4.0 Made Real details

In collaboration with

AM INTEGRATED DEMONSTRATOR

Our new manufacturing system will build upon past experiences and popular requests. We'll produce a watch again, but this time we are allowing more personalization options, different designs, etc. Our system will reflect a flexible manufacturing environment where even 'lot size 1' is feasible. We'll start at the beginning: with the watch design. We'll take into account the challenges and potential of additive manufacturing, the restrictions of machining operations, the surface finish requirements and the assembly challenges. A multi-disciplinary team will apply end-to-end engineering methods in creating the optimal watch design.

NOVEL DATA ARCHITECTURE

Data is becoming the most valuable asset of a manufacturing company. It allows you to evaluate and optimise equipment usage, process efficiency, lead times, and so on. These factors will determine your competitive advantage and therefore you want to be free to gather, process and analyse your manufacturing data. A novel data architecture will be implemented to combine different data sources but also be able to use different management software (ERP, MES, …) parallel to each other.

eID - GATEWAY TO CERTIFICATION

With the rise of additive manufacturing technologies, where material is built from powder, the traceability of not only product but also manufacturing processes gains importance. Even more if product or process certification is envisioned. However, it goes without saying, you don't want to pass detailed information on your manufacturing processes (methods, parameters, …) along the value chain since you would give away your competitive edge. An eID enabling a secured and tailored access to share well defined levels of information whilst guaranteeing full traceability will be developed and implemented. Of course, the eID is not limited to additive manufacturing technology but can be used for all manufacturing processes.

CONNECTED MACHINES

At the heart of Industry 4.0 is the idea that all manufacturing equipment is connected and data can be exchanged. New machines and controllers are being equipped with a variety of connectivity options, like OPC/UA, which at least provide some access. However, seldom a company can afford to modernise all of their equipment at once or standardise to a single system. You'll face a variety of 'connectivity options' ranging from zero to full access. We will develop, implement and demonstrate cost efficient ways to connect the all machines a manufacturing company typically has.

In collaboration with

TRANSPARENT SHOP FLOOR

The days of the shop floor being a black box were orders are sent in and products come out without clear view on what, when and where, are over. Both your clients as well as your business units are expecting detailed information on product status, equipment efficiency, etc. Different methods to track, trace and/or monitor both products and equipment will be implemented and demonstrated.

INTEGRATED QUALITY ASSURANCE

When machines are connected and data is gathered, you'll be able to use real time information to adjust processes and predict quality issues. The demonstrator will integrate quality inspection systems and historic data analysis to ensure and guarantee the quality of our watch.

OPERATOR ASSISTED MANUFACTURING

Within a flexible manufacturing environment, a lot of pressure is being put on operators. They have to deal with a wide range of product variations, different assembly options, highly personalised products, etc. We'll demonstrate some digital aids to support operators during order picking and assembling end products.

NOVEL MANUFACTURING TECHNOLOGY

We will create our flexible 'lot size 1' production with the aid of novel manufacturing technology. At the base will be additive manufacturing technology creating the watch casing. Precision milling will be introduced for achieving strict dimensional tolerances. Novel surface finish technology will create a mirror-like finish. Finally, laser texturing will add a touch of personalisation. Each part of the chain will add value to the product and we'll keep the budget in mind.

MACHINING 4.0

When in 'Industry 4.0' modus you will be gathering data on your processes. But at the same you'll probably notice that the information for really making the difference, is missing. Key process parameters, such as tool wear, process temperature, cutting forces, ..., are not monitored and thus process optimisation options are limited. We will add sensors to the machines and integrate their data stream to enable a detailed look on what's really happening within a process and how it can be optimised. We call it 'Machining 4.0'.