ICE 2015‐ProRegio Project Overview

Dr. Nikolaos PapakostasLaboratory for Manufacturing Systems and Automation (LMS)

Director: Prof. G. ChryssolourisUniversity of Patras

Innovative Product‐Service design usingmanufacturing intelligence

Motivation – Challenges in production

New consumers often require very different

products to meet their needs, with

different features, quality and price pointsLocations of production

facilities are following markets taking

advantage of competitive input factors

New forms of intelligence, such as big data and the use of data-gathering sensors in production machinery and in logistics (the so-called Internet of Things) offer new production potentials

Customers in more established markets are demanding more variety and faster product cycles

Growth opportunities in the domestic market decrease while demand in

emerging economies rapidly increases

Increasing specialisation of

locations regarding markets, products or

processes

Additional and adapted production capacity distributed over the whole production network is needed to fulfill increasing and varying customer demand

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Manufacturing Industry

ICT-Enabler

Research Institution

Aeronautics Machinery DomesticAppliances

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Partners - Function

Partners - Origin

4

Germany KITAirbus Flexis Texxmo

Karlsruhe Hamburg Stuttgart Boeblingen

France ECNAudros

Nantes Lyon

Italy POLIMIComau ES

Milan Grugliasco Trento

Greece LMSGrobo

Rio Patras Athina

Turkey Arcelik Istanbul

Research questionsHow can customers be integrated in the innovation process?What kind of interdependencies exist between product structure and production capabilities? How can production systems efficiently be adapted to regionally differing products?What is the optimal customer-oriented design of production systems and of production networks? How can cyber-physical systems enable the ad-hoc (re-) scheduling of orders in production networks?

ObjectivesEnable globally operating companies to efficiently deliver innovative, customized products by using their globally distributed production network to meet strongly differing regional requirements regarding product design and functionality of their globally distributed customers

Integration of customer in the product development process allowing for an efficient incorporation of strongly differing customer requirementsDevelopment of integrated product and production adaptions regarding site-specific conditions and technology optionsInnovative product-service design by incorporating customers in the order-fulfilment processes Optimal design of production systems and allocation of production processes to production sites including a decision support for ad-hoc (re-) scheduling of customer orders

Customer-driven design of product-services and production networks to adapt to regional market requirements

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Research questions and objectives

Proposed benefitsImprovements in production performance

Reduction of production costs Shortening of throughput timesImprovement of delivery reliability through more transparent production processesShorten time-to-market of customized products/ services

Increasing the attractiveness of companies …by offering new added value services that make their products more attractive (e.g. more individualized products and shorter time to market) to different customers segments especially for emerging regionsby increasing customer satisfaction by providing more “power” to the customer comparable to effects ofsocial mediaby increasing supplier loyalty by even stronger integration into the order fulfilment processby increasing ability to export into emerging countries all around the world and in doing so the project willhelp to stabilize EU’s exports

Proposed benefits of ProRegio are expected to increase the attractiveness of European companies for customers from all around the world

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Benefits and impact

Cyb

er-p

hysi

cals

yste

ms

Enabler

Customer Product

Production Network

Production system

Strategic planning of production networks and

systemsRe-design of production networks and systems

Methodology for integrative design of product and production systems

Methodology to embed direct customer

involvement in the order-fulfilment process

Design of customer-oriented

products for frugal1 innovation

71) Frugal innovation can be defined as the process of reducing the complexity and cost of a good and its production.

Overall concept

ProRegio Approaches, Methods & Tools

ProRegio Platform

Tools, usages and interactionSoftware primary relationship to use cases

Design and Simulation Influence Execution Influence

Customers

Suppliers

PLM Platform (Audros)

Customer data

Design data

Manu‐facturingdata

Docu‐ments

Technical data

Plant data & Orders

MES data

ProductionProcessdata

Network data

Virtual Factory (Polimi)

Knowledge

Connector

RuleStream (Polimi)

Knowledge

Connector

Mod‐frontier

(Engin‐Soft)

Knowledge

Connector

Prod. Planning(flexis)

Knowledge

Connector

Artificial / human CPS (Texxmo)

Knowledge

ConnectorPortal Portal

Production network support 

tool (LMS)

Knowledge

Connector

Prod. Network 

Design (KIT)

Knowledge

ConnectorConnector

System Conf/Opt(Polimi)

Knowledge

Use Case 1

Use Case 2

Use Case 3 main application

main application

main application

Product-Service aspects and business & financial models

ProRegioPlatform

Operator

Maintenance Expert

Operator wears AR glasses and 

informs about the problem.

Provides info of the broken down machine  and transmits the video captured from the AR 

system

Adds annotations/ pictures and voice content on the real‐time video image

All the content is being integrated and displayed to the operator’s screen

Machine Breakdown in Factory’s 

Production Line (Arcelik)

Operator Guidance through ProRegio Platform’s Integrated Augmented Reality System

Cyber Physical Systems, Internet of Things

Track location (with RFID, GPS, ...) of components, material delivery unit (MDU), tools, aircrafts

Extract status‐information from IT systems (Ground test instructions, takt orders, planned and acknowledged work orders, …)  

Monitor tool usage (detect usage, count drilling/riveting, measure paint consumption, …) 

Image processing (installation of cabin, vertical/horizontal tail plain, …) 

Note: extra benefit is generated by linking the different solutions into a single network 

Potential Solution Clusters for Digital Shopfloor Management (Airbus)

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Arcelik Use Case

Design of a Refrigerator following Frugal Innovation Approaches and AugmentedReality Tools for Receiving Customer‘s Feedback followed by Supplier‘s NetworkMultiobjective & Automated Design and the Prompt Reconfiguration of the Networkin case of Supplier‘s Failure. Finally Remote Maintenace Approaches will be utilizedfaciliated by Augmented Reality.

25,000 employees Consolidated net sales in 2014 : 4,307 million Euros 10 brands Operating in 26 countries 15 production plants in 6 countries* (China, Romania,

Russia, South Africa and Turkey) Products and services in more than 130 countries

Production, marketing and after-sales services of consumer durable goods, consumer electronics

and components

Airbus Use Case

144,000+Total workforce

€690billionOrder book

€59billionAnnual revenue

Production network:Optimization of type‐allocation and order‐allocation to different FALs by …

specializing local production processes with respect to aircraft configuration utilizing differing local production capabilities (e.g. lead‐time, cost, …)  in terms of standardizing/ specializing production lines where beneficialbalancing of workload and lead‐time through a/c sequencing

Customer link:Improve IT link between customer and production to increase customer integration into the production process

Digital shop floor management:Enhance real‐time acknowledgement of work order status and disturbances in the production processImprove real‐time visibility of partsEnhance real‐time quality control

Comau Use Case

Need to manage globaloperations with growingdemand in emergingmarkets

Lack of a shared toolamong design engineers

Lack of explicit technicalknowledge – skill gap

Highly integrated designtool for better decisionmaking

Improve knowledgesharing and reuse acrossdepartments

Reduce Time, Cost andErrors

System Integrator and Manufacturing Equipment Provider Engineering-to-Order of Automotive Production Equipment

Cross Collaboration with other Projects

• Development of common digital models of customers, suppliers, product, process, resources employing semantic modelling approaches (ICP4Life)

• Investigation of novel business models for product‐services in the context of remote maintenance (Sense&React)

• Increase visibility at shopfloor employing IoT with real time asset tracking tools and embedded sensors (Sense&React)

• Joint Dissemination, Exploitation and Innovation activities

THANK YOU!

ProRegioCustomer‐driven design of product services and 

production networks to adapt to regional market requirements

http://www.h2020-proregio.eu/partenaire-KIT.php