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Next Generation Manufacturing
The document outlines CSIRO's role and achievements in future manufacturing, emphasizing its research in autonomous systems, robotics, and innovative technologies. It highlights the importance of adapting the manufacturing sector to emerging opportunities to enhance Australia's economic resilience. CSIRO operates numerous facilities and collaborates with global research institutions to drive advancements in various fields, aiming for a sustainable and productive future in manufacturing.
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Next Generation Manufacturing
- 1. Next Generation Manufacturing FUTURE MANUFACTURING FLAGSHIP
- 2. Who am I? 1. CSIRO Research Scientist Autonomous Systems Program (80+) QLD Centre for Advanced Technologies 2. 9 years in Manufacturing Low Pressure Die Casting 3. 4 years Machine Reliability Predictive Maintenance Machine Vision 4. 9 years Mining Robotics Robot Navigation 5. 5 years Robotic Perception 3D LiDAR Mapping 6. 1 year Manufacturing High Performance Workplace
- 3. Autonomous Systems Program Vision: A world in which humans and autonomous systems are able to seamlessly, reliably and safely collaborate.
- 4. Robot navigation Dynamic,difficult environments
- 5. Remote Collaboration Robots,vision and broadband
- 6. Pervasive Computing Platformtechnology
- 7. Robots in Mining Dragline Swing Automation Shovel Automation Tele-robotic Rock-breaker LHD Automation (Caterpillar) Explosive Loading (ORICA) Longwall Automation (CESRE)
- 8. CSIRO - Snapshot 62%of our people hold university degrees 2000 doctorates 500 masters Wodonga Armidale 2 sites CSIRO undertakes $~500M of externally funded R&D each year Partners = 1300+ Top 1% of global research institutions in 14 of 22 research fields Top 0.1%in 4 research fields Highest number of citations per scientist in Australia Darwin Alice Springs Bakers Hill Atherton Townsville 2 sites Rockhampton Toowoomba Gatton Myall NarraVbrai le Mopra Parkes Griffith Belmont Geelong Hobart Sandy Bay Werribee Newcastle Perth 3 sites Adelaide 2 sites Brisbane 6 sites Sydney 5 sites Canberra 7 sites People = 6000+ Locations = 57 Budget = $1B+ Murchison Cairns Melbourne 6 sites Infra = $3.5bn Patents = 3000+
- 9. Our track record:top inventions 4. EXTENDED WEAR CONTACTS 2. POLYMER BANKNOTES 3. RELENZA FLU TREATMENT 1. FAST WLAN Wireless Local Area Network 5. AEROGARD 6. TOTAL WELLBEING DIET 7. RAFT POLYMERISATION 8. BARLEYMAX 9. SELF TWISTING YARN 10. SOFTLY WASHING LIQUID
- 10. We are inthe world’s Top 10 institutions for 2 research fields. We are the only Aussie R&D organisation in the world’s Top 10. We have 14 research fields in the top 1% of global research organisations. CSIRO global positioning 45 40 35 30 25 20 15 10 5 0 Columbia UC San Diego U Michigan U Wisconsin Yale U Penns Chinese Acad Sci 1 2 3 4 5 6 7 8 9 10 11 12 13 NO. OF INSTITUTIONS NO. OF FIELDS IN TOP 10 GLOBALLY CSIRO CNRS Cornell Georgia Inst Tech INRA NASA Nat U Singapore NCI NIAID Princeton U Toronto USEPA USGS U Illinois U Tokyo USDA Wageningen U UCSF Johns Hopkins UCLA MIT U Washington UC Berkeley Harvar d Max Planck Standford CSIC U Carolina UC Davis Oxford Based on total citations. Source: Thomson-Reuters/ISI Essential Science Indicators
- 11. China Australia Alliancefor New Energy Vehicle Innovation Global connections 80+ countries
- 12. World-class science and technology CSIRO - the roles we play 1 2 3 4 5 Trusted advisor to government Leveraging Australia’s Innovation System Innovation supporting the creation of new businesses Helping existing companies transition to the future
- 13. Where does CSIROoperate? http://erc-assoc.org/book/export/html/745
- 14. Innovation Ecosystem NationalInnovation Networks CSIRO CRC HUBS Universities SME’s
- 15. How does CSIROdo this? CSIRO Innovation Partnerships Research Agreement Operator OEM License Agreement Purchase Agreement
- 16. National Research Flagships BIOSECURITY ENERGY TRANSFORMED DIGITAL PRODUCTIVITY AND SERVICES CLIMATE ADAPTATION WEALTH FROM OCEANS FOOD FUTURES SUSTAINABLE AGRICULTURE MINERALS DOWN UNDER FUTURE MANUFACTURING PREVENTATIVE HEALTH WATER FOR A HEALTHY COUNTRY Mission Oriented Research
- 17. The Australian Situation ~1m jobs Generally high wages 29% of exports Dominated by SMEs Highly productive? 30% of trade apprentices 8% of GDP and more in service industries 20% of output as input into other sectors 25% of Business Expenditure in R&D • Under pressure from high Australian dollar • Ageing workforce • Operating in high cost environment • Largely SME based • Remoteness and small local market • Skills shortage: losing capabilities to other sectors • Need to lift up productivity • Transitioning to a resource constrained future
- 18. National thought leadershipin manufacturing The combination of forces currently putting pressure on many Australian businesses threatens to undermine the capacity of the (manufacturing) sector to take advantage of future opportunities. If manufacturers are not in a position to capitalise on emerging opportunities, the Australian economy as a whole will be weaker and more vulnerable now and over the longer term. Prime Minister's Manufacturing Taskforce, Report of the Non-Government Members, 2012
- 19. Towards a competitive, productive and sustainable future for manufacturing The 7 “S” of Manufacturing Sustainability - License to operate, Sustainable products, Resource efficient Speed and agility Responsiveness, Customisation, Speed to market Scalability Low volume, reconfigurable, Scope vs scale Smart - Materials and processes, Information systems, Design led Services Solutions vs product, Moving up value chain reSources Natural assets, Human capital Supply chains Globally connected
- 20. •New Workflows •NewBusiness Models •New Enterprises Next Generation Manufacturing ? •New Processes •New Materials •New Production •Mass Customization •Maximize Flexibility •Mass Production •Minimize Waste Great Expectations Lean Agile Information Driven Advanced Virtually here More from Less • Additive • Titanium • Nano • Bio • Flexible
- 21. What’s in aName? Industrial Internet (GE) Industry 4.0 (Germany) Network Enabled Manufacturing (Boeing) Manufacturing 2.0 (European) IoT – Internet of Things Cloud Computing Big Data Semantic Web
- 22. iManufacturing Architecture FUTUREMANUFACTURING FLAGSHIP
- 23. Layered Architecture ExternalForces Virtual Factory – Executive Layer • Simulation of factory and the world around it. • Interactive and collaborative user interface • Decision support (simulated scenarios) Digital Factory – Strategic Layer • Live (Real-time) digital model of factory • Fully Integrated across the production cycle - Data Fusion • Optimization of production based upon demands Smart Factory – Tactical Layer • Smarter sensing and actuation around each process • Reconfigurable / Adaptive / Responsive processes • Improved situational awareness - QA/QC Demands Demands Demands Data Intelligence CRM Customer Relationship Management PLM Product LifeCycle Management SCM Supply Chain Management ERP Enterprise Resource Planning MES Manufacturing Execution System SCADA
- 24. Connected Architecture CRM PLM SCM ERP MES SCADA CRM PLM SCM ERP MES SCADA CRM PLM SCM ERP MES SCADA
- 25. subcontracting process Engineerat company A defines product specification in in-house ERP A raises purchase order and generates further specifications in ERP A Engineer at company B retypes specification in in-house ERP A ERP B ERP B Engineer at company B retypes specification in in-house ERP C ERP C Status Quo
- 26. Bridging the InformationGap • Bespoke solution are not scalable. • Previously required installation of software on-site. • Too expensive for SME. • The cloud can provide off-load the software • But still have a problem with inter-connections. Solution • Objects with relationships to other objects across strata exist. • Management by Semantic Web • Deliver information flows to the supply chain to allow secure, fit for purpose, interoperability across various platforms and processes
- 27. What are theinformation flows At the nodes, we need Informatics Client data Human Services Material, Products and Processes Supply chain events Supplier data ICT Automation, IoT, Robotics Factory events Factory data End to end data Product data Process data Supply chain management Nodes Assistive technologies Design, customisation Direction of data flow Sustainable Relationship manufacturing Management Informatics Workforce skills
- 28. Apple Treatment Process– Knowledge Representation Chemical Processing Engineers Informatics Engineers
- 29. Example: Knowledge Representationof Apple Processing
- 30. “eManufacturing Cloud” subcontractingprocess Engineer at company A defines product specification in in-house ERP A raises purchase order and generates further specifications in ERP A ERP A ERP B Machine-comprehensible specifications translated into data format for ERP C and automatically ingested by ERP C ERP C Machine-comprehensible specifications translated into data format for ERP B and automatically ingested by ERP B Proposal
- 31. High Performance Workplace FUTURE MANUFACTURING FLAGSHIP
- 32. LAMS – LightweightAssistive Manufacturing Solutions • Low-cost, from purchasing price and installation costs, to reprogramming and maintenance costs • Easy to use, without the need of technical expertise to deploy, • Support mass customisation, ideal for small runs of multiple Guardian Angel •Monitors environment • Tracks people and assets •Make work safer for humans Guardian Mentor •Worker augmentation • Provides skills and training •Make work easier for human Guardian Helper • Provides physical assistance • Robotic co-workers •Works with humans Guardian Worker • Provides remote assistance • Tele-operated robotics •Work for humans High Performance Workplace operate and reconfigure the systems types of products Augmentation • Collaboration • Interface • Observatory Assistive • Navigation • Manipulation • Cooperation Awareness • Monitoring • Modeling • Management Worker Centric: Increase productivity, safety and adaptability of future workforce through virtual and assistive automation technologies Social Science Human Factors Informatics Communications Sensors Robotics Engineering Investment Innovation Impact
- 33. Changing Manufacturing Paradigms Current automation in manufacturing Rigid Bulky Expensive Unsafe Lightweight Assistive Solutions Flexible Affordable Lightweight Human-centered Easy-to-use
- 34. Lightweight Assistive ManufacturingSystems Multi-Sensorial Augmented Reality Human/Robot Collaboration Augmented Human Worker Robot/Robot Collaboration Worker Safety: Always Aware Telesupervision
- 36. HMI LAMS ICT Perception Consumer Devices Robotics Mobile Tele-presence Lightweight Robotics Social Networking Mirror Worlding Sensing in Unstructured Dynamic Environments Dependability Robustness Field Robotics Military/Mining Collective Intelligence Cloud Services Big Data Internet of things Cheap sensor, processors and actuation Immersive Interfaces Gaming Additive Manufacturing Intuitive interfaces Mobile Devices Ubiquitous Connectivity Location based service Technology / Trends to Develop Assistive Robotics
- 37. Autonomous Safety Zones 1. Create 3D Model 2. Monitor environment 3. Track people and robots 4. Measure risk 5. Detects hazards 6. Alerts participant 7. Creates Safety Zone 8. Alerts bystanders 9. Monitors task 10. Alerts help if required. Bystander walks into factory Guardian Angel •Monitors environment •Tracks people and assets •Make work safer for humans Person starts to change tyre! Vehicle wants to move
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- 39. Prefab Challenges 1.Site Preparation Green Field / Brown Field – 3D Surveying – Mobile Mapping 2. On-site Assembly Skills – Remote Training 3. Certification / Inspection Remote Monitoring – Robotic Inspection
- 40. Mobile Mapping FUTUREMANUFACTURING FLAGSHIP
- 41. Zebedee • Hand-heldMobile 3D mapping system • Commercial system licensed to 3DLM • Formed JV to create company called GeoSLSAM
- 42. Lean Tower ofPisa Scanning
- 43. Scanning of theLeaning tower of Pisa
- 44. The Opera-Theatre ofClermont-Ferrand
- 45. Anzac Square InformationDriven Manufacturing
- 46.
- 47. Capabilities in RemoteCollaboration Gesture Tracking Vehicle Tracking People Tracking Face Tracking Security and Trust High Bandwidth Comms Quality of Service Haptics Augmented Reality Augmented Virtuality Panoramic Display Collaborative Environments Situational Awareness Communications Human Machine Interface
- 48. Assembly and RemoteAssistance Assisted Human Worker Autonomous Navigation Lightweight Robot Assistant Remote Instruction + Augmented Reality Remote Expert
- 49. Remote Maintenance RemoteExpert Virtual Collaboration Space Local Resource ReMoTe is hands-free, wearable, and is operational in various environmental conditions and designed so operators can operate it without any training or prior skill.
- 50. Confined Space Robotics FUTURE MANUFACTURING FLAGSHIP
- 51. Capabilities in FieldRobotics Dragline Shovel LHD HMC Rock Breaker Explosive Loading Cleanup Agriculture Helicopter Submarine Ground Boat Haulage Manipulation Navigation
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- 56. IMCRC Information DrivenManufacturing McFarlane for MIICRC to re-submit a combined bid with AMCRC by the end of May. He said: “In addition to this funding, the Advanced Manufacturing and Manufacturing Industry Innovation CRCs are well positioned to assist the Australian manufacturing industry to adapt to new, high tech manufacturing processes and will assist in opening new markets. These applications displayed merit and are proposing to address issues of national importance. As such I have asked these CRCs to submit a combined proposal for my consideration.”
- 57. Some Videos 1.ETHZ Construction Robots - https://www.youtube.com/watch?v=rl7u2pPf-ak 2. Hundegger Robot Drive https://www.youtube.com/watch?v=MnwVd7A-mtk 3. Contour Crafting https://www.youtube.com/watch?v=c8Dhdf6eheg 4. IAAC Minibuilders https://www.youtube.com/watch?v=G1iT8_QyP0M 5. 15 Storeys in 30 days https://www.youtube.com/watch?v=rwvmru5JmXk 6. Brick laying robots https://www.youtube.com/watch?v=0s6OF5awJKs 7. Swarm Robots https://www.youtube.com/watch?v=pxLfzWDs3HA 8. Collaborative Robots https://www.youtube.com/watch?v=4JNJ1LHSAwA Information Driven Manufacturing