OBLONG - "Factory of the Future" Report

FAC TO RY O F T H E F U T U R E Designed to progress

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IT'S PEOPLE, WITH OUR KNOWLEDGE AND ABILITY TO ADAPT TO CHANGE, WHO MOVE THE PIECES TO CHANGE THE NEW COURSE OF INDUSTRY. PROGRESS MEANS REDEFINING THE TRADITIONAL INDUSTRIAL MODEL. THE FACTORY OF THE FUTURE IS THE DRIVING FORCE BEHIND THE FOURTH INDUSTRIAL REVOLUTION.

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CURRENT INDUSTRY + NEW SOCIO-ECONOMIC FACTORS + INDUSTRY 4.0 = FoF

ACTIVATING PROGRESS

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IMPACT TECHNOLOGIES

CURRENT INDUSTRY + NEW SOCIO-ECONOMIC FACTORS + INDUSTRY 4.0 =

FACTORY OF THE FUTURE We are living in times of constantly changing socioeconomic factors, accelerated by technological development where businesses are taking some production centres back to their countries of origin.

This fact leads us to believe in a manufacturing concept forcing innovation inside the factory to maintain sustainable and fully connected environments.

The fourth industrial revolution is here.

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IN EUROPE, MANUFACTURING GOODS REPRESENT:

75%

UNSTOPPABLE GROWTH OF THE MANUFACTURING INDUSTRY:

80%

7.4 % Total exports

annual growth in developing countries

R&D&I expenses

2.7 % annual growth in developed countries

60%

Productivity growth

2011

2012

2013

2014

FAC TO RY O F T H E F U T U R E

Designed to progress

MANUFACTURING SECTOR IN EUROPE IN 2013:

7 billion

30 million

Euro in direct business volume

in people estimated direct employment

EUROPEAN TARGET 2020: If we could achieve a 20% contribution of industry to GDP by 2020, we would create 15.5 million additional jobs.

5%

GDP

employment

10% GDP

15% GDP

20% GDP

15.5 million

2014

2020

ACTIVATING PROGRESS Now more than ever we are ready to jump.

To make a jump from traditional factories towards a smarter production and manufacturing model. People are responsible for promoting that change together with the commitment to look after and respect our environment.

Six socio-economic trends to promote the factory of the future.

Moreover, a change in the traditional market definition, due to an already consolidated globalisation, forces the manufacturing sector to undertake this new line of thought and action. Social behaviour patterns changing at the same time as technological possibilities invite us to plan and model our factory of the future.

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NEW TECHNOLOGY PENETRATION AND AVAILABILITY.

SHORTAGE OF RESOURCES AND RAW MATERIALS.

ENVIRONMENTAL IMPACT.

Smarter factories will experience mass development of applications and tools which were unthinkable until now.

Such a breakthrough will enable us to reach targets we had never imagined.

We are living in times marked by restriction and shortage of natural resources. Therefore, efficiency is critical to addressing this new situation.

Far from being a mere trend, the impact of human activity on the environment indicates the need to adopt measures to improve sustainability as soon as possible.

FAC TO RY O F T H E F U T U R E

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AGEING WORKFORCE.

ONGOING CHANGE IN THE QUALIFICATIONS REQUIRED.

CUSTOMISATION.

Our inverted population pyramid and late retirement are leading us to a gradually ageing workforce entailing reduced efficiency in physical work. A breakthrough in manufacturing robotics will reduce impacts caused by this new industrial situation.

The increasingly growing need to have a workforce specialised in specific fields within the factory in relation to their activity, constantly demands workforce qualification levels to be adapted. This inevitably forces us to rethink the traditional model.

The demand for products adapted to the specific needs of each client is already a reality, however, it clashes with traditional mass production focused on the production chain as opposed to the product.

FoF KEYS At TECNALIA we are committed to business progress, real progress with the necessary strength to promote people's welfare. For this reason, we back the factory of the future as the smartest solution to tackle efficiency, sustainability and ultimately, competition.

This will be the factory of the future.

Smart factories will drive change in a connected environment which never stops evolving, where people and knowledge will continue to be the driving forces of their activity with even greater strength. The industry of the future feeds on knowledge.

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SOCIAL

SUSTAINABLE

SMART

The workforce knowledge and innovation skills are increasingly playing a leading role in the manufacturing sector. Although people are still the centre of the activity and concentrate the highest value in factories.

The concept of sustainable manufacturing is possible thanks to the rational use of resources and energy. A responsible production model with high productivity rates and contributing to global business sustainability.

Smart manufacturing in processes and systems with greater awareness of environmental changes and capable of reporting on maintenance tasks, thus helping the employee in programming and fine-tuning tasks.

FAC TO RY O F T H E F U T U R E

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FLEXIBLE

AUTOMATED

CONNECTED

Manufacturing flexibility accelerates resetting of machinery, plants and logistic processes. A flexible factory quickly adapts to production changes.

Factory automation increases speed and process repeatability, while overcoming ergonomic restrictions and improving plant productivity.

The digital era promotes the interconnection of all stakeholders in the Factory of the Future. Greater connection, improved relationships and around 20% increase in productivity thanks to better management of systems for business information exchange.

IMPACT TECHNOLOGIES Thanks to the identification and selection of key technologies, we can fully develop wide-ranging innovative solutions opening and positioning companies in the new 4.0 environment.

We make our motto “Inspiring Business� a reality by materialising real projects around the factory of the future.

1. Flexible Robotics 6. Additive Manufacturing 2. Advanced Mechatronics 5. Advanced Materials

3. Big Data and Cloud Computing 4. Internet of Things (IoT)

At TECNALIA we work to generate real business opportunities.

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1. FL E X I B L E ROBOTICS AT T E C NA L I A WE RESEARCH ON C O L L A B O R AT I V E R O B OT I C S TO C O M B I N E A N D S H A R E M AC H I N E CA PA B I L I T I E S WITH PEOPLE S K I L L S.

Hiro Flexible and Compact DESCRIPTION: HIRO is a two-armed mobile humanoid robot which is easy to transport. Thanks to this robot, precision operations in manufacturing and assembly lines can be automated in a flexible smart way.

PROBLEM-SOLUTION: The ideal solution for applications requiring great operating functionality, such as assembly processes.

Its vision system makes it more autonomous, offering greater ability to adapt to the environment and simplified programming.

ADVANTAGES: Automation of manual and semi-manual processes.

Highly flexible use.

Increased productivity.

Improved repeatability and final quality.

SECTOR: Manufacturing.

FAC TO RY O F T H E F U T U R E

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2. A DVA N CED MECHATRO NI C S WE FOCUS ON A DVA N C E D M E C H A N I CA L T E C H N O L O G I E S TO M A K E PROCESSES FLEXIBLE A N D AU TO M AT E D.

Maaximus Flexible and Automated DESCRIPTION: A new manufacturing concept that enables manual processes to be automated, incorporating flexibility into the production process and the plant configuration.

PROBLEM-SOLUTION: Maaximus is an automated solution for fuselage orbital joints, including drilling, countersinking, sealant application and blind rivet installation processes as well as computer vision reference system.

ADVANTAGES: Manual process automation.

High process lead time reduction.

Operation integration.

System flexibility for relocation to plant and target part adaptation.

Cost reduction.

SECTOR: Aerospace.

FAC TO RY O F T H E F U T U R E

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3. B I G DATA & CL OUD CO M P U T I NG W E F I N D T H E M O S T AC C U R AT E S O L U T I O N S I N T H E AG E O F B I G DATA A N D C L O U D C O M P U T I N G. WE MAKE THE MOST OF ITS P OT E N T I A L B Y S T R E A M L I N I N G M A N AG E M E N T A N D A N A LYS I S P R O C E S S E S.

Predice

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Predictive Maintenance DESCRIPTION: Monitoring, diagnosis and prognosis of tooling failures for cold-stamping machines.

PROBLEM-SOLUTION: Over the last twenty years several process control devices have been launched to the cold-stamping industry market, leading to a significant increase in the volume of data obtained from processes. However, this monitoring improvement did not always come with an improvement in sufficiently useful and effective failure diagnosis processes.

The use of Data Mining techniques facilitates major added-value provision in terms of robustness, reliability and flexibility of the systems monitored and knowledge optimisation.

ADVANTAGES: Advantages derived from failure prevention are not only based on minimising costs and increasing the machine useful life-cycle but also on inferring valid knowledge implicit in data analysed, typically difficult to process, about the process and the reasons behind the failures.

SECTOR: Maintenance and machine-tooling.

4 . I NT E R NE T OF THIN GS ( I o T) WE ARE COMMITTED TO S YS T E M S E N S O R I N G FOR THE PURPOSE OF M O N I TO R I N G T H E I R U S E .

Smart Bearing

FAC TO RY O F T H E F U T U R E

Flexible and Smart DESCRIPTION: Integrating sensors in bearings to be used in capital goods.

PROBLEM-SOLUTION: Sensor integration aims to promote the use of smart bearings to help monitoring the systems in working conditions contributing to improving both the useful life of current equipment and design of future equipment.

ADVANTAGES: Low Cost.

Wireless.

Energy Efficiency.

Predictive Maintenance.

SECTOR: Manufacturing.

Designed to progress

5 . A DVA NCE D M AT E RI A LS S O C I O - E C O N O M I C FAC TO R S TRIGGER DEMAND FOR NEW PRODUCTS WHICH REQUIRE N E W M AT E R I A L S AND THEREFORE NEW P R O C E S S E S A DA P T E D TO T H O S E R E A L I T I E S.

Caprocast Light and Automated DESCRIPTION: This is a versatile manufacturing technology enabling us to obtain recyclable light composite parts (reinforced plastic) yet only requiring low initial equipment and mould investment.

PROBLEM-SOLUTION: Applied to the automotive sector, Caprocast allows replacement of the vehicle structure metallic components with composite components to achieve a weight reduction of 60% while maintaining the same properties.

ADVANTAGES: It allows composite parts to be produced at competitive prices while considerably reducing the weight of systems.

SECTOR: Automotive and Aeronautical.

FAC TO RY O F T H E F U T U R E

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6 . AD D IT IV E MA N UFAC TU R I NG SET OF TECHNOLOGIES CA PA B L E O F P R O D U C I N G 3 D PA RT S O R C O M P O N E N T S

BY ADDING OR PILING UP D I F F E R E N T 2 D L AY E R S.

Amaze Flexible and Sustainable DESCRIPTION: Additive manufacturing for efficient production of metal products in the aeronautical sector.

PROBLEM-SOLUTION: Additive manufacturing of metals is starting to become a reality after TECNALIA has taken steps to manufacture parts for the aeronautical sector. Thanks to the European project Amaze, we embrace this challenge while exploring endless possibilities offered by part manufacturing through Plasma Arc Welding.

ADVANTAGES: Reduced production costs of high added value parts.

Raw material savings.

Possibility of part design optimisation.

Reduced machining operations.

SECTOR: Aeronautical.

FAC TO RY O F T H E F U T U R E

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INDUSTRY 4.0 INDUSTRY 4.0 is a strategic line of work for TECNALIA where ICTs serve production processes to provide intelligence leading to new services associated to new products demanded.

At TECNALIA we have developed our own diagnostic model [MDI 4.0], the first model capable of prioritisation and determination of R&D projects which bring the INDUSTRY 4.0 idea closer to each company.

Towards the future 4.0 of your company.

At TECNALIA we make it our business to ensure that you obtain results from your R&D investment in a smarter and more sustainable business.

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INDUSTRY 4.0

T E C N A L I A I S C O M M I T T E D T O T H E FA C T O RY O F T H E FUTURE AS THE STRONGEST SOLUTION TO EMERGING SOCIO-ECONOMIC CHALLENGES FORCING US TO REINVENT SOME OF THE TRADITIONAL PRODUCTION MODELS.

THANKS TO A FLEXIBLE SMART STRUCTURE WE WILL B E B E T T E R E Q U I P P E D T O FA C E T H E C H A N G E S O F A N I N C R E A S I N G LY M O R E U N C E R TA I N, V E R S AT I L E A N D C H A L L E N G I N G E N V I R O N M E N T.

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