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187 Pages·2017·6.54 MB·English

by  Haapalainen Tarja

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Towards a new era in manufacturing G E 288 SE
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Towards a new era in
manufacturing

Final report of VTT’s For Industry
ISBN 978-951-38-8514-4 (Soft back ed.)
ISBN 978-951-38-8513-7 (URL: http://www.vttresearch.com/impact/publications) spearhead programme
ISSN-L 2242-1211
ISSN 2242-1211 (Print)
ISSN 2242-122X (Online)
Edited by Jaakko Paasi
http://urn.fi/URN:ISBN:978-951-38-8513-7
VTT TECHNOLOGY 288
Towards a new era in
manufacturing

Final report of VTT’s For Industry
spearhead programme
Jaakko Paasi
Chief Editor
ISBN 978-951-38-8514-4 (Soft back ed.)
ISBN 978-951-38-8513-7 (URL: http://www.vttresearch.com/impact/publications)
VTT Technology 288
ISSN-L 2242-1211
ISSN 2242-1211 (Print)
ISSN 2242-122X (Online)
http://urn.fi/URN:ISBN:978-951-38-8513-7
Copyright © VTT 2017

JULKAISIJA – UTGIVARE – PUBLISHER
Teknologian tutkimuskeskus VTT Oy
PL 1000 (Tekniikantie 4 A, Espoo)
02044 VTT
Puh. 020 722 111, faksi 020 722 7001
Teknologiska forskningscentralen VTT Ab
PB 1000 (Teknikvägen 4 A, Esbo)
FI-02044 VTT
Tfn [phone], telefax [phone]
VTT Technical Research Centre of Finland Ltd
P.O. Box 1000 (Tekniikantie 4 A, Espoo)
FI-02044 VTT, Finland
Tel. [phone], fax [phone]

Juvenes Print, Tampere 2017
Preface
VTT Technical Research Centre of Finland Ltd launched at the beginning of 2015
a spearhead programme called For Industry that aimed at boosting the competi-
tiveness of the Finnish manufacturing industry. The For Industry programme dif-
fered from many earlier programmes through the strongly multidisciplinary nature
of the programme. In addition to technological aspects, the programme included a
strong focus on business aspects. The work in the programme was divided into six
modules from which three had a technological base and three a business research
base. The modules were called: Manufacturing Ecosystem, Business Models,
Digital Engineering, Automation & Robotics, Industrial Internet, and Decision Mak-
ing in a Complex World.
This VTT Technology report summarises the main results, highlights, achieved
in the For Industry spearhead programme. The approach of the report, however, is
not only to look backwards, but also to give visions for the future of manufacturing.
We are in the middle of a new industrial revolution, a rapid transformationtowards
a new era in manufacturing, and that is why we are emphasising the future vi-
sions from all the perspectives of manufacturing that were included in the For
Industry programme. Although the spearhead programme was closed at the end
of 2016, VTT’s work for the manufacturing industry will continue. The For Industry
programme created a new multidisciplinary platform producing research results
that could be further developed into new businesses in Finnish industry.
The report is structured in accordance with the modules of For Industry, each
module forming its own chapter. Each chapter contains an overview article on the
topic and a few articles focusing on specific research results written by research-
ers. The contents of the chapters were moderated by the leaders of the For Indus-
try modules: Senior Scientist, Tiina Apilo, in the module Manufacturing Ecosys-
tems, Principal Scientist, Jaakko Paasi, in the module Business Models, Research
Team Leader, Juha Kortelainen, in the module Digital Engineering, Principal Sci-
entist, Tapio Heikkilä, in the module Automation & Robotics, Research Team
Leader, Mikael Haag, in the module Industrial Internet, and Principal Scientist, Eija
Kaasinen, in the module Decision Making in a Complex World. The introductory
chapter of the report was written by the head of the For Industry programme,
Business Development Manager, Risto Kuivanen. Finally, the concluding remarks
were given by Vice President of Research, Kalle Kantola.
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In addition to the authors of this final report, there were tens of other people in-
volved in the programme work in roles of researchers, assistants and supervisors,
either at module or at programme level, etc. Among all of them, the role of Execu-
tive Vice President, Erja Turunen, as an initiator and key supervisor of the For
Industry programme must be highlighted.
Tampere, January 27, 2017
Jaakko Paasi
Chief Editor of report
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Contents
Preface ................................................................................................................. 3
1. Introduction .................................................................................................. 10
1.1 Overview of For Industry spearhead programme. ..................................... 10
1.1.1 Introduction. ................................................................................. 10
1.1.2 Success factors of manufacturing SMEs ....................................... 11
1.1.3 Structure of the programme .......................................................... 14
1.1.4 References .................................................................................. 15
2. Manufacturing Ecosystems ......................................................................... 16
2.1 Research cooperation with manufacturing SMEs ..................................... 16
2.1.1 Introduction. ................................................................................. 16
2.1.2 New approaches to support SMEs ................................................ 17
2.1.3 Future visions .............................................................................. 21
2.1.4 Further reading ............................................................................ 23
3. Business Models .......................................................................................... 24
3.1 Business models in the future of manufacturing ....................................... 24
3.1.1 Introduction. ................................................................................. 24
3.1.2 What is a business model? ........................................................... 25
3.1.3 Digitalisation and business models ............................................... 26
3.1.4 Review of main results ................................................................. 28
3.1.5 Future visions .............................................................................. 30
3.1.6 Conclusions ................................................................................. 32
3.1.7 References .................................................................................. 32
3.2 Alliancing for business development ........................................................ 34
3.2.1 The challenge with traditional project practices.............................. 34
3.2.2 The change to joint development .................................................. 34
3.2.3 Experiences from alliancing .......................................................... 36
3.2.4 Alliances for innovation and business development ....................... 37
3.2.5 Key features of a business development alliance .......................... 37
3.2.6 Joint process of a BDA ................................................................. 38
3.2.7 Conclusions ................................................................................. 39
3.3 VTT Model of Digimaturity ....................................................................... 41
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3.3.1 Introduction. ................................................................................. 41
3.3.2 Research framework .................................................................... 43
3.3.3 VTT Model of Digimaturity ............................................................ 44
3.3.4 Conclusions ................................................................................. 45
3.3.5 References .................................................................................. 46
3.4 Successful business at Finnish manufacturing companies beyond 2020 –
Four scenarios. ....................................................................................... 47
3.4.1 Introduction. ................................................................................. 47
3.4.2 Method for scenario and business model building ......................... 48
3.4.3 Four scenarios and successful business models ........................... 49
3.4.4 Conclusions ................................................................................. 52
3.4.5 References .................................................................................. 52
4. Digital Engineering. ...................................................................................... 53
4.1 Digital engineering and agile manufacturing as future enablers ................ 53
4.1.1 Introduction. ................................................................................. 53
4.1.2 Current status .............................................................................. 56
4.1.3 Review of main results ................................................................. 60
4.1.4 Future visions .............................................................................. 61
4.1.5 Conclusions ................................................................................. 64
4.1.6 References .................................................................................. 64
4.2 Integrated computational materials engineering for emerging
manufacturing technologies .................................................................... 66
4.2.1 Introduction. ................................................................................. 66
4.2.2 Multiscale modelling concept for metal AM. ................................... 68
4.2.3 Results ........................................................................................ 69
4.2.4 Summary and conclusions ........................................................... 70
4.2.5 References .................................................................................. 71
4.3 Simulation, optimisation and design of a 3D printed sand mould for a cast
metal component .................................................................................... 72
4.3.1 Introduction. ................................................................................. 72
4.3.2 Case study .................................................................................. 72
4.3.3 Simulation and component redesign ............................................. 73
4.3.4 Results ........................................................................................ 78
4.3.5 Conclusions ................................................................................. 79
4.3.6 References .................................................................................. 80
4.4 Improving the mechanical properties of SLM-processed tool steel by
process optimization ............................................................................... 81
4.4.1 Introduction. ................................................................................. 81
4.4.2 Experimental methods.................................................................. 81
4.4.3 Results ........................................................................................ 82
4.4.4 Conclusions ................................................................................. 85
4.4.5 References .................................................................................. 85
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5. Automation and Robotics ............................................................................ 86
5.1 Challenges and opportunities for automation and robotics ........................ 86
5.1.1 Introduction. ................................................................................. 86
5.1.2 Robotic markets & trends ............................................................. 88
5.1.3 Collaborative robotics. .................................................................. 89
5.1.4 New features & enablers .............................................................. 90
5.1.5 References .................................................................................. 91
5.2 HULDA – Human detection around vehicles ............................................ 93
5.2.1 Introduction. ................................................................................. 93
5.2.2 Method ........................................................................................ 94
5.2.3 Specifications .............................................................................. 94
5.2.4 Hardware implementation. ............................................................ 95
5.2.5 Software modules ........................................................................ 95
5.2.6 Results and future actions ............................................................ 97
5.2.7 Conclusions ................................................................................. 97
5.2.8 Further reading ............................................................................ 97
5.3 Edge Computing for Industrial Internet of Things – the HW programming
concept .................................................................................................. 98
5.3.1 Introduction. ................................................................................. 98
5.3.2 Experimental design..................................................................... 99
5.3.3 Findings..................................................................................... 100
5.3.4 Conclusions ............................................................................... 102
5.3.5 References ................................................................................ 102
5.4 Interactive robot programming by hand guiding. ..................................... 103
5.4.1 Introduction. ............................................................................... 103
5.4.2 Experimental.............................................................................. 104
5.4.3 Results/Findings ........................................................................ 106
5.4.4 Conclusions ............................................................................... 108
5.4.5 References ................................................................................ 109
5.5 VTT Dynamic Safety System and configurator ....................................... 110
5.5.1 Introduction. ............................................................................... 110
5.5.2 Findings..................................................................................... 110
5.5.3 Conclusions ............................................................................... 114
5.5.4 References ................................................................................ 114
5.6 Remote user interface for CyberPhysical Robotics ................................. 116
5.6.1 Introduction. ............................................................................... 116
5.6.2 Remote service application: Robot Hand-Eye Calibration ............ 116
5.6.3 User interface (UI) design. .......................................................... 117
5.6.4 Initial UI ..................................................................................... 119
5.6.5 Improved UI ............................................................................... 120
5.6.6 Final UI with video view .............................................................. 121
5.6.7 UI implementation technologies .................................................. 121
5.6.8 Remarks .................................................................................... 123
5.6.9 References ................................................................................ 123
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6. Industrial Internet ....................................................................................... 124
6.1 Overview on the Industrial Internet of Things ......................................... 124
6.1.1 Introduction. ............................................................................... 124
6.1.2 State-of-the-art........................................................................... 127
6.1.3 Review of main results ............................................................... 129
6.1.4 Future visions ............................................................................ 131
6.1.5 References ................................................................................ 133
6.2 Enabling a productivity leap with production data visual analytics ........... 135
6.2.1 Introduction. ............................................................................... 135
6.2.2 Visual analytics and VTT OpenVA concept ................................. 136
6.2.3 Feasibility studies....................................................................... 137
6.2.4 Using VTT OpenVA.................................................................... 139
6.2.5 Conclusions ............................................................................... 140
6.2.6 References ................................................................................ 141
6.3 Novel communication solutions in industrial measurement solutions ....... 142
6.3.1 Introduction. ............................................................................... 142
6.3.2 Research design ........................................................................ 143
6.3.3 Results ...................................................................................... 143
6.3.4 Conclusions ............................................................................... 147
6.3.5 References ................................................................................ 147
6.4 Blockchain technology in the manufacturing industry.............................. 149
6.4.1 Introduction. ............................................................................... 149
6.4.2 Method ...................................................................................... 150
6.4.3 Findings..................................................................................... 150
6.4.4 Conclusions ............................................................................... 153
6.4.5 Further reading .......................................................................... 153
7. Decision-making in a Complex World ........................................................ 154
7.1 New approaches to decision-making in a complex world? ...................... 154
7.1.1 Introduction. ............................................................................... 154
7.1.2 A complex and volatile world meets machine-like organizations? . 155
7.1.3 Leading complexity .................................................................... 157
7.1.4 Enhanced strategic intelligence .................................................. 158
7.1.5 Conclusions ............................................................................... 161
7.1.6 References ................................................................................ 162
7.2 Enhancing risk awareness of new and emerging technology
implementation, case circular economy ................................................. 165
7.2.1 Background ............................................................................... 165
7.2.2 Methods .................................................................................... 165
7.2.3 Findings..................................................................................... 166
7.2.4 Conclusions ............................................................................... 167
7.2.5 Further reading .......................................................................... 168
7.3 Digitalization and future industrial knowledge work................................. 169
7.3.1 Introduction. ............................................................................... 169
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7.3.2 Industrial knowledge work .......................................................... 170
7.3.3 Interaction tools for contextual knowledge sharing. ...................... 172
7.3.4 Conclusions ............................................................................... 173
7.3.5 References ................................................................................ 173
7.4 Data visualizations to support decision-making ...................................... 175
7.4.1 Introduction. ............................................................................... 175
7.4.2 Information visualization and the conventional types of
presentation ............................................................................... 175
7.4.3 Interactive information visualization and modern visual analytics in
making sense of complex phenomena and situations .................. 177
7.4.4 Supporting situation awareness and decision-making with real-
time information visualization ...................................................... 180
7.4.5 Conclusions ............................................................................... 181
7.4.6 References ................................................................................ 182
8. Conclusions ............................................................................................... 183
8.1 Concluding remarks .............................................................................. 183
Abstract
Tiivistelmä
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