European Roadmap for Cyber-Physical Systems in Manufacturing

sCorPiuSI4MS 2016 eventAmsterdam – 23rd June 2016

Luis UsatorreLuis.usatorre@tecnalia.com

•Overview•sCorPiuS purpose is to support the planning of the Research and Innovation activities with the involvement of the most important European stakeholders. For these reasons, one of the main objectives of sCorPiuS is to perform activities for creating consensus, community building and awareness within the targeted communities of the European Union.

sCorPiuS European Roadmap for Cyber-Physical Systems in Manufacturing

Project No: 636906

Duration: 24 months

Start date: Feb1st 2015

Partnership: 6 partners, 3 countries

Total Eligible Cost: 792.938,75 EURO

EC Contribution: 610.013,75 EURO

1

Apr 15

MARKET requirements Volatile markets Individual customer requirements Shortened delivery times Shortened product life cycles 24/7 worldwide service Social behavior, new cooperation Disruptive business models

FORCE manufacturing changes Customisation of products and processes High adaptivity of processes from planning to production Digitalisation of production Horizontal integration of customers and suppliers Vertical connection through all company functions Fast integration and flexible configuration Distributed intelligenceOpen standardsDigital twin for virtual real-time representationDigital life-cycle management

Overall plan positioning 2

4SOTA collection structure (1)

•13 suitable initiatives (roadmaps, projects, industrial reports, …)

5State of practice on CPS (experts view)

Guru interviewKnowledge

capture events

21 CPS experts’ interviews 4 capture events

1. Welcome, work methods, goals2. Round table discussion (experts)3. Inputs’ consolidation4. Ranking, discussion and closure

04080

Breakthroughs and Obstalces

Breakthroughs Obstacles

HDW/In-frastruc-

ture

Not-ICT Standards SW0

20

40

60

80

Enabling technologies

Overall plan positioning 2

7Key findings (state of the practice)

•Breakthrough and Obstacle Clusters:

1. New data-driven services and business models

2. Data-based improved products

3. Closed-loop manufacturing

4. Cyberized plant/ «Plug & Produce»

5. Next step production efficiency

6. Digital ergonomics

sCorPiuS - Clusters2

Apr 15

What is within sCorPiuS Roadmap focus

• Cluster Matrix for the Gap identificationMatch breakthrough and obstacle sub-clusters in a matrix, to select the most significant crosses, and so to identify the gaps.• 3 kinds of Obstacles were identified:- Out of sCorPiuS focus (not addressable by sCorPiuS project);- Not relevant for sCorPiuS Roadmap- Relevant for sCorPiuS Roadmap

Obstacles

ClusterObstacle sub-cluster x.1

Obstacle sub-cluster x.3

Obstacle sub-cluster x.

Breakthroughts

Breakthrough sub-cluster x.1

Breakthrough sub-cluster x.2

Breakthrough sub-cluster x.3 XBreakthrough sub-cluster x.4

High proirity

for sCorPiuS

Roadmap

Out of sCorPiuS focus Whitin sCorPiuS focus

Low priority for

sCorPiuS Roadmap

Reccomendation;

Research priority.

Gap Analysis Summary

Cluster Breakthrough Gaps

CL 1 New data-driven services and business models

Digital business ecosystems for sensing product/services

1. Uncertain ROIBenefits and costs not clearMissing KPI

CL 2 Data-based improved products

Data-driven products use/maintenance (MoL) 2. Communication problems -

smart products vs old factories

Improve quality and added value of product 3. Complexity vs usability

CL 3 Closed-loop manufacturing

Autonomous decentralized decisions 4. Data Security and privacyHorizontal and vertical integration 5. Integration and

interoperability

CL 4 Cyberized plant / “Plug & Produce"

Cyber-physical flexibility 6. Difficulties in transforming current plant into CPS based systems

Cyber-physical flexibility 7. Uncertain performance reliability

Reconfigurability 8. Safety and security limits

CL 5 Next step production efficiency

Improve energy efficiency 9. Legacy and old technologies CPS migrationPlant operations optimization

CL 6 Digital Ergonomics

Enhanced humans sensing and intelligence

10. Workers role and related aged regulations

Reduce management complexity 11. Management Complexity (over functionalities)

Other Aspects to be taken into consideration

Cultural, Educational and Perception

Overestimation of costs

Law, Regulations, Technology Enablers and EU Macro Economic Factors

Standards and certifications

Result of the analysis of findings not directly addressable with Research activities.

Two sets of recommendations will be mainly envisaged: one more oriented to address the soft and consensus aspects, the second more oriented to the Regulations, Standards and Enabling Technologies key

features expected to endorse CPS implementation.

• Executive Summary• Cyber-Physical Systems (CPS) in Manufacturing

• The need for CPS• What is a CPS?• CPS as a digital twin• CPS for European Manufacturing• State-of-Practice

• Vision• sCorPiuS Vision

• Gap Analysis• Methodology• Gap Analysis of 6 Clusters

• Cluster 1: New data-driven services and business models• Cluster 2: Data-based improved products• Cluster 3: Closed-loop manufacturing• Cluster 4: Cyberized plant/ “Plug & Produce”• Cluster 5: Next step production efficiency• Cluster 6: Digital Ergonomics

• Additional findings from the Gap Analysis Exercise• Gap Analysis Summary

• Conclusions•

Whitepaper: Table of Content

http://www.scorpius-project.eu/

Overall plan positioning 2

hierarchical structure

ERP

MES

SCADA

PLC

FIELD

Production planning, order processing

Detailed planning, production data acquisition, material & quality management

HMI, “recipe” management & execution, measurementOpen & Closed Control loop

actual sensors & actuators, data transfer

The Automation pyramid concept, traditionally used

to describe the different system levels of an overall

automation solution, needs to evolve.

CPS defies the concept of rigid hierarchical levels,

being each CPS capable of complex functions across all

layers.

1. The CPS and the end of the Automation Pyramid

15

• 2- Product-Factory Lifecycle

in EFFRA roadmap

Vision-relation with previous roadmaps

Industry 4.0 and IIC• Different IT layers depending of Product or Factory management• Circular economy of things and Data

sCorPiuS Draft Vision

Consultation Meeting

Enterprise Systems

Virtual World

PhysicalWorld

The new pyramid goes further than the

shopfloor

The Digital Twin – both Cyber and

Phisical

Overall plan positionoing 2

19Impact workshops

BRUSSELS April 2016

BARCELONA May 2016

Preliminary ranking exercise

sCorPiuS RP sCorPiuS RP title Rank

14 Material and resource efficiency in manufacturing 81 Predictive and preventive self-learning systems 64 CPS Enabled reconfiguration of automated manufacturing systems 5

10 Manufacturing as a Service (MaaS) – Servitisation of autonomous and reconfigurable production systems 4

3 Knowledge and skills for the next generation manufacturing 36 Full Product LifeCyle data collecting and analysis 37 Cyber Native Factories 38 Digitisation of value networks 39 Next generation customer driven value networks 2

12 Product Service Systems (PPS): products with embedded service delivery capability 22 Caring for People in manufacturing Systems 15 Novel production management tools for a responsive CPS-based production 1

11 Customer at the center - from design to disposal 013 European Circular Economy Open Platform for CPS 0

• Release of deliverables• D2.2, D3.1, Draft D4.3• First release of roadmap

D3.2 Preliminary (due M20)

• Open survey on vision and gaps

• Strategic actions• Circulation of WhitePapers

in EC community• Endorsement of sCorPiuS

survey• Join events with EFFRA

Next steps

• http://www.scorpius-project.eu/

European Roadmap for Cyber-Physical Systems in Manufacturing

Luis Usatorre – TecnaliaLuis.usatorre@tecnalia.com

http://www.scorpius-project.eu/