MADE RESEARCH
The nine themes in the MADE Research
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop processes for product development
using modular principles in product design
and the use of supportive IT tools in order to
achieve rapid development and introduction
of new products”
Work package 1
High speed product development
The challenge today:
It is crucial for Danish companies, that they can reduce the time from product development to the product is
at the customer. If a company can reduce the time from development to earning can they increase the
production, but the challenge is to do this in a complex and constantly changing world.
Product development is costly and often it can be difficult to predict how long the production itself takes. A
small change in some part of the product can lead to a number of changes throughout the production line.
Today, it is complex production programmes that calculates where in the business model a product is placed
and it is limited how much the company reuse parts and ideas from previous projects.
MADE research:
The MADE research within this theme works on finding a number of solutions that can reduce the time from
concept to customer. This would make it possible to develop more products with fewer resources and lower
risk, for example by reusing modules in the production.
In MADE Work Package 1 the research focus on current products and modular processes, that a number of
companies can start using to optimize their production. This will, among other things, include how a
company can develop visual descriptions of all phases of the production, even when the product is still at a
high level of abstraction level. This helps both the engineers who are responsible for R&D, while at the same
time improves the price predictions of future products.
The future:
In the future, companies will be able to reduce their time to market and costs by using simple models. With
MADE software will a company easily be able to make the right decisions and recycle solutions from other
projects. This will increase the quality of the products, eliminate routine tasks, make sales stronger in the
global market and make it easier to monitor and main products.
MADE-matrix:
This Work Package is located in our Value Chain and Business Systems level – with a focus on Rapid Product
and Production Development. The research being done here facilitates the challenges that Work Package 2
focus on.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop flexible production
systems that can quickly be
changed so fast ramp-up of
production and profitable
production of small series is made
possible”
Work package 2
Modular production platforms for high speed ramp-up
The challenge today:
Today customers demand more types, more customized products and a quick introduction of these new
products, which is the challenge. If their suddenly arises a rapid increase in demand, the companies must be
able to adapt and scale up their production. However, there are large uncertainties associated with this, and
it involves a financial risk. Today, the production system is often not flexible and adaptable enough, thus the
newest technologies are not being fully used.
The introduction of new product types in the production is costly. The challenge is to have a production line
in which the different products share the same production equipment. By reducing the product specific
equipment, it is possible to produce different products with the same tools. This has to be done economically
and considerate for the environment, so the production system quickly can be modified to reflect a constantly
changing market.
MADE research:
In MADE Work Package 2 the focus is on a number of areas, including how each part of the production system
can be divided into a number of modules. Today, the “modular concept” is most clear in the product design
area and it is that experience that MADE Work Package 2 will transfer to the production system. If a company
can identify a module’s specific features and connectivity options, the speed of production will be increased
and several variants can be created.
Another area that MADE Work Package 2 will focus on is the relation with the development process. Where
you make full use of the data there is about the products in the company. This could be the structure of the
various components. If you analyse the constrains and possibilities of each module, then one can estimate and
simulate a number of important parts of the production. This could for example be setup times and waste.
The future:
In the future, production foundation and readjustment will happen faster, with the same equipment being
able to make several types and quickly switch from low to high volume. Simultaneously will the link between
development and production be closer, so that modules easily can be reused in other contexts in the
production system.
MADE-matrix:
This Work Package is located in our Integrated Production Systems level – with a focus on Rapid Product and
Production Development. The research being done here facilitates the challenges that Work Package 1 focus
on.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop techniques and technologies
that enable rapid ramp-up of production
and profitable small series using 3D
printing, joining processes and injection
molding technology”
Work Package 3
3D print and new production processes
The challenge today:
With the constant demands for new designs and material, the companies must ensure that the time from
production to the product is with the customer is short. The knowledge of new production technologies is
important in the design phase, so that the knowledge about forming, joining and finishing, is being used. All
of the process steps that a product goes through, before it is assembled in a final design, is the core of MADE
Work Package 3. If Danish manufacturing companies shall continue to be leading within new production
processes, then it is important, that they can develop new prototypes quickly, cheaply and accurately.
MADE research:
New technologies offers new opportunities. In MADE Work Package 3 the focus of the research is on a number
of solutions, which will make Danish companies quicker in introducing new products in the production. There
is an overall focus on three technologies, all of which alone and together supports rapid product-and
production development.
o
Advanced injection-moulding technologies for use in joining different materials,
replicating microstructure surfaces, etc. One example is the production of components
with ID codes, so you have traceability throughout the production.
o
Methods that will optimize the jointing of different materials, for example with laser.
o
3D print methods and quality assurance of these, so one can print prototypes and small
volumes quicker, more accurate and cheaper than today.
The future:
In the future, new technologies will facilitate faster introduction of new products.
MADE-matrix:
This Work Package is located in our Enabling Technologies level – with a focus on Rapid Product and Production
Development.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop and test models for
effective global supply chains and
identify how to maximize the
benefits of maintaining
headquarters and development
capacity centralized”
Work package 4
Model based supply chain development
The challenge today:
Danish companies operate in a variety of markets and often with unique products. Danish companies have,
with the increased globalisation, a challenge in maintaining the leading role in the development of new
products, while at the same time involve their international partners and outsource production. This makes it
difficult to develop the supply chain to make it the most effective. Changes in the supply chain results in
significantly higher costs, because the business model is based on long-term relations where complex
knowledge is being shared.
MADE research:
In MADE Work Package 4 the research is on how Danish companies can use their full potential in their global
operations. They want to find out how they can maximize the advantages by keeping the headquarters and
development capacity centralized.
One of the areas in the research is how to use model based thinking to improve the national coordination and
development. In the Work Package will there be developed a number of models and methods, that are based
on the national strengths, which can support the Danish headquarters in the future, so they can retain the
controlling and developing role in the supply chain by creating a strong centre. Some of these national
strengths includes a high level of education, good team working skills and flexible employees.
There is also research being conducted that will focus on how the companies can optimize their supply chain
with the restrictions the local environment give.
The future:
Manufacturing companies will in the future have a number of specific concrete models so they can see how
to best coordinate knowledge and development in a global supply chain. It will then be possible for Danish
companies to main control and development in Denmark.
MADE-matrix:
This Work Package is located in our Value Chain and Business Systems – with a focus on Model Based
Production.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop the use of digitalisation of
the supply chain in production and thus
provide greater predictability,
adaptability and efficient use of
resources”
Work package 5
Digitalisation of supply chains
The challenge today:
Today only parts of the supply chain is digitalised, but many companies are already far with Industry 4.0, where
the software factory and the physical factory work closely together. The challenge is to create a virtual model
of products, the production and the supply chain, so it becomes possible to make decentralized decisions
based on real-time data and events. With increased digitalisation, will companies continually develop and
manage the supply chain as needed, and the interfaces between the individual factories will disappear. The
challenge is also to be able to model, simulate and emulate future changes and exploit these to optimize
production as much as possible.
MADE research:
MADE Work Package 5 wants to challenge the way that companies work with digitalization. The research will
focus on how to create a close integration between data from the supply chain the production systems of the
future
The area of the work package draws on the concept Industry 4.0, where the production becomes “smart” and
leaves the factory, by means of information dissemination via the internet. Part of the research focuses on
how Danish companies can act quickly in a global environment, where political decisions can turn the market
upside down. Companies must be able to respond to changes in their supply chain with just one-days’ notice.
At the same time, there are also changes inside the factory, where more data provide increased predictability,
when the production and processes communicates. It makes the production more agile and easier to optimize.
The future:
In the future, there will be a greater link between the customer, products and the production. With increased
digitalisation will the companies quickly adapt and makes changes in real time. With the application of Internet
of Things and Big Data will the business processes quickly be optimized, so the supply change rapidly can adjust
to new demands.
MADE-matrix:
This Work Package is located in our Integrated Production Systems level – with a focus on Model Based
Production.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop digital ecosystems and
augmented reality technologies that
connect production systems, products
and users, thus enabling quick software
update, fewer physical variants, efficient
production and new customer services”
Work package 6
Lifelong product customization
The challenge today:
Information- and communication technology, ICT, is developing rapidly, particularly within the area of network
communication. However, this is not being fully used in the production. Companies today produces many
physical variations, but in the future it will be possible to produce fewer variants, but those can then be
changed regularly using software.
If the products are a part of an open ecosystem, then third-party users and manufacturers be able to
continuously develop and improve a product, even after it has left the factory. The challenge is then how to
create a connection between the physical factory and the “software factory”, so they work more integrated
together. In this way, a lifelong learning of IT services will be created.
Augmented Technology provides a range of opportunities that are not being used to the full today. The
challenge is to create a user-friendly way to utilize this technology, for example for manuals and when a
product needs to be repaired or installed.
MADE research:
MADE Work Package 6 will research on how to effectively integrate ICTs in the production process. There will
also be research in how to use all of the data from the products to improve them in the future. The research
will take the current knowledge of “software ecosystems” that are used in smartphones and see how industrial
products can be improved.
One of the aspects that MADE Work Package 6 will work on, is concrete models and ideas for infrastructure,
that companies can use. There will also be a focus on how augmented technology can be used in the
production, and how to exploit the knowledge that more data from the products will provide.
The future:
Companies will in the future be able to adapt and extend a product, even after it has left the factory. The
interfaces between the different industrial products will be so close that they can ”talk” together. There will
also be a list of models that makes it possible for companies to decide whether it is worthwhile to implement
digitisation in the company.
With lifelong product customisation, a new market for “post-production suppliers” will open and in that way
extend the value chain using open source.
MADE-matrix:
This Work Package is located in our Enabling Technologies level – with a focus on Model Based Production.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Exploring various options for
production systems that are
internationally competitive and suitable
for Danish companies' competencies
and framework conditions, such as
production systems like Co-localization,
Ramp-up or Agility”
Work package 7
The “new” Manufacturing Paradigm
The challenge today:
The challenge today is that we do not get the full effect of having development and production in Denmark,
as there is no clear overview over the advantages and disadvantages, of having different types of organisation
and management tools in the production. If we want to avoid ”bottlenecks” in the production, then we have
to fully utilize and develop the unique circumstance that are in the Danish labour market, such as the flat
hierarchies with independent and resourceful employee. These employees must be ready to standardise,
while maintaining their high flexibility. The challenge is; how do we maintain and expand manufacturing
without compromising on efficiency, the requirements from the customers, wages and the flexibility?
MADE research:
In MADE Work Package 7 the research will focus on the future production paradigm and tree possible
alternatives to Danish manufacturing companies will be specially explored. These models are:
o
A Ramp-up model; where development and the early production is in Denmark, after which it
moves to other parts of the world when the volume increases.
o
An Agility model; where the companies work in small series and have a more customised
production. This model will for example be effective and small and medium enterprises.
o
A Co-location model; where the companies uses the interaction between the production and
development and all other departments by bringing them together in one place.
It is not necessarily the same solution for every company and the MADE research will explore the advantages
and disadvantages of the different models and how they can be implemented in Danish companies.
The future:
In the future will Danish manufacturing companies fully use and develop the unique circumstance of the
Danish labour market in order to increase production.
MADE-matrix:
This Work Package is located in our Value Chain and Business Systems level – with a focus on Complexity
Management.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop flexible user friendly robot
solutions that enable rapid automation
at low cost in small series production”
Work package 8
Hyper flexible automation
The challenge today:
Today the most effective production is large quantities and low flexibility, but increased flexible automation
can change that. The existing automation solutions with robots are too expensive and not flexible enough to
the changing needs of manufactures changing needs and production of small series.
Companies are looking for cheap automation solutions that are flexible enough to cope with frequent
introduction of new products, that easily can be programmed by the employees, so the production quickly can
be adapted. The challenge, that MADE Work Package 8 focuses on, is to develop hyper flexible robots, that
quickly and cheaply can be integrated into the production.
MADE research:
In MADE Work Package 8 the research focus on the development of new technologies that makes it possible
for a robot to be moved around the company and solve various tasks. A “bottleneck” that has a special focus
is: How can a company, with new methods, easily and flexibly bring objects forward to the robot without much
preparation.
Another issue that the Work package examines is how a robot recognise and handles a product that is not
always the same shape and/or where this shape change during the handling.
The future:
In the future the research results will enable companies to quickly and cheaply introduce hyper flexible robots
to new tasks and change between existing processes. The automation will then become almost as easy as
moving a person around, due to the fact that a robot quickly can be introduced to a new job and start working
right away.
MADE-matrix:
This Work Package is located in our Integrated Production Systems level – with a focus on Complexity
Management. The research in Work Package 8 is closely related to Work Package 9, that focus on Sensors and
Quality Control.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk
”Develop advanced sensors, better
quality control and utilize the
application of Big Data to optimize
and streamline production”
Work package 9
Sensors and quality control
The challenge today:
A nimble and innovative production with short changeover times and high productivity that delivers products
with a consistent high quality and a minimal waste, gives new demands to control systems. The challenge in
MADE Work package 9 is how to develop sensors and quality control systems that can adapt itself to new
products or fast and intuitive be installed by the operating staff.
Another challenge is the full use and application of Big Data in the production so to optimise it to the fullest.
MADE research:
In MADE Work package 9 is the research focus both in the field of the latest sensor technology and on methods
for quality control. These sensors will ensure the best possible quality right down to the submillimetre level.
In addition, there will also be done research on how the interaction with the operating staff and the new
technologies can be made easier.
Lastly, there will also be research in the application of Big Data, where a number of parameters can be analysed
and this knowledge can be used to optimise the production.
The future:
In the future will one be able to, by using MADE technology, to develop products of uniform high quality,
minimal loss and with low resource usage.
With MADE technology will even non-experts be able to configure and train robots in an easy way, ”teach” a
robot or control system the correct identification of gripping points or search after defects.
MADE-matrix:
This Work Package is located in our Enabling Technologies level – with a focus on Complexity Management.
Work Package 9 works closely together with Work Package 3 where the focus is 3D print and with Work
Package 8 where the focus is flexible robots.
MADE – Manufacturing Academy of Denmark
Industriens Hus, Vesterbrogade 1E, blok D, 4. sal, 1620 København V
Telefon: 21 12 39 30, CVR-nummer 34 95 21 75, e-mail: [email protected] – www.made.dk