Europe is still lacking an efficient systemic multi-level approach that enables a recursive, cost-effective, holistic and integrated application of circular principles to the digital uplifting of factory 4.0 capital investments; addressing issues at product, process, system as well as the entire value-chain levels, integrating best practices from emerging enabling digital technologies and avoid a two speed digital transformation across industries in different sectors.
LEVEL-UP will offer a scalable platform covering the overall lifecycle, ranging from the digital twins setup, modernisation actions to diagnose and predict the operation of physical assets, to the refurbishment and remanufacturing activities towards end of life. In-situ repair technologies and the redesign for new upgraded components will be facilitated through virtual simulations for increased performance and lifetime.
LEVEL-UP will therefore comprise new hardware and software components interfaced with the current facilities through IoT and data-management platforms, while being orchestrated through eight (8) scalable strategies at component, work-station and shopfloor level. The actions for modernising, upgrading, refurbishing, remanufacturing, and recycling will be structured and formalised into ten (10) special Protocols, linked with an Industrial Digital Thread weaving a seamless digital integration with all actors in the value chain for improved future iterations.
LEVEL-UP will be demonstrated in 7 demo sites from different sectors.
The impact of LEVEL-UP to the European manufacturing industry, but also the society itself, can be summarised in the following (with a horizon of 4 years after project ends):
- increase of the material and re-source efficiency by 11.5%,
- increased reliability by 16% of the equipment in an extended lifetime by 20%,
- over 50% increase of the Return on Investment (ROI),
- about 810 new jobs created and
- over 80M EUR ROI for the consortium.
|Total budget - Public funding:||17 039 855,00 Euro - 14 027 950,00 Euro|
|Call topic:||Refurbishment and re-manufacturing of large industrial equipment (IA) (DT-FOF-06-2019)|
This is a set of Specific Objectives and Research & Innovation Objectives that is subject to a consultation in preparation of the Made In Europe Partnership. For more guidance about the consultation, please see www.effra.eu/made-in-europe-state-play.
FMECA and KRI analysis will be performed for each pilot line in the project, so the condition of those critical components identified in the machines will be monitored. The data gathered will be utilized for the development of machine learning algorithms for shifting from preventive maintenance to predictive maintenance. A decission support system will help the operator to manage the unexpected failures regarding the components performance. This will allow to avoid non-planned maintenance times and decrease the machine downtimes.
LEVEL-UP project aims to create an scalable system involving different components and technologies that will extend the lifetime of large industrial equipment, making them competitive in the Industry 4.0 paradigm. For that, a series of 10 protocols will be created, which will guide manufacturers in the path to modernize their equipment focusing on 4 main technical blocks: CPSization, Knowledge management or data analytics, Digital Twins and end-of-life actions.
LEVEL-UP will undertake end-of-life actions to components or spare-parts from the large industrial equipment that have reached the end of their working useful life. Depending on the conditions of the components and the user requirements, a different protocol will be triggered: repair, remanufacturing, refurbishment, upgrade or recycling, and different actions will be perform in the component, including laser techniques for additive manufacturing application.
The protocol Upgrade involves the assessment and utilization of new materials and alloys with better technical capabilities for those components that are more frequently broken or worn out and have to be replaced by new ones.
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- | AIMEN (Coördinator)
- | ASOCIACION DE EMPRESAS TECNOLOGICAS INNOVALIA
- | ATLANTIS Engineering S.A.
- | AUSTRIAN STANDARDS INSTITUTE OSTERREICHISCHES NORMUNGSINSTITUT (ASI)
- | BIBA - BREMER INSTITUT FUER PRODUKTION UND LOGISTIK GMBH
- | BRUNEL UNIVERSITY
- | CORE INNOVATION AND TECHNOLOGY OE
- | Centre Technique Industriel de la Plasturgie et des Composites
- | Centro Ricerche Fiat SCPA (CRF)
- | DANOBAT
- | ESI SOFTWARE GERMANY GMBH
- | ESTAMPACIONES MAYO SA (ESMA)
- | FAGOR ARRASATE S.COOP.
- | FRAUNHOFER GESELLSCHAFT
- | HOLONIX SRL