The document discusses the concept of a "Factory of the Future" (FoF). It begins with background on current issues facing manufacturing, including lack of innovation and low value-add. It then defines key FoF concepts like open value chains, flexible production, and e-factories. The document outlines important enabling technologies like advanced manufacturing processes, mechatronics, ICT, and knowledge workers. It concludes with proposed research priorities focused on these technologies to help manufacturing adapt.

1. Presented To: Prof. Cao Huajun
Presented By: Salman Jafar
Factory of Future

2. Catalogue：
1. Background
2. Connotation of the FoF
3. Key technologies & Enables
4. Research and Innovation Priorities
5. Case study

3. Background
The manufacturing industry is the main body of the national economy, the
main battlefield of scientific and technological innovation, the foundation of our
country, the power of rejuvenating the country and the foundation of the
powerful nation.To create an internationally competitive manufacturing industry
is the only way to enhance the comprehensive national strength, protect the
national security and build a world power.
《Made in China 2025》clearly poited out: We must firmly grasp the strategic
opportunity, through three steps to achieve the strategic goal of powerful
manufacturing country.

4. Background Current Manufactuing Environment
Since the founding of new China, especially since the reform and opening
up, China's manufacturing industry has been developing rapidly, built a
complete, independent and complete industrial system, significantly enhance
the overall national strength, support the status of the world's great powers.But
compared with the world advanced level, China's manufacturing industry is
still large and not strong.
There exists obvious differences in the following parts:
independent
innovaation
ability
resources
utilization
efficiency
industrial
structure
level
information
level &
quality
benefit

5. Background Current main issues
Factories demonstrate a huge potential to generate wealth and to create
high-quality and highly skilled jobs, but now it faces lots of challenges.

6. Background Current main issues
 the less of independent innovation ability-----the low enterprise benefit
 limited reources & high degree of dependence on foreign trade-------the difficulties of cost
reduction
 low added value------the low enterprise benefit
 more severe standard systems------slow speed development of enterprises
 high resources comsumption------environment pollution

7. Background Current main issues
Figure shows the development
from craft manufacturing to
mass production, which made
a wide variety of products
available for a wide range of
people, followed by a shift
back towards specialized and
diversified production in order
to reflect the individual needs
of customers – but on a more
efficient and high tech level.
Evolution of production
Over the past millennia, several major social transformations have determined
the course of humanity, including the agricultural, industrial and information and
service revolutions. Production is changing with the development of age.
Continuously Developing Product Requirements

8. Background Current main issues
Smile curve of value added in production industries
Manufacturing industries are undergoing rapid changes, which are driven
by globalization and the exploitation of the early and late phases of production
chains.
(past factories)
low added value means
the low enterprise benefit
Low Added Value

9. Four long-term paradigms will guide the transformations that
manufacturing needs to undergo:
Factory and nature green/sustainable
 Lowest resource consumption energy — lean, clean, green
 Closed loops for products/production and scarce resources
 Sustainability in material, production processes/workers
Factory as a good neighbour close to the worker and the customer
 Manufacturing close to people (in cities/metropolitan areas)
 Factory integrated and accepted in the living environment
 Event-oriented production/integration of customers
Factories in the value chain collaborative
 Strive for highly competitive distributed manufacturing (flexible, responsive, high speed
of change)
 Integration of the product and process engineering — agile and demand driven Mastering
the collaboration from simple to sophisticated products in the value chain
Factory and humans human centered
 Human-oriented interfaces for workers: process-oriented simulation and visualization
 Products and work for different type of skilled an aged labor, education and training with
IT support
 Regional balance: work conditions in line with the way of life, flexible time and wage-
systems
 Knowledge development, management and capitalization
Background The long-term developing trends

10. • Manufacturing the products of the future
o Satisfy changing needs of society, potential of creating new
markets
o Service provisioning and enhanced product functionalities
• Economic sustainability of manufacturing
o Realising reconfigurable, adaptive and evolving factories capable
of small scale production
o High performance production, combining flexibility, productivity,
precision and zero-defect
o Resource efficiency in manufacturing, including addressing the
end-of-life of products
• Social sustainability of manufacturing
o Increase human achievements in future manufacturing systems
o Creating sustainable, safe and attractive workplaces for future
o Creating sustainable care and responsibility for employees and
citizens in global supply chains
• Environmental sustainability of manufacturing
o Reducing the consumption of energy, while increasing the usage
of renewable energy
o Reducing the consumption of water and other process resources
o Near to zero emissions in manufacturing processes
o Optimising the exploitation of materials in manufacturing
processes
Background Challenges and Opportunities

11.  What is Factories of Future?
The Factories of Future innitiative aims at helping manufacturing enterprises to
adapt to global competitive pressures by developing the necessary key enabling
technologies across a broad range of sectors.
It will help industry to meet increasing global consumer demand for greener, more
customised and higher quality products through the necessary transition to a demand-
driven industry with less waste and a better use of resources.
Connotation Concepts

12. Catalogue：
1. Background
2. Connotation of the FoF
3. Key technologies & Enables
4. Research and Innovation Priorities
5. Case study

13.  Open value chain
As the demand for personalized products increases, product lifecycles are
becoming shorter and shorter. To respond to requests arising from these changes,
value chain systems need to become more adaptable, agile and resilient and
need to be optimized with regard to capital expenditure.
 Flexible production
Flexible production includes products/design/market/delivery/process:
Connotation Concepts

14.  Human-centerd manufacutring
Future human-factory relations will become more flexible through the use of
advanced technologies.
Connotation Concepts

15.  Business models
Crowdsourcing
Crowdsourcing describes the process of obtaining ideas, services or content from a
large, collaborative group of participants rather than from traditionally specifed
employees, contractors or suppliers.
Benefits:
Innovate via new perspectives and
ideas coming from talent outside of
the company.
Design new products with better
alignment to the customers’ needs.
Fexibly integrate manufacturers for
the production of new products or
prototypes, for which customers do
not have their own facilities.
Connotation Concepts

16.  Advanced Manufacturing
Concepts
Advanced manufacturing technology is a set of mechanical engineering technology,
electronic technology, automation technology, information technology and other
technologies as one of the technology, equipment and systems.It includes CAD,
CAM, CIMS.

17.  E-Factory
Concepts
The E-Factory is achieving an advanced use of the industrial internet with regard to
both manufacturing control and data analytics, with the aim of effecting an
optimization of productivity and energy conservation.
The potential significance of the next generation e-Factory approach is indeed broad:
enabling technologies include sensing, smart robotics, automation of knowledge
work, IoT(Internet of Things), cloud services, 3D printing.

18.  Intelligent Manufacturing
Concepts
The core of the idea behind Intelligent Manufacturing is to gain information from a
ubiquitous measurement of sensor data in order to achieve automatic real-time
processing as well as intelligent optimization decision-making.
Target: improve product innovation ability
gain quick market response ability
enhance automatic, intelligent, flexible

19. Catalogue：
1. Background
2. Connotation of the FoF
3. Key technologies & Enables
4. Research and Innovation Priorities
5. Case study

20. FoF roadmap framework

21. Key Technologies & Enablers
The research priorities of the Factories of the
Future will focus on the development,
applications or integration of a set of enablers and
technologies.
These KTEs are as follows:
 Advanced manufacturing processes
 Mechatronics for advanced manufacturing
systems
 Information and communication
technology
 Manufacturing strategies
 Modelling, simulation and forecasting
 Knowledge workers

22.  Additive manufacturing
 Photonic based material processing (光子材料加工)
 Shaping technologies (incremental forming and marching)
 High productivity and self assembly technologies development of conventional and new micro/nano-
manufacturing processes
 Methods of handling of parts, metrology, and inspection, including non-destructive examination
technologies ensuring the ability of manufacturing at scale (volume) with high reliability and les in
controlled environments such as regular workshops.
 Integration of non-conventional technologies toward multifunction or hybrid manufacturing
processes.
Advanced Manufacturing Process
Key Technologies & Enablers

23. Technology Impact
Control technology
Use of light actuators to increase sensing and
intelligent power
Cognition base
intelligent features
To provide machine and robots an intuitive
cooperation, navigation, well awareness of work
and environment.
Advanced machine
human interaction
Ubiquitous interaction via ubiquity of mobile
devices based on information and communication
technology(ICT).
Continuous
monitoring
Advanced metrology, signal processing,
calibration and sensing would provide continuous
measurement of variable to improve system
performance and reliability.
Intelligent
machinery
components and
architecture
Will enable the deployment of safe , energy
efficient, accurate, and flexible manufacturing
system.
Key Technologies & Enablers
Mechatronics for advanced manufacturing systems

24. ICT solutions for factory floor and physical world inclusion
Real world resources need to be connected each other and to back end systems, and also to be well aware of the
surroundings.
ICT solution for next generation and information mining
Data need to be stored in a fault tolerated way.
ICT solutions will allow complex queries on databases to be run in fraction of seconds.
ICT solutions for modelling and simulation tools
main priorities are concern-integrated simulation techniques (product–process– production systems)
• integrated knowledge-based systems supporting the self-learning capabilities for semi-automatic design rules
update;
• modelling and simulation of production process constraints influencing the characteristics and performances of
the materials;
• modelling and simulation methods of manufacturing processes involving mechanical, energetic, fluidic and
chemical phenomena;
• CAE models interoperability to allow fast and complete complex process of virtual verification;
Key Technologies & Enablers
Information and communication technologies

25. Main focus of FoF is not only R&I also to
understand the mechanism to create value.
Approach Impact
Delocalization to
globalization 2.0
To cope transportation cast, green products,
shortening lead time will require a new
paradigm for western countries
(reindustrialization)
User centered design to
user well being design
User comfort, safety, performance, style, to
support a quick and dynamic response to
market changes.
Virtualization and
digitalization of the
interrelation between
manufacturing and new
business models
As products are virtually designed and tested,
holistic virtual models need to be made to
support the company design and test through
products, services and manufacturing
processes.
Key Technologies & Enablers
Manufacturing Strategies

26. Technology Impact
Modeling and simulation
for the (co-) design and
management to integrated
product-process—
production systems
Similar to the sustainable manufacturing modelling, simulating and
forecasting tools new methods and tools are needed for the multi-
stakeholder co design and management of integrated product-process-
production system in the context of social, environmental and
economical context.
Virtual models spanning
all levels of the factory life
and its life cycle
Holistic and coherent virtual model to support all the phases of the real
factory life cycle (e.g. site and network planning, conceptual design,
technology selection and process planning, resource design and
componnet selection, layout planning, operational/execution,
maintenance, end of life).
Key Technologies & Enablers
Modelling, simulation and forecasting methods and tools

27. Key Technologies & Enablers

28. o To create a large amount of employment and enhance number of
people available for and interested in manufacturing work.
o New technology base approaches to accommodate age limitations.
o New technical, educational and organizational ways to increase the
attractiveness of the factory for the young potential workforce.
o New approaches for skill and competence development
o Human centered work environment based on safety and comfort.
o To organize and compensate factory knowledge workers.
Key Technologies & Enablers
Knowledge-workers

29. Catalogue：
1. Background
2. Connotation of the FoF
3. Key technologies & Enables
4. Research and Innovation Priorities
5. Case study

30. • Advanced manufacturing processes
o Innovative processes for both new and current materials or
products – sub-domains:
o Processing novel materials and structures (into products)
o Complex structures, geometries and scale
• Adaptive and smart manufacturing systems
o Innovative manufacturing equipment, including mechatronics, control
and monitoring – sub-domains:
o Adaptive and smart manufacturing devices, components and machines
o Dynamic Production systems and Factories
• Digital, virtual and resource-efficient factories
o Factory design, data collection and management, operation and
planning, from real-time to long term optimization approaches
• Collaborative and mobile enterprises
o Networked factories and dynamic supply chain
• Human-centerd manufacturing
o Enhancing the role of people in factories
• Customer-focused manufacturing
o Customers in manufacturing value chain, from product-process design
to innovative services
Research and Innovation Priorities

32.  Manufacturing for custom made parts
 Integrate design with manufacturing and incorporate control methodologies
 Flexible and rapid changes in processes to be developed
 Development in advanced materials
 Advanced joining and assembly technologies for advanced and multi-materials
 Joining and assembly are key enablers for advanced materials into structures
 Materials process interactions need to be understood (simulation models, failure principle)
 Focus on hybrid joining technologies
 Self assembly technologies Material efficient manufacturing processes
 Minimizing energy coupled with material saving
 Process modification `
 On-site recovery and reuse of waste material
 Transformation of waste into useful by products
Research and Innovation Priorities
Advanced manufacturing processes

33.  High volume manufacturing at the micro-and nano-scale
 Development of conventional and new manufacturing processes
 Methods for automated handling of parts
 Inline metrology and inspection with high reliability
 Integrated manufacturing processes
 Integration of non-conventional technologies toward multifunction
manufacturing process (hybrid machining)
 Enhance manufacturing efficiency while minimizing raw material and
energy consumption
 Product life cycle management for advanced materials
 Modern high-tech products are poorly recovered and reused
 Solutions for the reuse, re-manufacture and recycling
 resin and fibers need to be separated and recycle from composites
 Additive laser manufacturing to refurbish damaged parts
Research and Innovation Priorities

34.  Flexible and reconfigurable machinery and robots
 Development of ICT tools to support autonomous reconfigurable machinery and robots
 focus on improved communication structures
 plug and play machine integration
 It would provide self-adjustment, correction, control networking, changeover cost/time
 Embedded cognitive functions for supporting the use of machinery and
robot systems in changing shop floor environment
 Development of cognitive functions into machinery and robot systems
 Advanced sensing and perception
 Development of self-monitoring and self-healing capabilities
 Adaptive process automation and control for a sensing shop floor
 Intelligent plug and play system
 Improved autonomy, reliability and efficiency
 Software capable of monitoring KPIs
 Monitoring, perception and awareness on manufacturing
 For high value adding actual state of component and machine is essential
 Ubiquitous approach based on smart sensor
 Continuous monitoring, measuring, the events and situations which effect performance
 M2M connectivity for future manufacturing enterprises
Research and Innovation Priorities
Adaptive and smart manufacturing systems

35. Research focuses on networked factories and dynamic supply chains .
Development of remote service management to improve equipment uptime,
reduce cost such as travel of servicing, improve service efficiency, like remote
updating of device software. Out-standing challenges to be encountered via
innovative ICT are following :
• Facilitating secure data exchange for collaboration in design, engineering,
services, and supply chain between multiple stakeholders;
• Visualization and tracking of processes, delays, and inventory flow;
• Accommodating dynamically changing orders and requirements from
customers and suppliers;
• Encompassing new product take-back laws, especially for end-of-life
(EoL) services for products;
 Mobile store and applications for an agile and open supply network
 Development of combined power of cloud infrastructure and mobile devices
to provide data of holistic supply network to stakeholders for.
I. Quick decision making
II. Better monitoring will save revenue and resources
 Manufacturing app store to be a one stop-solution for SMEs and large
enterprises.
Research and Innovation Priorities
Collaborative and mobile enterprises

36. Enhance the role and utilizing the potential of people working in factories. Four main
aspects need to be considered:
• How people work and learn;
• How people interact with technology ;
• How people add value to the manufacturing ;
• New manufacturing education and e-learning ;
 Innovative education methods to support advanced long life training
 Exploit advanced human-computer interface
 Immersive virtual technology
 Web-based collaborative environments
 Integrated e-learning
 Levels of automation and continuous adaptation of workplace
 Traditional system must be replaced by adaptive and dynamically changing systems
 Increased cognitive automation (automated decision making )
 Human-centered automation
 Exploiting technologies virtual reality and augmented reality
 Layout simulations
 Industrial social networking tools
Research and Innovation Priorities
Human-centered manufacturing

37.  New ways of human interaction and collaboration between workers and other
resources in manufacturing systems
Appropriate interfaces (e.g. visual, audio, etc.) and assistance tools for knowledge communication
.Advanced human machine-machine interfaces for workers require, considering
I. Usability and the related learning process
II. Physical, sensorial and cognitive interaction
III. Fulfillment of safety and health conditions during interaction
 Approaches to cooperate (human-robot) problem solving to be explored
 Automation level automation optimization
 Human and robot sensor packages
 Human/robot dialogue-based ways of automation programming
 New recommendation systems for the European workforce
 Next generation of recommendation systems
 Use IoT to capture worker interaction with machines, business systems, and workflows
 Development of well structured knowledge warehouses
Research and Innovation Priorities

38.  Manufacturing intelligence for informed product design
 Frequent feedback loop without interruptions between product engineering, manufacturing
and assembly phases
 ICT should enable integration between engineering and manufacturing phases ( integrating
CAD , CAM, and PDM/PLM tools)
 Shared and secure middleware, leveraging cloud offerings for exchanging manufacturing
data in the design networks
 ICT solutions for energy efficient product life cycle and ECO-design
 New software solutions to monitor and improve energy efficiency of products by leveraging
smart embedded systems, IoT, low-powered sensors, and M2M integration
 Data collection about energy consumption at each step of product life through (autonomous,
smart and embedded devices) through advances in IoT.
 new standardised virtual model and eco-design-related KPIs (within life cycle simulations
tools)
 New innovative UIs and apps for displaying KPIs on product energy consumption .
 Product-service simulation for sustainability impact
 Develop a frame work for life cycle simulations
 Development of digital mock-ups for product and service (based on financial, environmental
and social views)
 Simulation tools for product servitisation, recycling, and its impact/values for stakeholders
should be developed.
Research and Innovation Priorities
Customer-focused manufacturing

39.  On-demand manufacturing of customer focused products
• Fast integration between different tools to reduce lead time in a variable
supply network
• Manufacturing processes should flexibly be integrated with design
specifications
• ERP, MES, supply chain, planning and scheduling, and lean
manufacturing should be integrated.
 Costing and manufacturability assessment
• Fast decisions (regarding parts, materials sourcing, detailed product
design, etc.)
• Predictive models for cost and technical capabilities
 Data collection, analysis and anonymisation during product
usage
 Minimize resource , energy consumption by monitoring customer’s
product use pattern
 advanced sensors and the IoT to transfer product data to monitoring logic
hosted in cloud infrastructure
 Data anonymisation techniques like obfuscation, reduction and
perturbation should be investigated
Research and Innovation Priorities

40. Catalogue：
1. Background
2. Connotation of the FoF
3. Key technologies & Enables
4. Research and Innovation Priorities
5. Case study

41. Smart Factory Platform
Live-Webcam: http://www.smartfactory.de/webcam.de.htm
Germany-DFKI

42. Smart Factory Platform
Live-Webcam: http://www.smartfactory.de/webcam.de.htm
Germany-DFKI

43. Smart Factory Infrastructure Backbone
Germany-DFKI

44. Characteristics of the Factory of the Future