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Multi-disciplinArY integrated simulAtion and forecasting tools, empowered by digital continuity and continuous real-world synchronization, towards reduced time to production and optimization

Periodic Reporting for period 2 - MAYA (Multi-disciplinArY integrated simulAtion and forecasting tools, empowered by digital continuity and continuous real-world synchronization, towards reduced time to production and optimization)

Reporting period: 2017-04-01 to 2018-09-30

In Europe, manufacturing is the largest of the NACE sections for the non-financial business. Back 2008, it contributed with 24.2% of the workforce and 27.1% of the value added. However, due to the economic crisis EU countries are undergoing, GDP is still likely to stagnate, the economic growth is expected to be low in the near future and some 3.25 million jobs have been already lost. Now, more than ever, Europe’s need for productivity growth has become more pressing against both the low rate of economic growth and the international financial crisis that is clouding the outlook for all companies. Modern IT is a key factor for the future of manufacturing, especially simulations and virtual reality will contribute to the innovative developments of complex products and processes. Widespread use of ICT in industry is the cornerstone of productivity and thus of economic growth.
MAYA aims at developing simulation methodologies and multidisciplinary tools for the design, engineering and management of CPS-based (Cyber Physical Systems) Factories, in order to strategically support production-related activities during all the phases of the factory life-cycle. The concurrence and the cross-combination of the Cyber and the Physical dimensions with the Simulation domain is considered as cornerstone in MAYA innovations, to successfully address a new generation of smart factories for future industry responsiveness. MAYA finds complete validation in one of the most competitive, advanced and complex industrial sector in Europe, the automotive (with two use-cases: VOLKSWAGEN and FINNPOWER), where it will accomplish reduced time to production and reduced time to optimization.
In order to realize such a vision, MAYA addresses actual technological constraints through research and development activities focusing on the following three high level objectives:
1. MAYA for Digital Continuity: MAYA will support digital continuity developing a standardized, open semantic meta-model capable to fully describe the properties and functional characteristics of the CPS simulation models, as a key element to empower multidisciplinary simulation tools
2. MAYA for the Synchronization of the Digital and Real Factory: MAYA will support synchronization of digital and real factory creating the infrastructure to support seamless data flow from real to simulated devices
3. MAYA for Multidisciplinary integrated simulation and modelling: the new envisioned meta-model, together with the reference framework, represents the key enablers to implement real multi-disciplinary simulations
MAYA’s concept and motivation have been born within the framework set by the Pathfinder initiative, and represent a concrete first step to empower the vision that is there drafted and consolidated, thanks to the contribution of several academic experts and industrial key-players.
Activities performed mainly focused on:
- Definition of the MAYA overall framework, both in terms of industrial requirements and technological architecture;
- Design and implementation of the CPS representation and communication tiers that are at the base of the MAYA Framework, and that implement respectively the concepts of digital-continuity and digital-real synchronization;
- Development of the MAYA runtime as the integration of the Centralized Support Infrastructure (CSI) and the Simulation Framework, created for the management of the multi-disciplinary simulations and the concurrent orchestration of the models;
- Implementation of the High-end scenario at Volkswagen with a workshop in Wolfsburg with personnel from different VW Group departments;
- Implementation of the SME scenario at Finn-Power in the Technology and Training Center at Kauhava and with an internal Workshop;
- Evaluation of the results of the scenarios by providing a questionnaire and interview during the workshops.

For each MAYA objective, the results of these activities are available:
1. MAYA for Digital Continuity
Results: technical reference of the new semantic meta-data model for CPS-based factory representation; common language specification for behavioural simulation models; data model implemented in the deployed CSI.
2. MAYA for the Synchronization of Digital and Real Factory
Results: mimiddleware devices for data acquisition and in loco processing integrated with MAYA CPS framework (middleware node connected with Finn-Power’s PLC); specification of standardized API for communication driver development; specification of NoSQL database system deployment for the storage of MAYA simulation models; deployment of a CSI instance.
3. MAYA for Multidisciplinary integrated simulation and modeling
Results: specification and reference implementation of the MAYA Simulation Framework for the real-time synchronization of multidisciplinary simulation engines; integration of simulation with FMI (FMU module, developed in MatLab, to compute energy consumption).
MAYA potential impacts:
1. Increased productivity in design and ramp-up will be a direct consequence of the application of the MAYA multidisciplinary simulation tools. Expected impacts: improved reliability by 50%; time to manufacturing system optimization down of 20%
2. MAYA reliable modelling of production flows and value streams will lead to a better understanding of the system. Together with the possibility to implement decision rules and control logics in the simulated environment, reliable modelling will improve resource optimization and efficiency, reducing the time to acquire such results. Expected impacts: time to production down of 20%
3. MAYA framework ensures that data are maintained and enriched in each manufacturing stage and the CPS-based approach guarantees that a global state monitoring can be achieved flawlessly. Expected impact: achievement of common semantic understanding; definition of open interfaces, data formats and protocols.
MAYA framework