PLANERINGSUNDERLAG: HÖGA HUS, CENTRALENOMRÅDET

24

25

26

Development analysis Gullbergsvass is arguably the most significant development area in the whole of Gothenburg. There is enormous potential here, in the absolute city center, which makes it extra important to get it right. Eliminating barriers caused by heavy infrastructure, without cumbersome overdeckings, and achieving a dense urban fabric of diverse use is of utmost importance. Shown below are a synthesis of 24,25,26

various planning documents and studies

, combined

and slightly modified. This imagined development forms the future urban context for the building proposal.

24. SBK GÖTEBORG. (2014) CENTRALENOMRÅDET: STADSUTVECKLINGSPROGRAM 1.0 25. CITY PLANNING OFFICE, GÖTEBORG. (2013) SAMRÅDSHANDLING: DETALJPLAN FÖR BRO ÖVER GÖTA ÄLV 26. SPACESCAPE, WEST8, WHITE. (2013) QUEENS PARK: CENTRAL STATION AREA PARALELL STUDY

27

SITE ANALYSIS (INTERVENTION IN BLACK)

28

Logistics

Morphology

Fundamental to the operation of any factory is the

With the surrounding parameters set, a set of possible

conventient flow in and out of the facility. Therefore, the site

building volumes were quickly and heuristically explored

chosen was close to existing heavy infrastructure. Ideally

(opposite page). Meaning little as forms in themselves,

submerged, this highway could be accessed by delivery

especially set in an arbitrary immediate context, the final

trucks (probably automated) by a likewise underground

building envelope would depend on the functions within.

loading bay.

Working within the most generic boundary possible, a

The factory would be be a plug-in unit into a larger network

square, the process went on. In the end, the building volume

of manufacturing spread across the city, a constant flow

was a simple extrusion of this footprint to a appropriate

of material and goods passing unnoticably in and out of

height. Avoiding a discussion of local urban adaption and

the facility in a dense city context. It is possible to imagine

for argument's sake streamlining the project to focus on

this underbround artery serving as an organising logistical

content and program, this choice of a very simple volume

spine at the urban level, forming a line or factory row along

was deemed the most appropriate strategy.

which to string functions requiring frequent and heavy transport.

A manufactured object for the manufacture of objects, the Corner Factory is an autonomous architecture that could exist in a number of places. It is is not tied to its site, but

+

=

depends primarily on a convenient logistical connection.

This is not to say it is autistic to its surroundings. The city-block in question also contains the landmark building Pagoden, a monumental former tobacco warehouse.

Likewise, the Corner Factory is also a building with monumental properties, possibly viewed separated from any context.

Unit

Island

Archipe

lago

LOGISTIC CONNECTION TO UNDERGROUND HIGHWAY 29

Autonomous architecture with integrity after separation AUTONOMOUS UNIT IN CITY-FABRIC

Current state

Closed perimeter block - 12m depth Current state

Knot Knot block block Knot Knotblock block Rising towards corner

ClosedNarrow perimeter block - 12m depth Narrow lots lots Narrow Narrow lots lots Irregular stacking

Power plant massing Narrow Narrow stacking stacking Narrow Narrowstacking stacking

Two Two lots lots Current state Two lotsmassing Two lots Power plant Rising towards corner

Knot block Narrow Narrow and and low low Current state Rising towards corner Narrow and Narrow andlow low Prism Irregular stacking

Narrow lots Squeezed slab Squeezed slab Rising towards corner Irregular stacking Squeezed Squeezedslab slab

Prism

Narrow stacking Irregular stacking

Knot block Closed perimeter block - 12m depth

++ tower Podium tower ClosedPodium perimeter block - 12m depth Podium ++lots tower Podium tower Narrow Power plant massing

lots object Discrete object Closed Discrete perimeter block - 12m depth PowerTwo plant massing Discrete object Discrete object Narrow stacking Prism

Narrow and low Raised portal Raised portal Power plant massing Prism Raised Raisedportal portal

Squeezed Prism slab

Two lots Knot block

Podium + tower Two lots

Knot block Narrow and low Narrow lots

Two lots Discrete object Narrow and low

Podium +lots tower Knot block Narrow Squeezed slab Narrow stacking

Two lots Narrow and low Raised portal Squeezed slab

Discrete object Narrow lots Narrow stacking

Narrow and slab low Squeezed

Raised portal Narrow stacking

Squeezed slab

MORPHOLOGICAL HEURISTICS 30

Use In a future economy characterised by more sharing, various user models could be concieved. For instance, as part of the infrastructure, a service bureau operating a ‘print shop’ for additive manufacturing is imagined as a permanent tenant in the building. Naturally it would strive for maximum use of its machines. In pursuit of this, excess capacity could be offered to outside industry, printed parts delivered just-in-time to meet peaks in demand.

Most of the building floor area was decided to consist of

FOR THE MANUFACTURER

FA C T O RY S PA C E QUALITY CAPITAL & SPACE AVAILABLE RAPID PROTOTYPING & SHORT LOOPS SMART, NIMBLE & SAFE ROBOTS COMPETITIVE LOCATION & LOGISTICS LEASING OPTIONS

generic loft space, reminiscent of the manufacturing lofts of the Garment District skyscrapers of the 20's. These areas would basically be industrial halls, bright and spacious, tall

FOR THE ‘MAKER’

enough to comfortably fit mezzanine floors in. Available for long-time leases, these stacked halls or sheds are the essential factory space.

PUBLIC WORKSHOP ACCESSIBLE EQUIPMENT PERSONAL PROJECTS & REPAIRS PRODUCT DEVELOPMENT EMPOWERING INCUBATOR MEMBERSHIP OPTIONS

FOR THE CONSUMER & OUTSIDE INDUSTRY

PRINT SHOP LARGE CAPACITY SERVICE BUREAU SELECT, UPLOAD OR SCAN OBJECT AGILE MEETING OF EXTRA DEMAND WIDE RANGE OF PREMIUM MATERIALS PAY PER CM

3

BASIC DIVIDE, FIRST DRAFT

Grundläggande programidé - fabrikens 3 delar

31

Users In conversation with a property development consultant, a ‘factory hotel’ model was devised. Like in an office hotel, certain amenities and infrastructure would be provided. For the sake of detail and specificity, four synergetic tenants are imagined, cherry-picked for exposing the various themes previously discussed.

The Aerospace Company As part of a larger supply chain, a smaller aircraft engine model is manufactured in the bulk of the buildings spaces.

A high-tech, low-run product still relying on plenty of human input, it is a spectacular artifact in itself. Final assembly is carried out in the lower, more robust floors, exposed to the city. The many small parts are provided by the in-house print shop, precision assembly by a fleet of mobile robotic arms.

The Service Bureau An integral part of the facility, the service bureau operates an array of 3D printers, in close collaboration with other tenants. Using electron beam melting, various sintering techniques, fused deposition and stereolithography, all materials and finishes can be accomodated.

The Drone Startup A growing drone service operates the air delivery terminal.

Finetuning a standardised mass production process, the finished drones are put directly into service delivering printouts from the service bureau, or delivered as products in themselves.

The Public Workshop At the top floor, a public workshop makes the translation of ideas into objects possible for the ordinary consumer. On a day pass or membership basis, quality equipment and and expertise is easily accessible.

USE & USERS

32

Program Following the defining of use and users, the functional program was sketched out in a program draft. The stacking of these spaces were continously evaluated and reconfigured, resulting in the opposite program diagram.

Public areas Public areas Public areas Public areas

Air cargo Air cargo Auditorium Auditorium Air cargo Air cargo Auditorium Auditorium

Manufacturing Manufacturing Manufacturing Manufacturing

00 m (52Manufacturing 0mManufacturing 2 2 / Manufacturing + mManufacturing ezza floor nine s)

Light manufacturing Light manufacturing Light manufacturing Light manufacturing

~48

Public workshop Public workshop Public workshop Public workshop

Public

Public Workshop Public Workshop Public Workshop Public Workshop Print shop Print shop Print shop Print shop Street Street Street Street

BASIC DIVIDE Basic divide Basic divide Basic divide Basic divide

Hall Hall

HallTerraceTerrace Air Cargo Air Cargo Air Cargo HallTerraceTerrace Air Cargo Office hotels Office hotels Office hotels Office hotels

Light manufacturing Light manufacturing Light manufacturing Light manufacturing

Heavy machinery Heavy machinery Heavy machinery Heavy machinery Public workshop Public workshop Public workshop Public workshop Exposition Exposition Exposition Exposition

Events Events Events Events

Lobby Lobby Lobby Lobby

Print shop Print shop Print shop Print shop

stacking GeneralGeneral stacking GeneralGeneral stacking stacking

HallTerraceTerrace Air Cargo Air Cargo Air Cargo HallTerraceTerrace Air Cargo

Print Print Print Print shop shop shop shop

Lobby Lobby Lobby Lobby

Logistics Logistics Logistics Logistics

59m (7/14 fl oo 2 base rs, ments )

Facto ry

Hotel

2600 m

2

Public workshop Public workshop Public workshop Public workshop Office hotels Office hotels Office hotels Office hotels

Light manufacturing Light manufacturing Light manufacturing Light manufacturing

Heavy machinery Heavy machinery Heavy machinery Heavy machinery Exposition Exposition Exposition Exposition

Events Events Events Events

AM & AA Reception Reception AM & AA AM & AA Reception Reception AM & AA

Packaging Packaging Deliveries Deliveries Packaging Packaging Deliveries Deliveries

Packaging Packaging Deliveries Deliveries Packaging Packaging Deliveries Deliveries

*Additive manufacturing *Additive and automated manufacturing assembly and automated assembly

op

Packaging Packaging Deliveries Deliveries Quay QuayE45 Packaging Packaging Deliveries Deliveries Quay QuayE45

Reception Reception AM & AA* AM & AA* Reception AM & AA* AM & AA* Reception

FurtherFurther divisions divisions FurtherFurther divisions divisions

Street Street Street Street

INITIAL STACKING

Hall Hall

works h

Public Workshop Public Workshop Public Workshop Public Workshop

Public workshop Public workshop on top on top Public workshop on top on top Public workshop

Fixed Fixed Free Free Free Free Fixed Fixed space space systems systems space space systems systems lobby, lobby, logistics, logistics, lobby, lobby, logistics, logistics, workshops, workshops, heavy heavy workshops, workshops, heavy heavy office hotel, office hotel, machines, machines, office hotel, office hotel, machines, machines,

Lobby

Manu

factur ing Sh

op

Techn i

cal

2Free Freedivision / fixed division 3m / fixed Free / fixed Freedivision / fixed division

*Additive manufacturing *Additive and automated manufacturing assembly and automated assembly

FURTHER DIVISIONS

33

PUBLIC WORKSHOP ON TOP

FINAL PROGRAM, SIZE

23m

E45 E45

PUBLIC WORKSHOP

~520 m

Emissive machinery

2

FLOORS 2-6

Auditorium

Workplaces

AUTOMATED STORAGE & RETRIEVAL SYSTEM

- LOGISTICAL CORE

FACTORY HOTEL

~2600 m

2

FLOORS 2-6

Office hotel

R&D

XS-S Assembly

Planning

Dual-arm cobots

Service bureau Robot farms

Meeting areas

M-L Assembly AGV’s + 6-axis arms

Drone hub

LOBBY

Build space

~520 m

Pick-ups

FLOOR 0

Reception

MANUFACTURING SHOP Additive

2

Subtractive

Stereolithograpy

CNC Milling

Fused deposition

Wire EDM

Laser sintering

Injection moulding

~520 m

Exposition

2

FLOOR -1

Deliveries

Loading bay

E-beam melting Deburring Heat treatment Coatings Powder recovery Packeting UV oven

Quality control

Chem baths

FINAL PROGRAM 34

MATERIAL “SQUARE”

Principle

TION 1

ON-SITE RECYCLING RAW MATERIAL

TION 3

DELIVERY

FUNCTION 2

Production line nal” product workshop Process flow principle ow with central material “square” IN IN

OUT OUT

PROCESSING

ASSEMBLY

STORAGE IN OUT PACKAGE STORAGE

Process flow studies

DELIVERIES

PRE-”CUSTOMIZED” TOOLING

ASSEMBLY

FUNCTION 4 FUNCTION 4

IN

SUBWORK MATERIAL “SQUARE” MATERIAL “SQUARE” ASSEMBLY

IN

SUBWORK

FUNCTION 4 STATION 4

SUBWORK

SUBWORK

SUBWORK SUBWORK

FUNCTION

SUBWORK

SUBWORK

Production line PRODUCTION LINE PRINCIPLE Production line Process flow principle RAW MATERIAL Process flow principle RAW MATERIAL

PRODUCT PRODUCT RAW MATERIAL

STORAGE DELIVERY STORAGE

PRODUCT

STORAGE

MATERIAL DEPOSITING

MATERIAL STORAGE

DELIVERY

PREPARE MATERIAL DEPOSITING ON-SITE RECYCLING MATERIAL

(OUTSOURCING) DELIVERY

SUBWORK SUBWORK STATION 1 STATION 1

STATION 2 STATION 2

PRODUCT SUBWORK FINISHINGSUBWORK SUBWORK SUBWORK SUBWORK INSPECT

DEPOSIT MATERIAL PACKAGE DELIVERY PACKAGE

PART FINISHING

DEPOSIT MATERIAL

PART FINISHING WAREHOUSE SRS SRS

SUBWORK SUBWORK SUBWORK STATION 2

STATION 3

STATION 4 SUBWORK

SUBWORK

SUBWORK

SUBWORK

QUALITY CONTROL

PACKAGE SUBWORK SUBWORK SUBWORK SUBWORK

PRODUCT STORAGE

PRODUCT

PACKAGE

MATERIAL MATERIAL

Additive manufacturing PART FABRICATION Simple / total processTRUCK flow PART FABRICATION FLAT PACKAGING FLAT PACKAGING

35

TRUCK

END USER FLAT PACK

SUBWORK

SUBWORK

PRODUCT Additive manufacturing with assembly SUBWORK Process flow with possibly multi-material machinery SUBWORK

INSPECTION

FINAL ASSEMBLY

CLIENT ORDER

PRODUCTION PLANNING

MOBILE FABRICATION UNIT HUB

DISPATCHED FABRICATION UNIT

BUILD SITE

MATERIAL

FLAT PACKAGING

TRUCK

FINISHING FINISHING

QUALITY QUALITY CONTROL CONTROL

PACKAGE PACKAGE

PRODUCT PRODUCT

MARKET MARKET IN

OUT

MATERIAL DELIVERIES ASSEMBLY

MARKET

FUNCTION 4

PACKAGE

Job shop CAD MODEL JOB SHOP PRINCIPLE Process flowMODEL CAD

FINAL FINAL ASSEMBLY ASSEMBLY

END USER FLAT PACK

CLIENT ORDER CLIENT ORDER

FUNCTION 3

INSPECT

MOBILE DISPATCHED PRODUCTION BUILD MATERIAL MOBILE DISPATCHED FABRICATION FABRICATION PRODUCTION BUILD Additive manufacturing with assembly PLANNING SITE MATERIAL FABRICATION FABRICATION UNIT HUB UNIT PLANNING SITE UNIT HUB UNIT Process flow with possibly multi-material machinery DESTINATION ORDER DESTINATION ORDER

Mobile on-site fabrication unit CAD MODEL Mobile on-site fabrication unitmanipulator Deliverable general purpose MATERIAL MOBILE DELIVERY DISPATCHED RAW MATERIAL Deliverable general purpose manipulator PRODUCTION FINAL STORAGE

ASSEMBLY

CLIENT ORDER

PLANNING

FABRICATION UNIT HUB

MATERIAL “SQU

ASSEMBLY

Process flow with possibly multi-material machinery Process flow with possibly multi-material machinery

INSPECT

WAREHOUSE

MATERIAL

Mobile on-site fabrication unit Deliverable general purpose manipulator

ON-SITE RECYCLING

(OUTSOURCING)

“Ikea” model - end user assembly “Ikea” model end user assembly Process flow-principle Process flow principle PART FABRICATION

BUILD SITE

DESTINATION ORDER

CUSTOMIZATION CUSTOMIZATION DISPATCHED FABRICATION UNIT

END USER END USER FLAT PACK FLAT PACK

ASSEMBLY

CAD MODEL

- TOTAL FLOW WAREHOUSE WAREHOUSE

MARKET

SUBWORK

ASSEMBLY QUALITY PREPARE PART MATERIAL DEPOSIT MATERIAL DEPOSITING FINISHING PACKAGE RAW MATERIAL PRODUCT DELIVERY CONTROL FINISHING PART MATERIAL STORAGE DEPOSIT MATERIAL DELIVERY RAW MATERIAL FINISHING STORAGE MATERIAL DELIVERY Mobile on-site fabrication unit RAW MATERIALON-SITE ASSEMBLY - DELIVERABLE ALL-PURPOSE MANIPULATOR ASSEMBLY DELIVERY PRODUCT RAW MATERIAL DEPOSIT DELIVERY RAW MATERIAL ASSEMBLY CUSTOMIZATION PRODUCT FINISHING general purposePRODUCT manipulator STORAGE DEPOSIT MATERIAL PRODUCT Deliverable PART STORAGE DEPOSIT PRODUCT FINISHING STORAGE manufacturing, flow MATERIAL generic PRODUCT Additive PART FINISHING STORAGE DEPOSIT MATERIAL FINISHING MATERIAL Process flow principle PACKAGE INSPECT PACKAGE INSPECT INSPECT PACKAGE FUNCTION 1 INSPECT PACKAGE FUNCTION DEPOSIT 4 PART FINISHING MATERIAL DELIVERY RAW MATERIAL DELIVERY RAW MATERIAL Additive manufacturing PRODUCT DEPOSIT Additive PRODUCT FINISHING STORAGE MATERIAL PRODUCT Simple /manufacturing total process flow STORAGE PART DEPOSIT Additive manufacturing with assembly FUNCTION 3 Simple / total process flow FINISHING MATERIAL Additive manufacturing with assembly FUNCTION 2

(OUTSOURCING) (OUTSOURCING) ADDITIVE MANUFACTURING

MARKET

INSPECT PACKAGE INSPECTION STATION 5INSPECTION STATION 6 STATION 7

ASSEMBLY

ON-SITE RECYCLING PREPARE MATERIAL MATERIAL DEPOSITING PREPARE MATERIAL MATERIAL STORAGE MATERIAL DEPOSITING MATERIAL STORAGE CAD MODEL

DESTINATION ORDER

PACKAGE

PACKAGING

“Ikea” model - end user assembly Process flow principle Additive manufacturing with assembly SRS Process flow with possibly multi-material machinery ON-SITE RECYCLING

MOBILE FABRICATION UNIT HUB

QUALITY CONTROL

SUBWORKSUBWORK SUBWORK

INSPECT

PACKAGE

Additive manufacturing, generic flow PRODUCTION FINAL CLIENT ORDER Additive flow PLANNING ASSEMBLY Processmanufacturing, flow principle generic Process flow principle

Principle

STATION 4 STATION 5 STATION 6 STATION 7 PART DEPOSIT STATION 4 STATION 5 STATION 6 STATION 7 FINISHING MATERIAL DELIVERY RAW MATERIAL SUBWORK SUBWORK SUBWORK SUBWORK SUBWORK SUBWORK PRODUCT STORAGE PRODUCT PART DEPOSIT SUBWORK SUBWORK SUBWORK SUBWORK SUBWORK PRODUCT FINISHING MATERIAL SUBWORK SUBWORK

IKEA MODEL - END USER ASSEMBLY

DELIVERY DELIVERY

STORAGE PRODUCT MARKET Flow groups on logistical axis STORAGE PRODUCT MARKET

STATION 3 STATION 3

PACKAGING MARKET PREPARE PRODUCT STATION 1 PACKAGING MATERIAL

STORAGE

PRODUCT Driven Line with sub-stations STORAGE PART FABRICATION DEPOSIT “Fishbone” process flow MATERIAL TRUCK FLAT PACKAGING MATERIAL

RAW MATERIAL RAW MATERIAL

PACKAGE PACKAGE

FINISHING

SUBWORK

RAW MATERIAL

Flow groups on logistical axis Flow groups on logistical axis Principle Principle

PREPARECUSTOMIZATION PROCESSING ASSEMBLY MATERIAL SUBWORK SUBWORK SUBWORK SUBWORK SUBWORKPRE-”CUSTOMIZED” TOOLING SUBWORK SUBWORK SUBWORK

MATERIAL STORAGE

manufacturing Driven Line Additive with sub-stations Driven Line with sub-stations PRODUCTION LINE WITH SUBSTATIONS - 'FISHBONE FLOW' Simple /flow total process flow “Fishbone” process “Fishbone” process flow

ZATION

PRODUCT

Sequential flow groups

INSPECTION “Functional” product workshop ON-SITE RECYCLING ON-SITE RECYCLING Process flow with central material “square” QUALITY PREPARE PROCESSING ASSEMBLY QUALITY CONTROL PREPARE MATERIAL PROCESSING ASSEMBLY CONTROL MATERIAL

PREPARE PREPARE MATERIAL MATERIAL

QUALITY RAW MATERIAL FINISHING CONTROL PRODUCT

SUBWORK

WORKPIECES Principle WORKPIECES

FUNCTION 2

SRS

DELIVERY

E RECYCLING

STATION 7

SUBWORK Sequential flow groups Sequential flow groups Principle SUBWORK Principle

PRE-”CUSTOMIZED” TOOLING PRE-”CUSTOMIZED” TOOLING ON-SITE RECYCLING

Additive manufacturing, generic flow Process flow principle Production line DELIVERY RAW MATERIAL DELIVERY Process flow principle RAW MATERIAL

STATION 6

WORKPIECES

MATERIAL MATERIAL STORAGE STORAGE

DELIVERY DELIVERY

STATION 5 SUBWORK

FUNCTION 1

MATERIAL “SQUARE”

PRODUCT FUNCTION 3

SUBWORK

RAW MATERIAL RAW MATERIAL

SUBWORK

STORAGE

“Functional” product workshop workshop Process flowproduct with central material “square” Process flow with central material “square”

FUNCTION 2 SUBWORK

Job shop Process flow

G

SUBWORK

STATION 6 “Functional” STATION 7

STATION 5

FUNCTION 3

MARKET

FUNCTION 3

4 preliminary flow diagram for the Corner Factory.

FUNCTION 1

UBWORK

RK

STATION 4 OUT SUBWORK

FUNCTION 2 SUBWORK FUNCTION 3 specific, were studied in preparation for the draftingFUNCTION of a 2

Job shop Process flow Process flow

PRODUCT

INSPECTION

STORAGE

STATION Job2shopSTATION 3

STORAGE

SUBWORK

SUBWORK DELIVERIES FUNCFUNCSUBWORK TION 1 TION 1

of a production process. A number of these, generic and

SUBWORK

SUBWORK

STATION 3

STORAGE STORAGE MARKET SUBWORK

Essentially, a factory is an enclosure for the sheltering PACKAGING

Driven FUNCTION 3 Line with sub-stations SUBWORKFUNCTION 2 SUBWORK FUNCTION 3 “Fishbone” process flow 2 FUNCTION

PACKAGE

OUT OUT

STATION 2

PRODUCT

FUNCTION FUNCTION 4 4

FUNCTION 1 FUNCTION 1

IN

DELIVERIES SUBWORK DELIVERIES SUBWORK

SUBWORK ASSEMBLY ASSEMBLY PREPARE STATION 1 MATERIAL

DELIVERY

QUALITY CONTROL

ASSEMBLY

PRE-”CUSTOMIZED” TOOLING

Flow groups on logistical axis Principle

RAW MATERIAL STORAGE PRODUCT STORAGE QUALITY CONTROL

RECYCLING

PROCESSING

WORKPIECES

DELIVERIES DELIVERIES ASSEMBLY ASSEMBLY

PREPARE MATERIAL

MATERIAL STORAGE

FABRICATION UNIT

“Functional” product wor Process flow with central m

ON-SITE RECYCLING PREPARE PROCESSING BUILD MATERIAL MATERIAL SITE

PRE-”CUSTOMIZ

BLOOD BLOODPROCESSING PROCESSING

DRIED DRIEDBLOOD BLOOD HIDES HIDES

HIDE HIDEPROCESSING PROCESSING

HAIR HAIRRECOVERY RECOVERY WATER WATER &&FEED FEED

LIVESTOCK LIVESTOCK PENS PENS

REMOVE REMOVE HIDE HIDE

KILLING KILLING

HOG HOGHAIR HAIR

EVISCERATING EVISCERATING

COOLING COOLING

PROCESSING PROCESSING

CUTTING CUTTING DEBONING DEBONING

SORTING SORTINGAND ANDSIZING SIZING GRIND, GRIND,CURE, CURE,COOK COOK

FATS FATS

RENDERING RENDERING VISCERA VISCERAHANDLING HANDLING DRIED BLOOD HIDE PROCESSING

OVERY EVISCERATING

COOLING

HOG HAIR PROCESSING

CUTTING DEBONING

SORTING AND SIZING GRIND, CURE, COOK

MEATS

PRE-MIX PRE-MIX

INGREDIENTS INGREDIENTS

DRY DRYGOODS GOODS

MIXING WASTEMIXING

MARKET MARKET

DELIVERIES DELIVERIES

OFFALS OFFALS HEAT HEAT//LANDFILL LANDFILL

PACKING STORAGE

MARKET

DELIVERIES

FATS

RENDERING VISCERA HANDLING

PACKING PACKING STORAGE STORAGE

WASTE WASTE

HIDES

Pig Pig products products Process Process flow flow

MEATS MEATS

OFFALS FORMING FORMING

BAKING BAKING

SHAPE SHAPE/ /SIZE SIZE

VERTICAL VERTICAL COOLING COOLING HEAT / LANDFILL FILLING FILLING

METAL METAL DETECTION DETECTION

WRAPPING WRAPPING

PACKING PACKING STORAGE STORAGE

MARKET MARKET

BISCUITS

Biscuits Biscuits Process Process flow flow BLOOD PROCESSING

DRIED BLOOD

HIDES BODY BODY STAMPING COATING METAL BLOOD PROCESSING BLOOD STAMPING DRIED COATING METALCOILS COILS SHOP SHOP HAIR RECOVERY HOG HAIR VERTICAL METAL PACKING NG HIDES HIDE PROCESSING PACKING BAKING COOLING WRAPPING MARKET ZE FILLING DETECTION STORAGE DRIED BLOOD PROCESSING FOUNDRY ENGINE CUTTING WATER FOUNDRY ENGINE LIVESTOCK REMOVE SORTING AND SIZING EVISCERATING COOLING KILLING MEATS STORAGE MARKET CHASSI FINAL HAIR RECOVERY HOG HAIR CHASSI FINAL HIDES DEBONING HIDE PROCESSING& FEED PENS GRIND, CURE, COOK HIDE METAL MARKET RECEPTION METAL MARKET RECEPTION PACKING ASSEMBLY ASSEMBLY BODY DELIVERIES ASSEMBLY ASSEMBLY BODY DELIVERIES TRANS&&HANDLING TRANSHANDLING DELIVERIES FORGE SHOP PROCESSING FORGE SHOP CUTTING WATER MISSION LIVESTOCK FATS RECOVERY REMOVE HOG HAIR RENDERING MISSION SORTING AND SIZING EVISCERATING COOLING KILLING MEATS STORAGE MATERIAL MATERIAL FINAL MARKET MATERIAL MATERIAL FINAL DEBONING PACKING & FEED PENS GRIND, CURE, COOK HIDE MARKET MARKET &&PARTS PROCESSING ASSEMBLY PARTS PROCESSING ASSEMBLY POLYMER PROCESSING POLYMERMOULDING MOULDING VISCERA HANDLING OFFALS CUTTING DELIVERIES SORTING AND SIZING EVISCERATING COOLING MEATS CHASSI STORAGE MARKET FATS CHASSI RENDERING DEBONING GRIND, CURE, COOK ASSEMBLY SOFT ASSEMBLY WASTE HEAT / LANDFILL SOFTTRIM TRIMWORKSHOP WORKSHOP DELIVERIES OUTSOURCED VISCERA HANDLING OFFALS OUTSOURCEDPARTS PARTS BODY FATS RENDERING STAMPING COATING METAL COILS Pig products SHOP WASTE HEAT / LANDFILL Process flow VISCERA HANDLING OFFALS Near-vertical Car Near-vertical automobile automobile plant plant Car plant, plant, reduced reduced FOUNDRY ENGINE Pig products Process flow Process flow flow Process flow WASTE HEAT / LANDFILL CHASSI ProcessFINAL METAL MARKET RECEPTION Process flow PORK BELLY ASSEMBLY ASSEMBLY DELIVERIES TRANS& HANDLING FORGE MISSION MARKET POLYMER MOULDING VERTICAL METAL PACKING FORMING PRE-MIX BAKING COOLING WRAPPING INGREDIENTS MARKET MIXING SOFT TRIM WORKSHOP DRY GOODS SHAPE / SIZE FILLING DETECTION STORAGE OUTSOURCED PARTS PARTICLE PARTICLEBOARD BOARDMANUFACTURING MANUFACTURING VERTICAL METAL PACKING FORMING PRE-MIX SAWDUST, &&CHIPPINGS BAKING COOLING WRAPPING SAWDUST,FLAKES FLAKES CHIPPINGS INGREDIENTS MARKET MIXING DRY GOODS SHAPE / SIZE FILLING DETECTION STORAGE HEATING HEATING Near-vertical automobile plant Biscuits VERTICAL METAL PACKING MING BAKING COOLING Process flow MARKET INSPECT ROUGH FILLINGDRYING TRIM INSPECT Process E / SIZE TRIM WRAPPING DRYINGDETECTION SELECTED MACHINE AREA ASSEMBLY FINISHING PACKING STORAGE STORAGE SANDING MARKET SELECTED flow ROUGH MACHINE AREA SANDING ASSEMBLY FINISHING PACKING STORAGE MARKET AIR/KILN &&REPAIR CUT DEPT. AIR/KILN REPAIR CUT DEPT. WOOD WOOD Biscuits HIDE PROCESSING

Process flow Wood Wood furniture furniture Process Process flow flow

WOODEN CHAIR

BODY METALSHOP COILS

MACHINE AREA

MARKET

N ON

GAN UATION

BODY STAMPING SHOP MATERIAL MATERIAL FINAL MARKET INSPECT &SANDING PARTS PROCESSING ASSEMBLY FINISHING BODY ASSEMBLY & REPAIR FOUNDRY ENGINE SHOP CHASSI MATERIAL MATERIAL FINAL METAL ORGAN RECEPTION ORGANSCAFFOLDING SCAFFOLDING ASSEMBLY DELIVERIES BIO-POLYMER MARKET TRANS&BIO-POLYMER PARTS PROCESSING MATERIAL & HANDLING MATERIALPREPARATION PREPARATION ASSEMBLY FORGE MISSION CHASSI

METAL COILS

STAMPING

BODY SHOP

METAL COILS PARTICLE BOARD MANUFACTURING METAL RECEPTION DELIVERIES & HANDLING COATING HEATING

FOUNDRY STAMPING

BODY ENGINE SHOP

FORGE FOUNDRY

TRANSENGINE MISSION

RECIPIENT

MACHINE AREA

CEMENT

FINAL ASSEMBLY

MARKET

FINAL ASSEMBLY

MARKET

QUALITY TEST

ASSEMBLY

QUALITY TEST

COATING CHASSI ASSEMBLY

CHASSI METAL RECEPTION ASSEMBLY PACKING DELIVERIESSTORAGE MARKET POLYMER MOULDING TRANS& HANDLING FORGE MOISTURE CHASSI FINAL MISSION MOISTURETESTING TESTING MARKET SOFT TRIM WORKSHOP ASSEMBLY ASSEMBLY CEMENT CEMENT POLYMER MOULDING OUTSOURCED PARTS QUALITY TEST

RECEPTION POLYMER MOULDING RECEPTIONplant Near-vertical automobile ORGAN Car plant, reduced FOUR-NOZZLE ORGAN FOUR-NOZZLE SAND OUTSOURCED PARTS SAND RECIPIENT RAW CAD RECIPIENT RAWMATERIAL MATERIAL CADMODEL MODEL CLAY/SILT EVALUATION “INKJET” CLAY/SILTTEST TEST EVALUATIONSOFT TRIM “INKJET”BIO-PRINTER BIO-PRINTER Process flow Process flow STORAGE WORKSHOP STORAGE OUTSOURCED PARTS Near-vertical automobile plant Car plant, reduced CARS AGGREGATE AGGREGATE COMPATIBLE COMPATIBLECELL CELL RECIPIENT GRADING Process flow Process RECIPIENTflow GRADING MATERIAL MATERIALPREPARATION PREPARATION Near-vertical automobile plant ADDITIVES ADDITIVES Process flow MOISTURE TESTING

Artificial Artificial kidney kidney Process Process flow flow

COATING

SOFT TRIM WORKSHOP MOULDING MOULDING DEMOULD DEMOULD CURING CURING

Concrete Concrete elements elements

Process Process flow flow SAWDUST, FLAKES & CHIPPINGS RECEPTION MOULDING FINAL QUALITY SAND MARKET DEMOULD RAW MATERIAL CLAY/SILT TEST CURING CONTROL INSPECT ROUGH TRIM CURING MACHINE AREA STORAGE SAWDUST,DRYING FLAKES & CHIPPINGS SELECTED SANDING ASSEMBLY AIR/KILN & REPAIR CUT DEPT. WOOD PARTICLE BOARD MANUFACTURING AGGREGATE INSPECT ROUGH TRIM DRYINGGRADING SELECTED MACHINE AREA SANDING ASSEMBLY AIR/KILN & REPAIR HEATING CUT DEPT. WOOD Wood furniture INSPECT ADDITIVES SANDING ASSEMBLY FINISHING PACKING STORAGE MARKET Process flow & REPAIR

FINAL FINAL CURING CURING

QUALITY QUALITY CONTROL CONTROL

MARKET MARKET

PARTICLE BOARD MANUFACTURING

FINISHING FINISHING

HEATING PARTICLE BOARD MANUFACTURING PACKING STORAGE MARKET HEATING PACKING

STORAGE

MARKET

Concrete elements Wood furniture

Process flow flow CONCRETE ELEMENT Process

BIO-POLYMER

MOISTURE TESTING

ORGAN SCAFFOLDING MATERIAL PREPARATION

CEMENT

ORGAN SCAFFOLDING RECEPTION MATERIAL PREPARATION ORGAN FOUR-NOZZLE RECIPIENT RAW MATERIAL MOISTURE TESTING CAD MODEL EVALUATION “INKJET” BIO-PRINTER STORAGE CEMENT RECEPTION FOUR-NOZZLE QUALITY TEST ORGAN RECIPIENT RAW MATERIAL CAD MODEL COMPATIBLE CELL EVALUATION “INKJET” BIO-PRINTER RECIPIENT STORAGE MATERIAL PREPARATION RECEPTION MOULDING FINAL QUALITY SAND DEMOULD RECIPIENT RAW MATERIAL CLAY/SILT TEST CURING CONTROL COMPATIBLE STORAGE CELL CURING RECIPIENT MATERIAL PREPARATION KIDNEY Artificial kidney Concrete elements AGGREGATE BIO-POLYMER

Process flow Artificial kidney Process flow Concrete elements Process flow

GRADING

ADDITIVES

Process flow Concrete elements Process flow

QUALITY TEST MOISTURE TESTING

CEMENT

SAND QUALITY TEST CLAY/SILT TEST SAND AGGREGATE CLAY/SILT TEST GRADING

MOULDING CURING MOULDING CURING

DEMOULD

FINAL CURING

QUALITY CONTROL

MARKET

DEMOULD

FINAL CURING

QUALITY CONTROL

MARKET

MARKET ADDITIVES AGGREGATE GRADING

ADDITIVES

36

Flow chart FACTORY SPACE

LOGISTIC SYSTEM

IDEA DEPARTMENT

OFFICE HOTEL

Prototyping

Service bureau

Production planning

Incubator

XS

STORAGE LOCATIONS

SHUTTLE SPACE

Complete drone Ship to HQ

Meeting areas

Robot training

S Assembly by dual-arm co-bots

CEO Administrator

Design

VR engineer

Testing

M

Prototype

RECEPTION

Elevator cage

FACTORY WORKERS

Workshop

Buffer spot Drone parts set

ASSEMBLY

PROCESSING / MACHINING

ASSEMBLY BUFFER

PUBLIC WORKSHOP WORKSHOPS

LOBBY

Exposition

PUBLIC GROUND FLOOR

Wood ‘Maker’ Seat bracket

Metal

Workplaces

Additive manufacturing

Reception

Laser sintering

Large builds

Coatings Powder coating

PACKAGE & DELIVER

Start-up CEO Sensor engineer Production manager Medical service bureau VR engineer Counter-nausea expert Home consumer Wants easy repair Chair bracket Replacement part

Headset prototype #34, fit mock-up Drone Fairly complex product Hip implant Simple, print only order Stock materials

MATERIALS PLA plastic Stock materials

PRINT SHOP ADDITIVE MANUFACTURING

Stereolithograpy

FINISHING

Chem bath

(pull system)

MATERIAL PREP

UV oven

Gas atomizer

Fused deposition Direct laser sintering E-beam melting

Resin Titanium Polymers Metals

Coatings

PRODUCT

Quality scan

Powder recovery

Hip implant Headset mockup Parts 3-24

CNC Milling Machining

Wire EDM Injection moulding CONVENTIONAL

37

Deburring

INSPECTION

Flow groups

WORKPIECE BUFFER Drone parts Workpieces

ASSEMBLY

FLOWS

Flödesschema - arbetshypotes, illustrativa exempel (under utveckling)

Vertical flow problem When Henry Ford abandoned the outdated five-storey Highland Park in favor of the sheds of River Rouge, organising

vertical

production

lines

was

likewise

abandonded. The ramps of Lingotto are spectacular in themselves, but not a very efficient way of organising space. This is the vertical problem. In search for a solution, the 'Direct Input / Output System' was found.

Floor loops

Production line

Processes and business separated on floors

Linear production throughout building

Gravity flow Chutes and lifts moving material and product

FLOOR LOOPS

GRAVITY FLOW

PRODUCTION LINE

ProcessesFLOOR and business separated on floors LOOPS Example: Building, Starett-Lehigh Processes and Bricken business separated on floors

Chutes and lifts moving material and product GRAVITY FLOW Example: Park, Murray’s Chutes and lifts moving Highland material and product

Example: Bricken Building, Starett-Lehigh

Example: Highland Park, Murray’s

Linear production throughout building PRODUCTION LINE Example: VW Gläserne, Fiat Lingotto (reversed) Linear production throughout building Example: VW Gläserne, Fiat Lingotto (reversed)

Early 20th century vertical flow principles, all with high circulation space demands) Early 20th century vertical flow principles, all with high circulation space demands)

EARLY 20TH CENTURY FLOW PRINCIPLES

Early 20th century

Expan

Exp

dabilit

and

Exp

ity

and

Tota l Tota l

abil

ity

Total fl la you t

layo ut

y

abil

exibilit

y

flex

ibilit

flex

y

ibilit

y

ProdPr uco tid ou ncliti no en line PW W roodrk so hok uc psfl tir ho on ow p lin e flow Work sho p flo w

DIRECT INPUT / OUTPUT SYSTEM

VERTICAL DIRECT INPUT / OUTPUT SYSTEM core handling all flows VERTICAL‘Smart’ DIRECT INPUT / OUTPUT SYSTEM 19401930'S AND FORWARD: HORIZONTAL FLOWS The competition -- flat, straight-forward flows, flexible, expandable , cheap

1940’s and forward: flat, straight-forward flows, flexible, expandable , cheap 1940’s and forward: flat, straight-forward flows, flexible, expandable , cheap

‘Smart’ core handling all flows Near future THESIS FLOW CONCEPT Material flow concept - Central logistics core handling all flows

Future vertical flow concept Future vertical flow concept 38

Direct Input / Output System Handling the material flows is the main task of the

Kusuda, Y. (2008) Direct input and output system.

infrastructure of a vertical factory. In this regard, the 'Direct An automated warehouse with a stacker crane is installed at the center of a factory floor.

Input / Output System' (DIOS) pioneered by Seibu Electric co. of Japan in the 80's has been influential. In its original

Machines are arranged around the warehouse and inlet and outlet holes corresponding

form, it describes the flows in a flexible material system

to the machines are made on the side of the warehouse.

(FMS), where everything related to production is handled by a single, automated warehouse.

The warehouse stores everything related to the production – materials, parts, half finished products, finished goods, fixtures, etc.

Translated to a building component in a high-rise factory, this logistic principle translates to a 'smart core' featuring

A computer controls the material storage and material flow of the DIO system. It

an automated storage / retrieval system (see next page)

commands the stacker crane to take care of transportation from storage to machines,

acting throughout the building. This infrastructural spine

from machines to storage, from a machine to another machine, stock in storage, ship

handles all flows, coordinating transport orders with

out, etc.

maximum efficiency. Components, equipment and anything that is not directly used are tucked away and stored by the common IoT-guided logistic system.

Elec

sink

ing

e

tric die

cr an

Mate

st or ag e

St

ac ke r

rial

Work p

Bu ffe r

iece

Strip

+

=

90°

-guid

ed A GV

CNC

mill

DIO SYSTEM

Flexible manufacturing system (FMS) (Direct input/output system (FANUC Robotics, 1980’s))

KUSUDA, Y. (2008) DIRECT INPUT AND OUTPUT SYSTEM.

39

+ 90°

VERTICAL DIO SYSTEM + ASRS = FLOW PRINCIPLE

Vertical FMS

Automate

Automated storage / retrieval system Originating in the 60's, an automated storage / retrieval system (ASRS) is a compact logistic solution for computerized management of a warehouse. Reducing inventory and labor, they are typically used in applications where there are a high volume of loads being moved in and out of storage, space constraints make storage density important and where accuracy is critical because of expensive loads. Such as in the Corner Factory.

Factory Worker

Outside Industry Material

Maker Consumer

Lobby

exposition events large objects

Product / Workpiece

Maker Space

all-material workshop accessible equipment assistance available Production

Logistic Hub

Auditorium education events

Production

deliveries packaging drone central

Core

direct input / output system

Idea Production

Office Space design & planning start-up incubator office hotels

Factory Space manufacturing assembly spaces research & development

Fabrication Data

Production

Machine Park

highly automated flexible manufacturing systems technical systems Fabrication Data

CORE FLOW HANDLING

Fabrication Data

CORNER FACTORY ASRS

40

Machinery Like the tenants of an apartment building, the machinery

neighbouring street. Increasingly automated, these robots

is just as much as the workers the inhabitants around

works tirelessly around the clock, unconcerned with being

which the factory needs to be designed. Below, the main

watched, moving and assembling components with almost

types of equipment found in the Corner Factory are shown.

uncanny autonomy and precision. By day, workers arrive to

These machines are in themselves a large portion of the

tune and monitor their choreography.

spectacular quality provided by the Corner Factory to its

Generic platforms Basic, scalable components 3D PRINTER

7-AXIS ARM

AUTOMATED GUIDED VEHICLE

Smart & mobile Intraconnected IoT machinery

AGV + TELESCOPE + ARM S

AGV + ARM L

ARM + GANTRY

AGV + TRAY

AGV + ASRS CAROUSELS

Conventional equipment For when additive isn't rational

ELECTRIC DIE SINKING MACHINE

INJECTION MOULDING MACHINE

FLATBED CNC ROUTER

WATERJET CUTTER

Classic tools For the Public Workshop

LATHE 41

BAND SAW

DRILL PRESS

TABLE SAW

Space-making equipment The potential for the machinery itself to act as spacemaking elements was recognized early. Shown right are 3D printers assembled into walls. In the final proposal, two of these elements acted in conjunction with the core 'slab' to define a logistic area.

OBJECTS IN SPACE

OBJECTS DEFINING SPACE

OBJECTS ENCLOSING SPACE

42

Core placement The position of the core defines the basic spatial

or a

configuration of a high-rise. An early decision to push

vast halls of mass production are no longer that relevant

the visually potent core towards the facade ruled out a

in most manufacturing, but the option to divide a larger

central placement. The 'fragmented' option was thoroughly

volume of space at will is still appealing in this sector. In

evaulated and found to have a lot of spatial potential, but

the end, clustering the core functions in a bundle, placed

to be more suited for a factory with a larger floorplate,

asymmetrically for a differentiation of space, was chosen.

CENTRAL CENTRAL CENTRAL BALANCED STRUCTURE GENERATING HOMOGENOUS SPACE

typology with lesser demands on flexibility. The

EXTERNAL EXTERNAL 'TOTALEXTERNAL FLEXIBILITY' - IN EFFECT OFTEN STATIC

e.g. Johnson e.g.

Wax, Johnson Seagram Wax, Seagram Balanced structure generating homogenous space Balanced structure generating homogenous space

Centre Pompidou, e.g. Centree.g.

Pompidou, Lloyds bldgLloyds bldg ‘Totalinflexibility’, in effect ‘Total flexibility’, effect often static often static

<< FRAGMENTED NEEDS FAIRLY LARGE FLOOR PLATE

ERNAL

oyds bldg pidou, Lloyds bldg often static in effect often static

43

ASYMMETRIC DIFFERENTIATING SPACE

FRAGMENTED FRAGMENTED

OFF-CENTER OFF-CENTER

e.g. Sendai e.g.Mediatheque Sendai Mediatheque Needs fairly large floorlarge platefloor plate Needs fairly

ExamplesExamples ubiquitousubiquitous Differentiating space space Differentiating

FRAG

e.g. Senda Needs fairl

STUDY MODEL FOR CORE PLACEMENT AND PARTITIONS

44

Core design The 'smart core', or automated storage and retrieval system (ASRS), physically consists of a tall warehouse

This larger lattice slab acts as the stiffening element for

pallet racking with a stacker crane. Or, a large number of

the entire building (see structure chapter). It also contains

storage locations for objects of various scales. Considered

the other necessary functions: freight- and personnel

as a large-scale object in itself, this pallet racking could be

elevators, fire escape stairs, air ducts, wiring and media

described as a lattice structure consisting of a myriad of

piping.

sticks. This idea of sticks was to inform the entire building.

The core is the building component most associated

Considering the possibility of the pallet racking to act

with the spectacular. Normally, a high rise core is an

as a structural member, various configurations were

opaque static element. But in the Corner Factory, the core

explored below. The theme of a 'trapped figure' or 'shape

comes alive while almost disappearing. Inside the delicate

within' was also explored. In the end, the core consists of a

skeletal tube, the stackers shifts goods around, providing a

larger exoskeleton overlaid over a pallet racking divided for

constant activity especially prominent at night.

accomodating two packet sizes.

TAPERING PALLET RACKING

45

'TRAPPED FIGURE' VOLUME

HYPERBOLOID CORE

LATTICE STICK

SLAB

CRUCIFORM

STICK

HEXAGON

CYLINDER

bISTICAL elf ly- structurally unstable SYSTEM in itself unstable-inSTRUCTURAL itself Tube - structurally Tube stable- structurally / space-making Tube stable - structurally / space-making Tube stable - structurally / space-making Tube - structurally stable / space-making stable / space-making LOGISTICAL LOGISTICAL SYSTEM - STRUCTURAL POTENTIAL LOGISTICAL SYSTEM LOGISTICAL - STRUCTURAL SYSTEM POTENTIAL -SYSTEM STRUCTURAL POTENTIAL - STRUCTURAL POTENTIAL POTENTIAL

FREIGHT

PERSONNEL

FIRE

AUTOMATED STORAGE

ELEVATOR

ELEVATOR

ESCAPE

/ RETRIEVAL SYSTEM

FINAL CORE BUNDLE 46

Structure Building on the 'stick logic' of the core, the global structure

more spatially rich iterations, were discarded in favor for

was initially approached as a 'stick field'. This tectonic

basic, space-maximising compartments. The system can

logic is especially prevalent in utilitarian structures due its

thus be read as a series of stacked 6m halls, the ones

inherent material efficiency. Columns and lattice girders

located higher up in the building coming with pre-inserted

were decided to be the basic components of the structural

mezzanine floors. The columns system is placed on a

system, in which the amounts and thicknesses were

subterranean box of concrete. A continous void, containing

constantly manipulated. Shown on next spread are some

the logistic system, runs throughout the entire height.

variations of slabs. Some heavily perforated, and perhaps

SLAB UNDERSIDE STUDY MODEL 47

CONCRETE FILLED TUBES, TAPERING DOWN: 400X400 1200X400

CONCRETE METAL DECK SLABS ON SINE PROFILE GIRDERS (H=800)

STIFFENING LATTICE CORE: STEEL SECTIONS 250X250 100X100

CONCRETE BASEMENT CASING

48

GRADATION OF STRUCTURE

OBSESSIVE THINNESS

CASCADING PLATFORMS

MIESIAN CORES

49

JAUNTINESS

CONTINUUM

SLANTED COLUMNS

STACKED VIERENDEEL

50

Facade The factory should not look like an office building or a cultural institution. The volume is the simplest possible, the facade the main contributor to visual impact. Given the column-based structure, a curtain wall facade was a given. The main objective was to be the showcasing and enhancement of the factory's contents, or the exposure of new manufacturing processes. As such, the facade interface called for a non-obscuring strategy. To this end, an architecture of disapperance or 'almost nothing' was

CURVED ELEMENTS DISTORTING VIEWS OPPOSITE: CUSHION EFFECT STUDY

51

pursued. Instead of exclusively working with glass, plastic ETFE membrane cushions was introduced to the material palette. Inflated with air, these lightweight elements adds depth and curves reflections, making the envelope more three dimensional. The other elements are largepane glass elements and units with operable windows.

Enhancing the spectacle inside the building, this gridded interface forms a certain rhythm, that like a comic strip format frames and directs attention.

52

Proposal

EXHIBITION 2016-05-25

OPPOSITE AND NEXT SPREAD: FINAL ITERATION 53

54

55

56

Views

SIDEWALK

57

NEIGHBOUR BALCONY

58

ASSEMBLY

59

PUBLIC WORKSHOP

60

Drawings

OPPOSITE: AXONOMETRIC 1

MATCHSTICK FACTORY

2

FUTURE CONTEXT

3

PUBLIC WORKSHOP

4

LOUD EQUIPMENT

5

AUTOMATED STORAGE/RETRIEVAL SYSTEM

6

DRONE STARTUP

7

AIR DELIVERY HUB

8

AEROSPACE COMPANY OFFICE SPACE

9

COBOT ASSEMBLY LINE

10 COBOT WORKSTATION 11 AUTOMATED GUIDED VEHICLE (AGV) 12 AGV + ITEM CAROUSEL 13 OVERHEAD GANTRY 7-AXIS ARMS 14 EXPERIMENTAL BUILD SPACE 15 LOBBY 16 LASER SINTERING MACHINE 17 4.5M SIDEWALK 18 BIKE LANE 19 INJECTION MOULDING 20 AUTOMATED PACKAGING 21 ADDITIVE MANUFACTURING ARRAY 22 LOADING BAY 23 CONNECTION TO E45 HIGHWAY 24 SERVICES EQUIPMENT 61

1

5

2 3 4

7

6

8

10

9

11

12

13

14

15 16

19

17 18 20

21

22 24 23

AXONOMETRIC 62

DETAIL SECTION THROUGH HEAVY ASSEMBLY FLOOR

63

64

PUBLIC WORKSHOP AUDITORIUM

DRONE STARTUP LIGHT ASSEMBLY AIR DELIVERIES

DEVELOPMENT PRODUCTION MANAGEMENT

LIGHT ASSEMBLY MEETINGS

HEAVY ASSEMBLY

HEAVY ASSEMBLY

LOBBY EXPERIMENTAL BUILD SPACE

PRINT SHOP PACKAGING DELIVERIES

BUILDING SERVICES

SECTION THROUGH CORE

65

SOUTH ELEVATION

66

BASEMENT

67

GROUND FLOOR

68

ASSEMBLY

69

OFFICE

70

MEZZANINE

71

PUBLIC WORKSHOP

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References Publications Marinetti, Somenzi, Mazzoni. (1934) Futurist Manifesto of Aerial Architecture Benedikt Frey, C., Osborne, M., (2015) Technology at Work: The Future of Innovation and Employment McKinsey & Company Manyika, J., et al. (2013) Disruptive technologies Kusuda, Y. (2008), Direct input and output system, Assembly Automation, Vol. 28 Bogue, R. (2013) 3D printing: the dawn of a new era in manufacturing, Assembly Automation, Vol. 33 Hardens, T. (2010) Vilém Flusser and Technics − From Homo Faber to Homo Ludens Universiteit van Amsterdam Fainstein, S. (2004) Cities and Diversity: Should we want it? Can we plan for it? Columbia University Heymann, R., Vetter, S. (2013) Europe’s re-industrialisation: The gulf between aspiration and reality Deutsche Bank Van Kempen, R., (2013) Hyper-Diversity: A new perspective on Urban Diversity. DIVERCITIES Brunnström, L. (1990) Den Rationella Fabriken: om funktionalismens rötter. PhD dissertation, Umeå University Shipp, S., et al. (2012) Emerging Global Trends in Advanced Manufacturing. Virginia: Institute for Defense Analyses Piskorz, W., Goulet, R. Cities of tomorrow: Challenges, visions, ways forward. Brussels: EC WSP., What!. (2015) Planeringsunderlag: Höga Hus, Centralenområdet City Planning Office, Göteborg. (2014) Centralenområdet: Stadsutvecklingsprogram 1.0 City Planning Office, Göteborg. (2013) Samrådshandling: Detaljplan för bro över Göta Älv SpaceScape, West8, White. (2013) Queens Park: Central Station area paralell study Heymann, R., Vetter, S. (2013) Europe’s re-industrialisation: The gulf between aspiration and reality Deutsche Bank Nager, A., Atkinson, R. (2015) The Myth of America’s Manufacturing Renaissance: The Real State of U.S. Manufacturing.

Sirkin et al. (2011) Made in America, again: Why Manufacturing will return to the U.S. Boston Consulting Group

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Literature Brynjolfsson, E., McAfee, A. (2014) The Second Machine Age. New York: W.W. Norton & Co Gregotti, V. (2010) Architecture: Means and Ends. Chicago: University of Chicago Press Le Corbusier. (1923) Toward an Architecture. New York: Dover Publications Jacobs, J. (1961) The Death and Life of Great American Cities New York: Random House Anderson, C. (2012) Makers: The New Industrial Revolution. New York: Crown Publishing Brunnström, L. (1990) Den Rationella Fabriken: om Funktionalismens rötter. Umeå: Umeå Universitet

Lecture series Rappaport, N. Vertical Urban Factory Brandt, J. The Future of Manufacturing

Articles Krugman, P. Sympathy for the Luddites. New York Times. Retrieved 2015-10-26 Jacobs, S. Machines of loving grace. Uncube magazine no 36: Uncanny Valley Retrieved 2016-02-03 PTI. China sets up first unmanned factory. Economic Times India, retrieved 2015-11-03

Images Tahoe-Reno, Bing Maps 2016.

Fiat Lingotto, z Gullbergsvass, Bing Maps 2016.

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