Approved for Public Release 1March 11, 2015Manufacturing in America Symposium
The Digital Manufacturing and Design Innovation Institute (DMDII)
Applying Digital Manufacturing Technologies to Solve Business Problems for Its Partners and the US Industrial Base
11 March, 2015
Prepared for: Manufacturing in America Symposium
George BarnychDirector of R&D [email protected]
Approved for Public Release 2March 11, 2015Manufacturing in America Symposium 2
Challenge: US losing leadership in manufacturing
U.S. Trade Balance for Advanced Technology Products
+ 40
+ 20
0
-20
-40
-60
-80
-100
US Trade BalanceAdvanced Technology
Products
($ Billion)
ISSUE: Economy, Jobs, and future competitivenesso When U.S. loses manufacturing base in advanced technology products, we lose
ability to innovate on next generation of those products
Approved for Public Release 3March 11, 2015Manufacturing in America Symposium 3
The “Scale-up” Gap or Missing Middle
Basic R&DCommercialization
The Need – Create the space for industry and academia to work on industry-relevant problems
o Government investment in private-sector led partnerships
o Addresses the market failure of industry underinvestment in “pre-competitive” applied R&D
o Focus on “de-risking” new technologies and materials to scale-up for U.S. manufacturers
Approved for Public Release 4March 11, 2015Manufacturing in America Symposium 4
Challenges Opportunities
• Separation of designers and
makers has slowed innovation
• Barriers for sharing data and
information including:
technology, skills, incentives,
security, trust, IP, standards
• Increasing cost of labor
globally, skills gap
• Digital link between designers
and makers
• Digital connections to physical
assets, machines, factories, and
supply chains
• Decreasing cost due to data
aggregation and analysis, do
more with existing resources
What forces are driving the digitization of manufacturing operations?
Approved for Public Release 5March 11, 2015Manufacturing in America Symposium 5
Manufacturing already generates more data than any other sector
Approved for Public Release 6March 11, 2015Manufacturing in America Symposium 6
Despite the recognition of importance most organizations feel they lack the necessary capabilities
14%
81%
Organizations
with "high“ digital
capability today
Participants
indicating digital
ops is a critical
driver of future
competitiveness
SOURCE: DMDII workshop, May 2014
Approved for Public Release 7March 11, 2015Manufacturing in America Symposium 7
A National Call to Action A series of reports to the President addressing
Advanced Manufacturing are developed (2011 & 2012)
National Science and Technology Council (NSTC) issues a preliminary design to establish a National Network for Manufacturing Innovation (2013)
President launches the Advanced Manufacturing Partnership Steering Committee 2.0 (AMP 2.0 Report – Oct 2014)
Revitalize American Manufacturing Act, Becomes Law (Dec 2014)
Approved for Public Release 8March 11, 2015Manufacturing in America Symposium 8
Revitalize American Manufacturing & Innovation Act
December 16, 2014 –Signed By President Obama
September 15, 2014 –Passed House
100 Cosponsors (51D, 49R)
December 11, 2014 –Passed Senate
18 Cosponsors (10D, 7R, 1I)
Bipartisan Momentum Supporting NNMI Passage
Sen. Sherrod BrownD Ohio
Sen. Roy BluntR Missouri
Rep. Tom ReedR NY-23
Rep. Joe KennedyD MA-4
Approved for Public Release 9March 11, 2015Manufacturing in America Symposium 9
Birth of the Institutes
Digital Manufacturing and Design Innovation Institute
(DMDII) is born on 25 February 2014
National Network for Manufacturing Innovation - Create a research-to-manufacturing infrastructure for U.S. industry and academia to collaborate and solve industry-relevant problems
NNMI
Institute for Advanced Composites Manufacturing Innovation
Knoxville, TN
Chicago, IL
Lightweight Innovations for Tomorrow
Detroit, MI
Wide Bandgap Semiconductors
Raleigh, NC
Additive Manufacturing
Youngstown, OH
Five Institutes Established
• $335M public funding has catalyzed over $480M from consortia
• At launch, 349 companies and universities active partners from all across the country
• 4 more institutes under competition (photonics/flex/smart/tbd)
Approved for Public Release 10March 11, 2015Manufacturing in America Symposium 10
What is “Digital Manufacturing”?
Digital Manufacturing is an integrated suite of tools that work with product definition data to support tool design, manufacturing process design, visualization, modeling and simulation, data analytics, and other analyses necessary to optimize the manufacturing process” – CIMData (modified)
Approved for Public Release 11March 11, 2015Manufacturing in America Symposium 11
What are the Institute’s Goals?Use the technology portfolio to:
Demonstrate and apply digital manufacturing technologies
Accelerate these technologies to market
– Digital links between design and fabrication– Connected machines, factories, and supply chains– Transparency into supplier factories– Data aggregation, analysis, and action across the product
lifecycle– Leverage the power of data analytics and networks to do
more with existing resources
Increase the competitiveness of American manufacturing firms
Approved for Public Release 12March 11, 2015Manufacturing in America Symposium 12
The DMDII Today
Working towards the completion of its new facility located on Goose Island in northwest Chicago, Illinois
– 96,000 ft2 of Leased Space
– 41,800 ft2 of Collaboration and Office Space
– 25,200 ft2 of Manufacturing Space
– 29,000 ft2 of Expansion Space
Mid April 2015 move-in plan is on track!
200 Mbps temp; 10 GHz dark fiber redundant transport w/ wireless BU
Approved for Public Release 13March 11, 2015Manufacturing in America Symposium 13
The New FacilityState of the Art Collaboration & Innovation Center
Manufacturing Cells
Collaboration Area
Entrance
Auditorium Venue & Lecture Room
UI LABS & DMDII Operational Area
Approved for Public Release 14March 11, 2015Manufacturing in America Symposium 14
Advanced Manufacturing CellsCell #1 – Multi-Axis High End Machining
Cell #2 – Traditional/Legacy Standard Machining
Cell #3 – Additive
Cell #4 – Metrology Room
Cell #5 – Welding & Fabrication
Cell #6 – Micro Machining
Cell #7 – Electronics
Tool Crib – Auto Tool Pre-setter
HaasMachines
Haas VMC
Mazak, ABB,
GOM, Haas
Electronics
Zoller, Parlec, DMG
Shipping/ReceivingRegular & Secured Storage Team Area
ToolCrib
Tool Room &Maintenance Equipment
Storage
#1
#2
#3 #
4
#5
#6
#7
Haas Mill
ITW Mill
Zeiss CMM & Software
DMG NHX6300
DMG NZ2000 T3Y3
Wolf Robot Cell
Haas ST-10 Lathe
Haas ST-30 Lathe
Haas VF-2 3-Axis VMC
Haas VF-5/50 3-Axis VMC
Haas UMC-750 5-Axis
Haas OM-2A Micro Mill
Haas TM-2 Tool Room Mill
Typical Cell40” x 40’
2 cells/bay
POC: Dan Hartman - Director of Manufacturing Research and [email protected]
Approved for Public Release 15March 11, 2015Manufacturing in America Symposium 15
The Essence of DMDII
An Agreement between the US ARMY Contracting Command – Redstone and UI LABS to:
1. Establish a member driven research institute
2. Manage the distribution of $70M of federal funds towards strengthening the capabilities of the US supply chain (requires 1:1 industry funding match)
3. Identify gaps in existing manufacturing technology and issue project calls to fulfill the needs
4. Distribute the Intellectual Property developed in the projects to the membership per the agreements
5. Engage small and medium enterprises
6. Conduct workforce development activities
Approved for Public Release 16March 11, 2015Manufacturing in America Symposium 16
Membership Types in DMDII
– Open to all U.S.-based companies, academic institutions, non-profits and other organizations
– Membership not offered to individuals
– Also open to affiliates and subsidiaries of foreign-based companies…IF the entity was incorporated under the laws of one of the 50 U.S. states
– No specific technical qualifications or other obstacles to membership
3 Industry Tiers
4 Academic/Non-Profit Tiers
State & Local Government Partner
U.S. Government
Approved for Public Release 17March 11, 2015Manufacturing in America Symposium 17
Membership Obligations and Benefits
INDUSTRY
Tier 1
Tier 3
Tier 2
Obligations Benefits
• $2M membership dues over 5 years
• $3M “Cost Share” over 5 years (labor, mat’l, capacity)
• Seat on Exec. Committee & TAC• Royalty-free license to use ALL IP
for internal R&D and operations worldwide
• $1M membership dues over 5 years
• Vote on Exec. Committee rep.• Seat on TAC• Royalty-free license to use ALL IP
for internal R&D only
• $500 membership dues per year, over 5 years
• Vote on Exec. Committee rep.• Vote on TAC rep.• Project participation• Networking opportunities• Access to Digital Manufacturing
Commons (DMC)
Approved for Public Release 18March 11, 2015Manufacturing in America Symposium 18
Membership Obligations and BenefitsACADEMIC/NON-PROFIT
Tier 1
Tier 3
Tier 2
Obligations Benefits
• $5M “Cost Share” over 5 years (labor, mat’l, capacity)
• Seat on Exec. Committee & TAC• Royalty-free license to use ALL IP
for internal R&D and operations
• $2M “Cost Share” over 5 years (labor, mat’l, capacity)
• Vote on Exec. Committee rep.• Seat on TAC• Royalty-free license to use ALL IP
for internal R&D only
• $1M “Cost Share” over 5 years (labor, mat’l, capacity)
• Vote on Exec. Committee rep.• Vote on TAC rep.
Tier 4 • $500 membership dues per year, over 5 years
• Vote on TAC rep.• Prohibited from Enterprise
Projects focused on technology• Eligible for workforce
development, training and education programs
*State and Local Governments can receive EC & TAC seats as well as IP rights for $5M commitment over 5 yrs
Approved for Public Release 19March 11, 2015Manufacturing in America Symposium 19
COLLABORATION
AND RESEARCH
DIRECTION
SETTING
COMPETITIVENESS
ENHANCING
PERFORMANCE
IMPROVEMENTS
ACCESS TO
INTELLECTUAL
PROPERTY
MORE ROBUST US
MANUFACTURING
ECOSYSTEM
• Access to cutting-edge, exclusive research to drive performance benefits
• Networking and knowledge sharing with leading experts• Federal and partner matching funds to support research
• Lower design costs through better collaboration with suppliers
• Lower manufacturing cost and capital requirements from better optimization of
end-to-end product lifecycle
• Reduced time to market due to more rapid iteration
• Next-gen innovations first: digital design, digital factories, digital supply chains• New and legacy products
• Access to leading manufacturer partner base and technology companies
• Internal R&D use and commercialization of IP
• Ability to iterate on cutting-edge products and services in live demonstration facility to show effectiveness to partners
• Workforce development to strengthen the talent pool
• Accelerating broad adoption of technologies, including a strengthened base of
Small and Medium Enterprises able to use digital manufacturing• Spinoffs and licenses leading to innovative new technologies
Benefits of Participation
Approved for Public Release 20March 11, 2015Manufacturing in America Symposium 20
Create an
Innovative Ecosystem
Increase the innovative capacity of
OEMs and their suppliers through
digital integration and strategic
collaboration.
A partnership of world-class companies including:
Top universities and the world’s most powerful computer including:
Proven talent from a consortium of state, educational, and vocational institutions:
Source: McKinsey Global Institute and team analysis
Commercialize
Research
Move ideas from TRL 4-7 through a
network of physical and virtual
demonstration sites.
Strengthen the
U.S. Economy
Offset the lower cost of labor used to
compete for our jobs
Create open source tools for use by
small businesses
Current Membership Portfolio
Approved for Public Release 21March 11, 2015Manufacturing in America Symposium 21
DMDII Technology Portfolio Guiding Principles
• Awareness about manufacturing technologies that will become available over the
next 2-5 years, which informs today’s decision making
• Knowledge about specific digital manufacturing technologies that have been
demonstrated and de-risked, and understanding about how to take advantage thereof
• Opportunities for commercialization along multiple paths including internal
implementation, licensing, and new ventures
Technical ProductsSpecific outputs of the technology project portfolio
Portfolio of InitiativesTechnology projects conducted by the DMDII membership
• Business value creation is at the center of our process
• Driven by the technical advisory committee, which brings an understanding of key
business problems, technical problems, and an awareness of potential solutions
• Problem statements are solution agnostic, which creates the conditions for
innovation
Problem IdentificationWhat should we work on?
• Each project proposal must have a compelling business case, technical case, and
potentially scalable impact
• Competitive process incentivizes innovation and rewards the best ideas
• Diverse and unique project teams form around specific project call opportunities;
this brings together communities who would not otherwise interact
Approved for Public Release 22March 11, 2015Manufacturing in America Symposium 22
Utilization of high performance computing to model materials, products and processes to enable “design with manufacturing in mind.”
INTELLIGENT MACHINING (IM)
ADVANCED ANALYSIS (AA)
Integration of smart sensors and controls to enable equipment to automatically sense and understand current production environment in order to conduct “self-aware manufacturing.”
ADVANCED MANUFACTURING ENTERPRISE (AME)
Information systems integration throughout the product lifecycle.
Digital links between design and fabrication.
Smart factory and supply chain management.
TECHNOLOGY FOCUS AREAS
OPEN SOURCE PLATFORM
An open source software platform that enables data aggregation, analysis, and action.
DIGITALMANUFACTURINGCOMMONS Meet industry and national needs
for security, trust, and IP protection within the manufacturing environment.
CYBERPHYSICALSECURITY
CYBER PHYSICAL SECURITY
Approved for Public Release 23March 11, 2015Manufacturing in America Symposium 23
Project Calls to Date
3 project calls released
12 project subject areas addressed
25-51 projects anticipated from these efforts
AVM DMDII-14-01 DMDII-14-02 2-8 projects
Core DMDII-14-06 DMDII-14-07 DMDII-14-08 3-10 projects
Cyber Security DMDII-15-01 2-3 projectsJan 2015 #1 DMDII-15-02 DMDII-15-03 DMDII-15-04 10-15 projectsJan 2015 #2 DMDII-15-05 DMDII-15-06 DMDII-15-07 8-15 projects
Digital Manufacturing Commons (online collaboration platform) 15Q1
Quickly brings to life DMDII approach to value creation
DMDII Internal Project
Approved for Public Release 24March 11, 2015Manufacturing in America Symposium 24
2014 Project Calls
Approved for Public Release 25March 11, 2015Manufacturing in America Symposium 25
Intelligent Machines
– Integration of smart sensors and
controls to enable equipment to
automatically sense and
understand current production
environment in order to conduct “self-aware manufacturing”
Advanced Analysis
– Computing to model
materials, products and
processes to enable “design with manufacturing
in mind”.
Advanced Manufacturing Enterprise
– Information systems integration
throughout the product lifecycle
– Digital links between design and
fabrication
– Smart factory and supply chain management.
AME1 Systems design using the digital thread
AME2 Smart factory visibility and real-time optimization
IM1 Communication standards for intelligent machines
IM2 Operating system for cyber physical manufacturing
AA2 Virtually guided certification
AA3 Shop floor augmented reality and wearable
computing
2015Q1 Project Call
2015 Strategic Investment Plan
Approved for Public Release 29March 11, 2015Manufacturing in America Symposium 29
Project Funding Summary
Projected Project Funding (Cost Share + DMDII Funds) = $54,800,000
$8,310,000 $7,000,000
$600,000
$5,500,000 $6,000,000
$8,310,000
$7,000,000
$600,000
$5,500,000 $6,000,000
$-
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
$16,000,000
$18,000,000
AVM Core Projects Cyber Security Jan 2015 #1 Jan 2015 #2
Cost Share DMDII Funds
$11.0M$12.0M
$16.6M
$14.0M
$1.2M
Approved for Public Release 30March 11, 2015Manufacturing in America Symposium 30
Project Call Status
AVM
CORE
Jan 2015 #1
Jan 2015 #2
Cyber Sec.
Proj. Call Released
Eval. Board
Req. GovApproval
Gov. Approved
ProjectedKick Offs
Proj. Call Released
Eval. Board
Req. GovApproval
Gov. Approve
ProjectedKick Offs
Proj. Call Released
Eval. Board
Req. Gov. Approval
ProjectedKick Offs
Work-Shop
Cost Proposal
Proj. Call Released
Eval. Board
Req. Gov. Approve
ProjectedKick Offs
Cost Proposal
Proj. Call Released
Eval. Board
Req. Gov. Approval
ProjectedKick Offs
Work-Shop
Cost Proposal
Approved for Public Release 31March 11, 2015Manufacturing in America Symposium 31
Project Call Process Overview
Project Call Workshop White PaperEvaluation
Board
Cost ProposalProject
AwardedGovernment
Approval
Project Kickoff
Approved for Public Release 32March 11, 2015Manufacturing in America Symposium 32
RFP Documents
Project Planning Document (PPD)– Project Summary, Submission Information, Requirements,
Background
Proposal Preparation Kit (PPK)– Project Call Process Overview
– White Paper & Cost Proposal Submittal, Evaluation, and Award
– Instructions for White Paper and Cost Proposal Preparation
– Resumes, Letters of Commitment (Stage 1)
– SOW, Reps & Certs, IP Management Plan, Technical Data/IP
Disclosure and Assertion Form (Stage 2)
Approved for Public Release 33March 11, 2015Manufacturing in America Symposium 33
Evaluation Process
Participants selected from industry, academia and govt.
Subject Matter Experts provide technical assessments
Evaluators conduct individual assessments and submit resulting scores and comments
Results aggregated, meeting convened, consensus established
Recommendations pushed forward (incl. request for clarifications)
Proposals selected for formal Cost Proposal submittal
Do not underestimate the importance of detail for this section!
Approved for Public Release 34March 11, 2015Manufacturing in America Symposium 34
Get Involved in DMDII Now
Go Online – No Obligation– http://dmdii.uilabs.org/– Sign up for the DMDII Newsletter
Build a Team, Submit a Proposal– Hurry! Next Project Call White Papers Due 1 April 2015!– No membership necessary to submit a proposal
Contact DMDII– Ask for Jacob Goodwin – Director of Membership Engagement