DIMOFAC

Project Overview

Motivation and rationale – Problem statement

  • Growing demand for customized consume products

    • From mass production to mass customization

  • Requires novel low volume, high mix, high complexity production schemes

    • Need to increase flexibility of reconfiguration and responsiveness of production lines

  • But capital investment can overwhelm part cost

    • Investments cannot be spread-out on large volumes (risk for  investors)
    • Requires high level technical personnel (scarce)

  • EU manufacturing companies facing both a pre-financing and pre-knowledge problem

    • Public support is needed to minimize risks for investors and leverage private funds

  • Need for a pan European network of vendor independent pilot manufacturing lines

    • To test and benchmark the productivity improvements,
    • As well as the business cases of investing in low volume modular production lines

Motivation and rationale – Gap analysis

  • Existing pilot manufacturing lines throughout Europe

    • Good at demonstrating the feasibility of connecting different types of production assets
    • Weak at translating the technical ability into benchmarking improvements and business cases

Motivation and rationale – Approach

  • Create impact by standing on the biggest previous public and private investments  

    • At both national (e.g. Industry 4.0)
    • And regional levels (e.g. Digital Innovation Hubs)

  • Achieve technical excellence

    • By sharing a holistic reference architecture for smart modular production,
    • Compliant with Industry 4.0 standards,
    • And previous EU-National investments (e.g., FIWARE, IDSA, FOF, euRobotics)

  • Provide benchmarked Success stories on high TRL levels

    • By sharing a common set of methodologies and tools,
    • for KPIs definition, benefits measurements, implementation of pathways

Vision

  • Novel methodology based on MBSE and simulation

    • to reduce the impact in time and cost of reconfigurations and adaptations,
    • enabling the early verification of the product and process,
    • and the modelling of the manufacturing assets for creating flexible production lines by Plug and Produce (PnP)

  • Digital Thread

    • linking product and process lifecycles with the enterprise applications (e.g. ERP, MES),
    • Keeping an up-to-date virtual representation of the production system.

  • Implementation, benchmarking and demonstration in industrial pilot lines

    • real manufacturing conditions,
    • across different market sectors,
    • covering a range of features, materials and processes.

  • Establishment of a pan-European network of open pilot-lines

    • granting access on the DIMOFAC to a broad basis of European manufacturing SMEs and mid-caps.

Objectives and KPIs

  • O1 – Establish a holistic architecture for smart modular production in compliance with global I4.0 standards

    • KPIs: A DIMOFAC holistic architecture that fits a range of industrial pilot line requirements

  • O2 – Demonstrate the DIMOFAC PnP Digital Thread for Modular production

    • KPIs: 6 industrial pilot lines implementing the DIMOFAC Digital Thread for Modular Production

  • O3 – Establish a portfolio of flexible multi-functional PnP production modules based on upgraded existing production modules from previous projects (TRL 5-6) to make them “plug and produce”

    • KPIs:

      • Portfolio of 12 fully-operational production modules enabling reconfigurable industrial-driven pilot lines;
      • Portfolio of more than 20 production modules enabling open-pilot lines network at pre-industrial level.

  • O4 – Establish flexible and reconfigurable production lines composed of modular production equipment and powered by Digital Twinning

    • KPIs: 6 industrial-driven pilot lines

  • O5 –Demonstrate DIMOFAC solutions across a broad range of industrial sectors at TRL7 and make the results available to the European Manufacturing Sector across a broad range of markets

    • KPIs:

      • 6 successful demonstrations on industrial-driven pilot lines at TRL 7 with the following performances:

        • i) More than 20% decrease in reconfiguration time;
        • ii) At least 12.5% increase in resource efficiency;
        • iii) At least 15% reduction in overall cost of production;
        • iv) More than 10% yield improvement.

      • 11 Open pilot lines available during and after the DIMOFAC project;
      • 4 services provided through the EOI during the project duration by the open-pilot lines network supporting the adoption of reconfigurable manufacturing;
      • +100 trainees through the technology transfer events;
      • +11 scientific publications aiming reaching +5,000 readers

Six industrial-driven reconfigurable pilot lines

Four pillars

PILLAR 1: PLUG AND PRODUCE MANUFACTURING INFRASTRUCTURE TOWARDS THE SMART ADAPTABLE FACTORY

PILLAR 2: PRODUCTION MANAGEMENT SYSTEM BASED ON MODEL-BASED SYSTEMS ENGINEERING AND DIGITAL TWINNING

PILLAR 3: RECONFIGURABLE PLUG-AND-PRODUCE PRODUCTION MODULES

PILLAR 4: BOOSTING MODULAR AND RECONFIGURABLE MANUFACTURING

Value Chain

Project partners

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