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20/05/2016 Prof. Marco Macchi ‐ POLITECNICO DI MILANO
Prof. Marco Macchi
SCENARI E TENDENZE PER LE FABBRICHE DEL FUTURO
20/05/2016 Prof. Marco Macchi – Manufacturing Group ‐ POLITECNICO DI MILANO – copyright 2
“It is not the strongest of the species that survives, nor the most intelligent, but those most responsive to change”
Charles R. Darwin ‐
“The origin of species”, 1859
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Background: mega-trend società, ambiente e tecnologie
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La società e l’ambiente
Cambiamenti demografici Scarsità delle risorse naturali
Cambiamenti climatici
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Le tecnologieNumber of transistors in Intel microprocessors
Pentium (0,8 m)
Pentium Pro (0,35 m)
Pentium II (0,25 m)
Pentium III (0,25 m)
Pentium 4 (0,18 m)
Pentium M (90 nm)
Core 2 Duo (65 nm)
Core 2 Duo (45 nm)
3rd Gen Core (22 nm)
2nd Gen Core (32 nm)
Source: Intel
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Le tecnologie
‘Ubiquitous computing names the third wave in computing, just now beginning. First were mainframes, each shared by lots of people. Now we are in the personal computing era, person and machine staring uneasily at each other across the desktop. Next comes ubiquitous computing, or the age of calm technology, when technology recedes into the background of our lives’’ Weiser, 1991 The computer for the 21st century. Scientific American, special issue on communications, computers, and networks
‘Ubiquitous computing names the third wave in computing, just now beginning. First were mainframes, each shared by lots of people. Now we are in the personal computing era, person and machine staring uneasily at each other across the desktop. Next comes ubiquitous computing, or the age of calm technology, when technology recedes into the background of our lives’’Weiser, 1991 The computer for the 21st century. Scientific American, special issue on communications, computers, and networks
Wireless SensorNetworks
Wearable Technologies
Cloud Computing
RFId
Advanced roboticsInformation System
Actuators
Bluetooth
Wi-Fi Sensors
Big Data analitycs
Virtualization
Smart Devices
Mobile Devices
Additive Manufacturing
Machine to Machine (M2M)
Cyber Physical Systems (CPS)
Service Oriented Architecture (SOA)
IPv6
Augmented Reality
Human MachineInterface (HMI)
Industrial Analytics
IndustrialInternet
Machine to Business (M2B)
NetworkedSystems
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Background: il Manufacturing in Italia
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L’Italia nel manifatturiero mondiale
Rank 2000 2010 2014
Cina
USA
Giappone
Germania
Korea, Rep.
Italia
Brasile
Francia
India
Regno Unito
Russia
Spagna
Messico
USA
Giappone
Cina
Germania
Regno Unito
Italia
Francia
Korea, Rep
Messico
Spagna
Brasile
Canada
India
USA
Giappone
Germania
Italia
Francia
Regno Unito
Cina
Brasile
Spagna
Canada
Korea, Rep
Olanda
Messico
1990
Cina
USA*
Germania
Giappone*
Korea, Rep.
India
Italia
Regno Unito
Francia
Russia
Brasile
Messico
Canada
12345678910111213
Le Top 13 potenze manifatturiere nel MondoValore aggiunto del settore manifatturiero sul GDP Mondiale
Fonte Dati: The World Bank*Proiezione anno 2013
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Valore aggiunto per attività nei principali paesi europei [2000-2013; EUR bn, %]
Germania FranciaUKItalia
25%
2000
25%
16%
16%
17%
25%
2013
26%
14%
17%
18%
2013
17%
26%
16%
18%
22%
2000
21%
24%
16%
16%
23%
16%
16%
24%
2013
18%
21%
20%
17%
24%
2000
23%
22%
25%
27%
12%14%
22%
2000
23%
26%
14%
13%
23%
2013 2013
14%
18%
17%
19%
31%
2000
21%
20%
15%
17%
28%
2013
13%
18%
19%
23%
27%
2000
18%
18%
17%
21%
26%
Polonia Spagna
Manifattura4Commercio3Altri servizi1 Pubblica Amministrazione2 Real Estate & Construction
1.841 2.454 165 346 1.071 1.399 570 933 1.453 1.678 1.289 1.845
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Produttività del lavoro
Fonte: OECD
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Investimenti in immobilizzazioni delle imprese manifatturiere
Fonte: Eurostat
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The Products of the Future
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I prodotti del futuro
Verdi Nuovi Materiali
PersonalizzatiConnessiIntelligenti
• Diagnostica• Localizzazione• Sensoristica
• Con il produttore• Con l’utente• Con gli altri oggetti
• Nella concezione/produzione• Nella fruizione/pagamento
• Bassi consumi di energia• Riciclabilità
• Proprietà fisiche e meccaniche• Producibilità
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I prodotti e la produzione del futuro
Manufacturing sta evolvendo verso paradigmi di mass customization e personalization
Perchè
la Responsiveness nel Manufacturing ?
La responsiveness porta a molte sfide per il manufacturing
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Product variety
Prod
uct volum
es
1850
1913
1955
1980
2000glo
balizat
ion
Time
Craft production
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Product variety
Prod
uct volum
es
1850
1950
1980
2000glo
balizat
ion
Time
MASS PRODUCTION1908
“You can have any color for your car as long
as it is black!”(Henry Ford)
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Product variety
Prod
uct volum
es
1850
1908
1950
1980
2000globa
lization
Time
Mass Customization
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Products become a service
Product Service to support
product
Service to differentiate
product
Service IS
the product
Service for product
Service for customer
K.D. Thoben 2001
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Examples of ServitizationCar Sharing: You do not “purchase” and “possess” a car anymore, but you purchase the “usage “ of a car.
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Examples of Servitization
Selling flying hours instead of aeronautical engines.
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Come reagire: la vision dello Smart Manufacturing
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La Quarta Rivoluzione Industriale
Prima RivoluzioneIndustriale
Seconda RivoluzioneIndustriale
Terza RivoluzioneIndustriale
Quarta RivoluzioneIndustriale
TEMPO1780 1870 1970 oggi
Introduzione di strumenti meccanici di produzione
Organizzazione del lavoro e produzione di massa grazie all’utilizzo dell’energia elettrica
Produzione ulteriormente automatizzata grazie all’utilizzo in fabbrica di sistemi IT ed elettronici
Prodotti e processi interconnessi grazie all’utilizzo in fabbrica dell’Internet delle Cose e delle nuove tecnologie digitali
Prima catena di montaggio (1870)
Primo PLC (1969)
Primo telaio a vapore
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Products become smarter (along the life cycle!)
• Information technology helps to improve energy efficiency
• Digital steering and control systems enable improved ergonomics
• Machines can be remotely controlled – humans are freed from working in uncomfortable and dangerous surroundings
• Machines can measure processes and output to optimise performance
• Machines can send data on output, lapsed time, and their own condition over mobile internet
• Improved conditions for fleet management• Need for repair and maintenance can be
anticipated to minimise downtime
Pictures: Sandvik, Ponsse, Metos
Slide courtesy of
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Le tecnologie abilitanti
BIG DATA CLOUD COMPUTING& CYBER SECURITY
INTERNET OF THINGS
INTERFACCIA UOMO MACCHINA
AUTOMAZIONEROBOTICA
ADDITIVEMANUFACTURING
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ICT Megatrends Technology Push Perspective
Human–centric Manufacturing
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Interconnected Manufacturing26
Stamatis KarnouskosCyber‐Physical Systems in manufacturing and production workshopBrussels 30th October 2013
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Dal MES (Mfg Execution System) al MOS (Mfg Operating System)
Real/virtual production plant
CPPR – Cyber Physical Production ResourceCPS enabled
production
resources
CPPR 3
Enterprise network (office)
App1 App3 App1 App2 App5 App2 App5
User/Process X User/Process Y User/Process Z
Standard
Production
equipmentAdditional
control
intelligence
+encapsulation
MOS –
Manufacturing Operating SystemApp1 App2
App3 App4
App5 App…
Manufacturing Service Bus / Real time / Industrial Middleware(Shop floor)
M‐Apps are aggregated
and customized based on user and business
needs
Existing
Monolytic
Applications
(e.g. ERP, MES,
…)
Interface Layer
Migration from MES world
Migration from Standard Equipments World
M‐Apps Store ManufacturingWorkspace
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Industrial Internet crea opportunità
• New business potential in industrial services
281.7.2014
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1000000110110101100101011101000110000101101100011011000110100
1011101000111010101101111011101000110010101110100011001010110
1111011011000110110001101001011100110111010101110101011001000
1100101011011000110110001100001001000000110111101101110001000
0001101000011110010111011011000011101001000111010000100000011
0010101110110110000111010010011000011101001000111010000100000
0110110101100101011011100110010101110011011101000111100101101
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Analysis of data
Better machines and equipmentImproved processes
More efficient production
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Dal factory floor al Cyber-twin
291.7.2014
Extracted from Lee, J., Bagheri, B., Kao, H., 2015. A Cyber‐Physical Systems architecture for Industry 4.0‐based manufacturing systems. Manufacturing Letters, Volume 3, 18–23.
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”Stay hungry, stay foolish.”
Prof. Marco Macchimarco.macchi@polimi.it+39 335 8282799