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A4BLUE | Adaptive Automation in Assembly For BLUE collar workers satisfaction in Evolvable context

01-10-2016

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30-09-2019

: 15 | : 4
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Business model aspects
Added value - impact - value proposition
Results:
Landing gear retraction actuator assembly: Manual deburring operation | Assembly process (CESA)
Landing gear retraction actuator assembly: Manual deburring operation | Assembly process (CESA)

In the deburring process, manual labor is reduced, resulting in improved ergonomic and safety conditions. Moreover, process variability is reduced while quality and productivity, increased. In the assembly process, training time has been reduced with the AR solution and access to centralized documentation is faster, with greater transparency and ease of use while its maintenance costs have been reduced.

Collaborative assembly in a fenceless environment (IK4-TEKNIKER)
Collaborative assembly in a fenceless environment (IK4-TEKNIKER)

Adaptation to human variation is boosted, reducing work requirements and worker’s physical demands without incrementing mental and cognitive workload. Additionally, safety and trust in collaborative workplaces are risen while improving usability and human satisfaction. Reconfigurability and flexibility are also improved, as well as efficiency due to the reduction of displacements.

Complex, manual hydraulic system assembly (AIRBUS)
Complex, manual hydraulic system assembly (AIRBUS)

The goals for this use case include assembly time reduction, minimization of errors, and increase of efficiency, productivity and quality. What is more, with AR training and learn-by-doing method adoption, productivity of newcomers is also increased. Finally, a full quality assurance approach and traceability for supervision is enabled.

Final assembly of electric vehicles (RWTH Aachen University)
Final assembly of electric vehicles (RWTH Aachen University)

Improved technician satisfaction has been noted, as well as reduced process times and improved process efficiency with reduced errors. Moreover, the assembly process has benefited from better ergonomics and shorter waste time.

COMPOSITION | Ecosystem for Collaborative Manufacturing Processes _ Intra- and Interfactory Integration and Automation

01-09-2016

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31-08-2019

: 157 | : 7
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Business model aspects
Added value - impact - value proposition
Comment: 1) Traffic Monitoring in IoT-enabled shopfloors, 2) Intra-factory Optimization & Decision support (i.e. forecasting services, trend analysis, predictive maintenance), 3, 4, 5) Robust module communication & message routing for Intra & Inter-scenarios

Factory2Fit | Empowering and participatory adaptation of factory automation to fit for workers

01-10-2016

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30-09-2019

: 46 | : 9
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Business model aspects
Added value - impact - value proposition
Results:
UTC Pilot - AR Assembly Guidance (ARAG) Solution - supporting workers in procedural tasks
UTC Pilot - AR Assembly Guidance (ARAG) Solution - supporting workers in procedural tasks

The ARAG solution reduces the cognitive load, and increases the technician’s satisfaction, while the precise guidance assures optimality and correctness in task execution. Furthermore, with the proposed solution training time is minimized as well as inspection by experts, also reducing manufacturing times and maximizing resource utilization.

Prima Power Pilot - Hands-on pre-training in a virtual environment
Prima Power Pilot - Hands-on pre-training in a virtual environment

With the proposed solution, online training can be scheduled optimally, shortening training time. Moreover, training supports understanding and dealing with exceptional situations such as disturbances in production. Increased productivity and job satisfaction are expected, lowering the threshold of operators to start using the manufacturing line independently.

Continental Pilot: Participatory Design Tool
Continental Pilot: Participatory Design Tool

The method selection tool can also be used by non-experts as there is no need of vast know-how for the utilization of the offered tool. Therefore, the layman can easily select the right method out of a wide range. Codesign itself strengthens the companies as the workers can include their tacit knowledge into the workplace - or work process design and therefore have a higher commitment to their job once their ideas are implemented.

UTC Pilot: On-the-job Learning
UTC Pilot: On-the-job Learning

With the proposed solution, access to expert knowledge is granted to anyone who is registered to the platform. What is more, supervisors are able to assign training courses to specific technicians for improving their skills.

Prima Power Pilot - Social Media Platform - Engaging worker participation and knowledge sharing
Prima Power Pilot - Social Media Platform - Engaging worker participation and knowledge sharing

SoMeP emphasizes in improving collaboration and communication between technicians and promotes knowledge sharing, and practices. In the long-term SoMeP can be used both as a communication channel and information exchange hub, but also as a valuable knowledge repository as well as an educational system.

Continental Pilot - Task Distribution Engine - Multi-criteria dynamic task prioritization and scheduling
Continental Pilot - Task Distribution Engine - Multi-criteria dynamic task prioritization and scheduling

TDE offers the generation of optimized production plans while the waiting time for the high-priority tasks has been reduced. Moreover, workplace is more user-friendly, and supervisors have a detailed overview of the running and planned work.

Prima Power Pilot - Worker Feedback Dashboard - Empowering feedback on work well-being and achievements
Prima Power Pilot - Worker Feedback Dashboard - Empowering feedback on work well-being and achievements

The proposed solution aims at raising spirits at work, by helping employees recognize their strengths as well as their development needs. In the long term, the application can assist employees to develop their working habits.

INCLUSIVE | Smart and adaptive interfaces for INCLUSIVE work environment

01-10-2016

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30-09-2019

: 43 | : 3
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Business model aspects
Added value - impact - value proposition
Results:
SCM Use Case: New HMI for woodworking machines
SCM Use Case: New HMI for woodworking machines

The use of the INCLUSIVE HMI leads to a 4.2 % reduction in the average time required. For the second use case, the use of the INCLUSIVE HMI leads to a much larger decrease in execution time of 69.7 % when compared to the current HMI system. Moreover, a usability questionnaire has been filled in by testers, allowing to conclude that the INCLUSIVE HMI was perceived as an improvement with regards to the current HMI for all dimensions, for instance frequently usage, complexity, ease of use, functions, consistency, and learning effort.

SILVERLINE use case: Introduction of a robotic cell in the production shop floor
SILVERLINE use case: Introduction of a robotic cell in the production shop floor

The introduction of the hybrid robot/bender panel system allows to reach production efficiency and accuracy, and a more flexible interchange of operators with different characteristics.

E80 use case: Management of intralogistics flows in complex production lines
E80 use case: Management of intralogistics flows in complex production lines

The customisation capability reflects in terms of reduced vehicles downtime and increased assignment of supervision jobs to vulnerable users. Moreover, the maintenance phases are shortened resulting in less downtime that provides an increase of the productivity of the total system (human and automation).

HUMAN | HUman MANufacturing

01-10-2016

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30-09-2019

: 30 | : 3
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Business model aspects
Added value - impact - value proposition
Results:
COMAU Pilot: Workplace optimization and operator mental support
COMAU Pilot: Workplace optimization and operator mental support

Thanks to the use of HUMAN technology, COMAU assembly lines are more flexible to the anthropometric, physical and cognitive needs of the workers, and hence to the cognitive and physical requirements of variable operations of variable orders. This will reduce the setup and production times.

AIRBUS Pilot: Short-term physical and mental support
AIRBUS Pilot: Short-term physical and mental support

As a result of the project, Airbus DS will be able to reduce the time to market of new aircraft and aircraft systems significantly, due to the important improvements in ergonomic and interactive workplaces, helping to increase the flexibility and pliability of the different production lines.

ROYO use case - short term physical and mental support
ROYO use case - short term physical and mental support

Through the solutions of HUMAN, it will be possible to process the production in smaller batches increasing the adaptability of each production line to all workers. Furthermore, HUMAN will enable ROYO to increase flexibility and adaptability in every production line at the shop floor, based on the ability to manage/predict their own effort during the shift avoiding pains beforehand, and moreover to eliminate waste and reduce errors and stress.

Z-Fact0r | Zero-defect manufacturing strategies towards on-line production management for European factories

01-10-2016

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31-03-2020

: 35 | : 1
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Business model aspects
Added value - impact - value proposition
Comment:

Z-Factor's uniques value propositions include the following features:

-Holistic & innovative ZDM solution

-Increases overall quality & customer satisfaction

-Reduces production costs, energy & material consumption

-Utilizes almost all the state-of-the art techniques for implementing ZDM

PreCoM | Predictive Cognitive Maintenance Decision Support System

01-11-2017

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31-10-2020

: 40 | : 3
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Business model aspects
Added value - impact - value proposition
Comment:

PreCoM impact is introduced below as an average of the impact achieved in the three uses cases: Sakana, Spinea and Goma Campus, based on the components monitored by PreCoM:
 

  • Reduced downtime by about: 88%
  • Maintainability (MTTR) improved by about: 24%
  • Reduced supervision time in the training for new technicians by about: 76%
  • Increased machine overall equipment effectiveness (OEE) by about: 5%
  • Applying PdM by company personnel has been increased. From previous level 0 to about 80%
  • Energy is rationalized by reduction equivalent to about: 16%
  • Material loss is reduced by about: 16%
  • Application of PreCoM versus work safety: No accidents previously as well as during PreCoM
  • Reduced maintenance hours by about: 16%
  • The saving in maintenance hours (at minimum) is about: 92 hours per year

QU4LITY | Digital Reality in Zero Defect Manufacturing

01-01-2019

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31-07-2022

: 77 | : 15
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Business model aspects
Added value - impact - value proposition
Comment:
  • Reference architecture and blueprints: Reference architecture, vocabularies, open data models, standards, best practices, SDOs/SSOs contribution, clustering activities, …
  • Digital enablers and Equipment solutions: digital enablers, ZDM platforms and equipment solutions, patents in autonomous manufacturing asset & control, autonomous digital twin MBSE platforms.
  • A Pan-European innovation ecosystem clustering activities (DMP Cluster, OPEN DEI Cluster, 4ZDM Cluster, Connected Factories) and the Digital Factory Alliance (DFA)
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