An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences

Project Information

KYKLOS 4.0

Grant agreement ID: 872570

DOI

10.3030/872570

Project closed

EC signature date 12 November 2019

Start date 1 January 2020

End date 31 December 2023

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Information and Communication Technologies (ICT)

Total cost

€ 19 227 110,00

EU contribution

€ 15 984 875,00

Coordinated by

FUNDACION TECNALIA RESEARCH & INNOVATION
Spain

Periodic Reporting for period 3 - KYKLOS 4.0 (An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences)

Reporting period: 2022-07-01 to 2023-12-31

Summary of the context and overall objectives of the project

KYKLOS 4.0 provides a full integration set of services that ease Manufacturing organisations understand and plan for the trip to circular manufacturing, while providing the means for these enterprises to measure and validate in real time their circularity goals so as to be able to make operational decision if the target KPIs are not as expected. The services are classified in three main categories: 1) Smart Design focused on maximizing the customization of products as well as providing additive manufacturing technologies as to enable the creation of customized products with the minimum use of resources and enabling the simulation of product prior to the manufacturing. 2) Product Optimization: These services target the need to have the manufacturing plant and resources in high quality status so as to be able to predict way before potential failures so as to simulate and even predict time downs in which the impact both in production as well as in the required potential substitution of parts by enabling a full real-time monitoring of both the elements for production as well as resources required in production, enabling a fill optimization of the resource allocation and usage at all times.
But even more important in a circular manufacturing is providing the adequate product lifecycle management support. KYKLOS 4.0 provides this management support while providing not only the capability for product lifecycle management but what is more important in the Circualr manufacturing process that is basically the Life Cycle Assessment service which enables an organisation to know through the manufacturing plant what is the actual foot print by monitoring the energy/water consumption as well as being able to identify based on the materials inflow the actual environmental foot print. At the same time KYKLOS 4.0 provide a blockchain based refurbishment services that enables and organisation to trace in a truthful manner the refurbishment undergone by a part, product or material, that an organisation may be considering using in their production instead of purchasing new parts/Products/materials reducing in this manner the overall footprint of the Manufacturing process.

One of the key challenges faced by the manufacturing industry when moving towards a circular manufacturing strategy is determining what KPIs or indicators have to be measured with respect to each specific manufacturing process. KYKLOS 4.0 has developed a Circular Manufacturing Approach that just provides the means for an organisation to know what needs to be measure based on the CM strategy the organisation wants to follow. The DSS in KYKLOS 4.0 has implemented this Circularity Approach a enables an organisation to know based on the production process information whether the CM strategy goals are being meet or a deviating and also provides potential insights on what the organisation needs to look into so as to get back in trace.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

One of the main result of the project is the KYKLOS 4.0 Platform which offers 17 services for organizations to create efficient and circular manufacturing environments. The platform is composed by 28 technical components that combined offer key services characterized in three main categories: Smart Design [Personalized product specification and Optimization of Additive Manufacturing design], Product Optimization [Maintenance optimization, Advanced support for production and Resource use monitoring and optimization] and Product life-cycle management support by Life Cycle Assessment (LCA) service (providing circular and sustainability related KPIs monitoring), the Refurbishment service (performing a trustworthy tracking of the different parts of the final product in order to ensure that all parts comply with the user requirements). At the same time by following ISO 10303-242:2020 [3], the Product Lifecycle Management (PLM): supports the stakeholders involved in the product lifetime, from design through manufacturing and even asset maintenance.

A key challenge in the KYKLOS 4.0 project as well as in the circular manufacturing is the capability of measuring the circularity and green impact of the manufacturing process. In the context of KYKLOS 4.0 we have defined the KYKLOS 4.0 Circularity Approach which is a methodology as well as a list of circularity indicators that enable any organization to measure and monitor their circularity aligned to their manufacturing process. This methodology can be used by anyone to actual monitor their processes or implement supporting tools for this. In the context of the project we have implemented a software solution in the Decision Support System developed in the project.

Within the project there are two means of exploitation, the individual exploitation of the different components developed in the project, but what is most important is that there have already been agreements in the joint exploitation of the following services: Personalized “Product Design and Refurbishment”, “Advanced Support for Production” and “Additive Manufacturing Design and Automation”. At the same time all the results have been included in the IoTCatalogue (https://www.iot-catalogue.com/projects/61eecf88120630002afdfef6).

The dissemination of the project results is as follows 7 newsletters were released, 45 project publications, 26 peer-reviewed publications, including 7 articles in journals, 15 publications in conference proceedings, and 4 dissertations. 19 non-peer reviewed publications and 187 blog entries, press releases, partners’ posts, flyers quickly summarizes the dissemination efforts of the project results. Another mean of dissemination of the project was the IoT Catalogue in which the use cases, usage of the KYKLOS 4.0 solutions and out comes are presented.

KYKLOS 4.0 participated in 68 relevant events. Demonstration and training sessions based on KYKLOS 4.0 pilots and solutions were organized during KYKLOS 4.0 validation phase #1 and #2, and during Open Call #2 demo/training sessions to address integration aspects.

As part of our clustering efforts, clustering with the following relevant projects and global initiatives:DMP Cluster, EFFRA, BDVA, SBS, OpenDEI, DFA, AI, Data and Robotics Partnership, DSBA, AI on Demand Platform, OpenAIRE, ETSI, European Green Digital Coalition.

KYKLOS 4.0 partners delivered 23 comprehensive videos (non-confidential) aiming at explaining the benefits for sustainable and circular manufacturing, including live demo showing the main capabilities of the components for sustainable and circular manufacturing.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

One of the main result of the project is the KYKLOS 4.0 Platform which offers 17 services for organizations willing to create efficient and circular manufacturing environments. These services are offered through the KYKLOS 4.0 Platform in which the services have been integrated. The main impact on the usage of the platform are alligned with the CM objective since the use of the provided services together with the LCA tool support the Decisiosn Support System as well as the KYKLOS circularity approach enables that any organisation is capable of monitoring the resource consumptium as well as the CO2 emission, and triger actions based on these results in the production itself.

kyklos-4-0-collaboration-platform.jpg