This document describes a project called Factory of the Future that uses virtual reality and other Industry 4.0 technologies to create an immersive virtual environment of a real factory. Sensors collect data from machines to detect status and failures, which is displayed in real-time dashboards. The virtual environment allows for remote machine control and maintenance training without affecting production. It brings together connected, smart, and virtual capabilities to generate new use cases and address industrial challenges.

1. Factory of the Future
Virtual Factory Twin

2. 2 Presentation title
The aim of this project is to demonstrate the benefits of Industry 4.0
technologies working together and enable the generation of new use
cases applicable to a real industrial environment, thanks to the full
immersion and a smart - connected platform.
Five countries were involved in the development (USA, France, Italy,
England and Spain). Technical development lead by AICAM in support to
WCC os Advanced Manufacturing. Real factory case based in Airbus
Puerto Real thanks to AICAM proximity and the relation created by sharing
technology incubation together with real industrial use cases.
It is a fully immersive virtual environment of a real
factory where intelligent sensors (SenseForge)
harvest data from different machines, performing
analytics to detect status and failures. IoT platform
(VueForge), collects information coming from
Industrial Information Systems and SenseForge and
then displayed on real time dash boarding in the
virtual environment, allowing the capacity to deploy
an early warning system through analytics at plant
level. Virtual reality is used for training purpose
(maintenance training) and as a remote control
platform being able to move robotic arm in remote.
WHAT IS SPARKLE?
Our industrial customers were
needing a platform as a playground
for generating new use cases related
to Industry 4.0 utilities and their
specific industrial challenges. For this
purpose, Altran designed a framework
merging industry 4.0 capabilities
(Connected, Smart and Virtual
Factory). Thanks to the latest
introduction of machines remote
control, Sparkle has become a 5G
showcase due to the low latency and
wide bandwith request when trying to
control big number of machines in
remote in real time.

3. > Immersive High-End Training.
> Real Time Data Analysis & Management.
> Analytics for Legacy Machines, Jigs & Tools.
> Hyperconnectivity.
> Dash boarding designed for different user profiles and accessible from
different platforms (VR, Tables, Mobiles,…)
> Moving from the ‘training’ concept to the ‘experience’ concept, to get real
training without affecting production flows.
> Digital twin control.
> Smart Sensors: SenseForge.
> IoT Platform: VueForge Connect.
> 3D Modelling: Laser Scanning (drones), Photogrammetry, CATIA
Conversion and from scratch modelling.
> Machine Learning Analytics: Machine Status.
> Virtual Reality: Immersive focus with natural interfaces, sounds, realistic
finishes…
The first Sparkle
prototype was
presented during
Paris Air Show.
Latest version, which includes
the remote control of a robotic
arm, was showcased as well
on the Mobile World Congress
2018.
https://youtu.be/1_Yxod9N52c
APPLIED TECHNOLOGIES
BENEFITS

4. SMART SENSORS
Accelerator Temp/IR
Hum %
Gyroscope
Magnet
Reed SW 4Mb ram Altimeter
Luminance
2.4 radio
Ana I/O
Dig I/O
› Sensor measurements
› FFT, Media, Deviation.
› Signal preprocessing
› Data Storage.
› Dashboard.
› Sensor synchro.
SenseForge is an advanced Monitoring System based on a sensors
mesh to optimize the efficiency and productivity of machines. Each small
device is easily installed on any machine to harvest, analyze and monitor
its operating data through vibro-acoustics analytics.

5. IoT PLATFORM
VueForge is Altran’s IoT platform
solution to receive different industrial
signals, being enable to translate them all
into the same language. This is allowing the
platform to perform Analytics and Big Data
to transform and unlock data into relevant
information at every plant level.
Customize Dashboards for every
plant user (from management to
operator)
Multiplatform presentation (Mobile,
Tablet, PC, VR, …)
Customized Early Warning System
to prevent plant events analytics
driven

6. Presentation title6
VR INTERACTIVE PLANT
(FULL SCALE IMMERSION)
Photorealistic immersion thanks to Photogrammetry
techniques, advanced CAD modelling, live factory
sound and synchronized machines simulations.
Use of virtual reality software to visualize and interact
with your factory in remote thanks to Virtual Reality
headsets.
Photogrammetry has to be combined with standard
in-game assets and post-processing effects in order
to create a believable, realistic environments and
objects. When we create an entire play-space
based on real world locations, we certainly use
photogrammetry to capture the raw textures and
scale of that particular place, but in order to make it
feel real we will need to augment that raw
information.
Adding stylized filters for things like lighting,
shadows, and reflections, as well as traditionally
generated game assets, helps to give environments
a sense of cohesion that makes objects feel more
“real” than what can be captured using
photogrammetric techniques alone. As it stands, we
usually mix different techniques (CATIA conversion,
3D modelling from scratch, texturizing with
orthophotography, modelling with photogrammetry,
and others) depending of the scenario we need to
recreate. In mixing techniques, we found
outstanding results.

7. This brain machine interface headset allows the user to move around the virtual factory,
hands free, by using your mind thanks to the latest EEG headset technologies.
The user can enter a world where the human brain connects directly with machines to
control real and virtual objects with thoughts and inject real time emotions into digital
experiences.
The EEG headset monitors cognitive load and discover emotional responses that are
preventing you from achieving peak mental performance.
COGNITIVE CONTROL

8. ROBOTIC ARM
Virtual reality is used for performing a pick and place task
within a manufacturing flow through the use of an EEG
headset working as a remote control platform being able to
move robotic arm in remote, showcasing the digital twin use
case.

9. Presentation title9
MAINTENANCE TRAINING
In this application, Virtual reality is also used with a training purpose:
specifically, a basic maintenance process training.The user will face a
common maintenance task, guided step by step by pop-ups and
dashboards, solving the issue and re-planning to ensure production.