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FP7

SuperFlex Report Summary

Project ID: 609198
Funded under: FP7-NMP
Country: Israel

Periodic Report Summary 2 - SUPERFLEX (Develop and demonstrate a ‘Mini-factory’ concept for production of personalized skin care products for elderly population)

Project Context and Objectives:
The SuperFlex project, develops and demonstrates the concept of modular mini-factory (stationary or mobile-‘in container’) to manufacture personalized products for skincare products for the elderly population. The project will design, produce and demonstrate an on-site manufacturing platform based on modular min-factory units and an ICT cloud-based platform. The concept is low cost and environmentally friendly.
The novel products are personalized and designed to answer to the elderly specific skin profiles derived from the customers’ skin biomarkers and health status.
Personalized skin care products pave the way for a new approach of more effective skin preparations due to the increasing awareness to the variability in skin conditions and supported by innovative technologies, capable of identifying specific biomarkers’ profiles for accurate personalized skin condition diagnosis and customized treatments. The main challenges of SuperFlex for the first period are:
• Develop the methodology for a fast and easy definition of the skin profile based on non-invasive or minimally invasive rapid analysis of skin biomarkers and health status of the elderly customers;
• Develop the mathematical models and algorithms to support the development of personalized products for the classification of customers’ conditions and definition of the required skin care product;
• Design and prototype the small and flexible mini-factory for on-site production of the personalized skin care products;
• Define and validate the low energy-consumption manufacturing processes and with minimal environmental impact;
• Initiate the development of an advanced cloud-based integrated ICT platform to include: Integration of the manufacturing IT system for distributed control and monitoring of the production network by IT modules for required functionalities: CAD-CAM; Enterprise Resource Planning (ERP); Secure Information Systems (BSI); Manufacturing Execution Systems (MES); Standard for the Exchange of Product model data (STEP);
• Define the decision support system (DDS) for skin care products formulation according to skin profile for product customization (including SW);
Specific tools to be used for the characterization and implementation of the entire mini- factory concept:
• A manufacturing Reference Model as a first step to achieve a common understanding of all the pertinent aspects, identification of various design alternatives and a mechanism for the analysis of these options for the design and implementation at operational level. It can also provide a clear description of the business problems and requirements
• The ‘value stream mapping methodology’ to analyze and design the flow of materials and information required to bring the product /service to the consumer through a lean production, i.e. considering the expenditure of resources for the creation of value-added products. Working from the perspective of the customers
• A cyber-physical system (CPS) to feature a reciprocal interaction of the physical and digital world, consisting of sensors, actors, embedded software and software services . The operation of cyber physical systems is a complex interaction of different information systems from the technical process and machine level up to the production network level
• Life cycle assessment (LCA) and life cycle cost (LCC) studies for platform optimization;
• Regulations and standards compliance;

Project Results:
The SuperFlex project, aims to develop and demonstrate the concept of modular mini-factory (stationary or mobile-‘in container’) to manufacture personalized products for skincare products for the elderly population. The project will design, produce and demonstrate an on-site manufacturing platform based on modular min-factory units and an ICT cloud-based platform. The concept will be low cost and environmentally friendly.

The novel products will be personalized and designed to answer to the elderly specific skin profiles derived from the customers’ skin biomarkers and health status.
Personalized skin care products pave the way for a new approach of more effective skin preparations due to the increasing awareness to the variability in skin conditions and supported by innovative technologies, capable of identifying specific biomarkers’ profiles for accurate personalized skin condition diagnosis and customized treatments.

Optimization of skin profiling for personalized topical treatment
In order to optimize skin profiling 84 volunteers of different groups, ages and skin conditions were recruited and thoroughly examined by a dermatologist. Skin samples of appropriate subjects were taken non-invasively by skin washes and semi-invasively by standard D-squame sampling disks from the right forearm, left feet and left facial area. Specimens from all subjects were subsequently biochemically evaluated. Biochemical analysis comprises the investigation of the inflammation status (detecting interleukin 1ß, 8, 10 concentrations in the skin washes) as well as determining the antioxidant profile and the oxidation status (Redox state) utilizing the D-squame sampling discs.
The collected data was analyzed to define biochemical and physical characteristics of the appropriate groups and stored in a specific data base. The SuperFlex database has undergone a number of iterative changes in terms to its structure and implementation. As implementation matured in different work packages towards production ready version, there were various changes that impacted the data models and therefore the database schemas and the implementation of connectivity mechanisms. Where models were not defined at previous stages, the database structure provided for more universal approach and contained excessive records or placeholders. Currently as recommendation algorithm and connectivity interfaces (such as between MES and DSS) are being shaped into a more concrete form, database or its parts have to be redesigned and the implementation has to be finalized and adjusted in a more efficient way following latest updates.
Development of low cost and energy manufacturing processes
Three bases (body lotion, serum, cream-gel) and relevant additives (actives, preservatives, fragrances) were produced and selected for SuperFlex manufacturing platform by DSL and HUJI. All bases and diluted bases with additives passed stability tests, safety tests and pilot scale up. Other tests are towards fine tuning for product information file (PIF) to be in line with EC regulatory demands.
Also, toward Sustainability, preparation of partial replacement, (up to 75%), of the silicone oil in the body lotion formulation contain DSW was successful and obtained a more eco-friendly product which was stable for long period, (3M), at high temperature, (40C).
TUB and GAI made the best selection of green packages according to results. Bio based PE is selected: 50% BIOHDPE/50% BIOLLDPE. Furthermore, label design is defined as DNA structure. Now, TUB is evaluating the best printing technology (offset y/o silk screen) in order to have a final label design that takes into account functional and aesthetic issues.
PRJ achieved the full picture of the Superflex manufacturing model based on comparisons between centralized and distributed manufacturing. Starting from variable formulations and water dilutions it was possible to achieve the environmental impact calibration curves supporting the manufacturing platform sustainability optimization activities. Analysis on different packaging solutions allowed also supporting the choice of sustainable (green) packaging solution.

Platform specification and the SuperFlex ‘Manufacturing Reference Model’ of the modular mini-factory
The following data was identified collected and analyzed
• Analysis of market structure, volume, share, trends and competition.
• Identifying of personae based on surveys
• Capturing of the state of the art and beyond for technologies enabling the SuperFlex’ manufacturing platform.
• Packaging identification, collection and specification
• Development of the SuperFlex’ Manufacturing Platform
o Refinement of use cases
o Elaborating of SuperFlex’ value proposition
o Refining variants and the bill of materials
o Refining the activity based cost model
o Refinement of cost model / Break even analysis
o Supply Chain and inventory model
o Refined process scenarios
o Implementation of the ICT-platform / Cyber Physical Systems

After the requirements were gained for the Cloud-based IT Platform, was planb ned, and the interfaces between the different modules were implemented. These modules are now available on the VFK Platform, and the XETICS Lean MES can keep controlling the production, send and receive information from the modules and display some of the information on the User Interface.
The following modules are now integrated in the sequence: Skin Analysis and Measurements, XETICS Lean MES, DSS, RGS, Mini-Factory, CFS. These modules are alreay connected, several tests were run during implementation, the simulation of the Measurements, Questions, DSS, the Formula and the Recipie of the cream is ready, communication tests with the Mini-Factory successful, and CFS System is also connected. All modules are up and running on the VFK Platform.

Development of the ICT cloud-based integrated platform
This activity is focusing on developing a decision support system for personalized product customization, developing a cloud-based IT platform for production, secure data handling and customer feedback system after product usage.

The DSS implementation is the IA and the DSS employing the MLA. MLA is convenient as the rest of the SuperFlex ICT platform does not have to be changed as the input/output to the DSS remains the same, therefore, the transition from the intermediate to the final DSS can be carried out without difficulties. The IA, which is provided by AHAVA, receives the patients’ physical and biochemical data and determines the percentage of each ingredient required for the final skin care product. The output ingredients form the face and body products where the face is divided to Serum or Cream/Gel products. These outputs are connected and sent to the cloud infrastructure. The determined percentages of the ingredients are calculated and sent to the manufacturing unit. The software of the DSS is wrapped into a component-module, and is integrated in the cloud-based IT platform – communicating with the MES System, deployed on the Virtual Fort Knox Platform.

The IT platform is split into 6 modules: Analysis (Mini-Lab), MES, DSS, RGS, Mini-Factory, CFS.
is registered or identified by the ID of the customer. The customer needs to enter some data, answer the pre-defined questionnaire, and the skin analysis is made with the Mini-Lab. Data is then processed and saved in the MES System, which provides the calling of the specific steps calling the standalone software modules deployed on the VFK Server. The DSS receives first the data from the physical and biochemical measurements and the questionnaire, and returns the information on the optimal formulation, which is saved in the system. After this, the Recipe Generator is called, returning a Recipe for the Mini-Factory. The Mini-Factory is called, and the production of the cream starts.

Potential Impact:
Impact:
Main Technological achievements expected:
A) Database of skin profiles and topical formulations for elderly people;
B) Modular mini -factory unit for the skincare market;
C) IT cloud platform for management of the mini-factory concept;
D) A general IT cloud base integration platform to be applied for similar concepts;
F) Advanced SW based tools for production and supply chain management of the mini-factory platform;

Expected Impact:
• SuperFlex project will customize the skincare products based on skin biomarkers’ profile and health status of the customers;
• The project will develop a framework for future network of mini factories (stationary and/or mobile) based on intensive studies of a Manufacturing Reference Model, cloud based integrated ICT platform and Cyber physical system approach; demonstration will be done for one local mini-factory
• The developed min-factories platform will be easy to ramp up due to the concepts used within its development described in WP2 and 3, and the demonstration within the project which will enable to optimize exchange and re-arrange platform modules.
• Reduced environmental impact per produced unit compared to traditional larger factories will be achieved due to: a) small production units, b) novel low energy, green processes, c) use of green raw materials (for packaging and for the products); d) production of small volumes avoiding addition of preservatives, e) reduction in transportation and storage;
• Scale reduction and increased flexibility of production is the main aim of the project achieved mainly through the mobile and/or stationary mini factory platform;
• The space will be much smaller as well as operation skills due to simple, automatic, low cost processes.
• The engineering integrated solutions will be based on mathematical models and IT tools;

List of Websites:
http://fp7-superflex.eu/

Related information

Contact

Ofer Achdut, (CEO)
Tel.: +972 29945100
E-mail
Record Number: 195811 / Last updated on: 2017-03-14
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