Periodic Reporting for period 2 - KYKLOS 4.0 (An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences)
Reporting period: 2021-01-01 to 2022-06-30
The manufacturing industry is facing new challenges that imply both social and ecological changes dealing with the urge needed worldwide to reduce the emissions as well as facing a raw material scarce foreseen situation in European studies in the coming years. The European Green Deal clearly states the need to take action in the industrial manufacturing sector so as to achieve the target of climate neutrality in 2050. The industrial sector represents 20% of the EU emissions, the annual extraction of raw materials is continuously increasing and 90% of the lost in biodiversity and de hydric stress is directly linked to the extraction of raw materials and the processing of these raw materials.
At the same time in the COM (2019) 640 Final The Green Deal communication letter (https://eur-lex.europa.eu/legal-content/EN/TXT/?qid=1596443911913&uri=CELEX%3A52019DC0640#document2) clearly states the situation and the urgent need to transforming EU`s economy for a sustainability future. At the same time in it Annex it presents a detail roadmap of key actions to be address in which actions such as “Zero pollution action plan for water, air and soil” as well as “Revision of measures to address pollution from large industrial installations” for 2021, clearly have direct implications in changes in current industrial process as well as in the green responsibility for industrial sectors.
KYKLOS 4.0 aims to develop an innovative Circular Manufacturing ecosystem based on novel CPS and AI based technologies, enhanced with novel production mechanisms and algorithms, targeting on personalised products with extended life cycle and promoting energy efficient and low material consumption intra-factory production processes, resulting reduced greenhouse gas emissions and air pollutants.
KYKLOS 4.0 aims at providing an Ecosystem which creates and supports the configurations, methodologies, production techniques, decisions and actions at all different levels and stages of the equipment manufacturing value chain so as to achieve the goals of i) increased energy efficiency, ii) decrease of raw material through to the second use of parts or material (including waste from manufacturing process), iii) customer centricity, iv) on-demand manufacturing and best meet the Industry 4.0 objectives of operational excellence, where mass customization and personalization have become the norm, while increase efficiency, reduce waste, boost competitiveness and lower costs for European manufacturers, particularly for the SMEs. KYKLOS 4.0 will deliver an advanced configuration variants’ framework and state-of-the-art production paradigm, embedding key technologies into a unified platform ecosystem to manage live product innovation, via building and shipping “configuration to specification”, through the seamless adaptation on new customer requirements. This
involves a set of intelligent tools for real-time analytics and prediction, and recommender systems, further integrated into KYKLOS 4.0 configuration environment.
In relation to the range of circular and flexible manufacturing aspects the KYKLOS 4.0 Ecosystem will provide a set of self-organizing, data driven modules (able to work independently) which will trigger dynamic interaction between them, and a smart orchestrator which will provide the ability to:
· exchange customized product information between involved actors (and their KYKLOS 4.0 modules) in the product life cycle, from manufacturers of basic equipment components to retailers and vendors up to the final customers via KYKLOS 4.0 Symbiosis Environment a
Decentralised B2B Marketplace;
· to dynamically handle any necessary production line changes (needs for energy and raw materials, fast reconfiguration and re-use) given a superior proficiency to tackle the varieties of personalized products and the corresponding flexible manufacturing processes;
· to deal with personalized product design issues (e.g. assembly or disassembly, reconfiguration, update or reuse, new materials, number of parts) and perform quality and economical improvements focusing on the extension of Product End of Life;
Thus, it will create favourable conditions for the rapid reconfiguration of manufacturing process, in order to continuously follow Circular Manufacturing Framework and the individualised consumer/customised products demands.
At the same time in the COM (2019) 640 Final The Green Deal communication letter (https://eur-lex.europa.eu/legal-content/EN/TXT/?qid=1596443911913&uri=CELEX%3A52019DC0640#document2) clearly states the situation and the urgent need to transforming EU`s economy for a sustainability future. At the same time in it Annex it presents a detail roadmap of key actions to be address in which actions such as “Zero pollution action plan for water, air and soil” as well as “Revision of measures to address pollution from large industrial installations” for 2021, clearly have direct implications in changes in current industrial process as well as in the green responsibility for industrial sectors.
KYKLOS 4.0 aims to develop an innovative Circular Manufacturing ecosystem based on novel CPS and AI based technologies, enhanced with novel production mechanisms and algorithms, targeting on personalised products with extended life cycle and promoting energy efficient and low material consumption intra-factory production processes, resulting reduced greenhouse gas emissions and air pollutants.
KYKLOS 4.0 aims at providing an Ecosystem which creates and supports the configurations, methodologies, production techniques, decisions and actions at all different levels and stages of the equipment manufacturing value chain so as to achieve the goals of i) increased energy efficiency, ii) decrease of raw material through to the second use of parts or material (including waste from manufacturing process), iii) customer centricity, iv) on-demand manufacturing and best meet the Industry 4.0 objectives of operational excellence, where mass customization and personalization have become the norm, while increase efficiency, reduce waste, boost competitiveness and lower costs for European manufacturers, particularly for the SMEs. KYKLOS 4.0 will deliver an advanced configuration variants’ framework and state-of-the-art production paradigm, embedding key technologies into a unified platform ecosystem to manage live product innovation, via building and shipping “configuration to specification”, through the seamless adaptation on new customer requirements. This
involves a set of intelligent tools for real-time analytics and prediction, and recommender systems, further integrated into KYKLOS 4.0 configuration environment.
In relation to the range of circular and flexible manufacturing aspects the KYKLOS 4.0 Ecosystem will provide a set of self-organizing, data driven modules (able to work independently) which will trigger dynamic interaction between them, and a smart orchestrator which will provide the ability to:
· exchange customized product information between involved actors (and their KYKLOS 4.0 modules) in the product life cycle, from manufacturers of basic equipment components to retailers and vendors up to the final customers via KYKLOS 4.0 Symbiosis Environment a
Decentralised B2B Marketplace;
· to dynamically handle any necessary production line changes (needs for energy and raw materials, fast reconfiguration and re-use) given a superior proficiency to tackle the varieties of personalized products and the corresponding flexible manufacturing processes;
· to deal with personalized product design issues (e.g. assembly or disassembly, reconfiguration, update or reuse, new materials, number of parts) and perform quality and economical improvements focusing on the extension of Product End of Life;
Thus, it will create favourable conditions for the rapid reconfiguration of manufacturing process, in order to continuously follow Circular Manufacturing Framework and the individualised consumer/customised products demands.
During this first year of the KYKLOS 4.0 project (M1-M12), the consortium has collaborated to manage the requirement engineering specification and to design, and follow up, a common design methodology to ensure the requirement elicitation process that has been used, and will be used, along the project.
Use cases initial designs, each one with each own context and goals, have been completed and important elements for the future KYKLOS 4.0 work (such as user roles, data exchange and data flows needs, functional and non-functional requirements, technical components, processes, etc) have been identified. All these elements have been taken into account to design the system architecture and its main technical components.
System and technical components are critical in KYKLOS 4.0 context but not only software and middleware technical elements have been identified and developed during this period but different hardware elements too. The intra-factory operation components analysis, design, specification and development have started during this period, focusing on the Shop Floor cognitive agents for the different pilots. Different techniques for data reduction have been identified according to state-of-theart
algorithms and a complete model for fault dependencies has been designed.
KYKLO 4.0 will implement different auditing mechanisms and during this period we have started the evaluation of the auditing needs and their related mechanisms. The data manager and everything that has to do with the testing and validation plans have been started during this period. The framework and the KYKLOS 4.0 system will demand supporting, and specific, toolkits due to the demand or personalized services and/ or product. To develop these tools and toolkits the consortium has started the compilation of information, requirements, needs, specifications and restrictions. Those components are:
· The recommendation engine
· The advanced additive manufacturing component
· The Online 3D modelling component
· The mixed reality simulator component
Use cases initial designs, each one with each own context and goals, have been completed and important elements for the future KYKLOS 4.0 work (such as user roles, data exchange and data flows needs, functional and non-functional requirements, technical components, processes, etc) have been identified. All these elements have been taken into account to design the system architecture and its main technical components.
System and technical components are critical in KYKLOS 4.0 context but not only software and middleware technical elements have been identified and developed during this period but different hardware elements too. The intra-factory operation components analysis, design, specification and development have started during this period, focusing on the Shop Floor cognitive agents for the different pilots. Different techniques for data reduction have been identified according to state-of-theart
algorithms and a complete model for fault dependencies has been designed.
KYKLO 4.0 will implement different auditing mechanisms and during this period we have started the evaluation of the auditing needs and their related mechanisms. The data manager and everything that has to do with the testing and validation plans have been started during this period. The framework and the KYKLOS 4.0 system will demand supporting, and specific, toolkits due to the demand or personalized services and/ or product. To develop these tools and toolkits the consortium has started the compilation of information, requirements, needs, specifications and restrictions. Those components are:
· The recommendation engine
· The advanced additive manufacturing component
· The Online 3D modelling component
· The mixed reality simulator component
KYKLOS 4.0 is in the first year of the project and the technical work has just started. During the specification of the use cases issues have been identified in which further work on circularity as to be address, in principle focusing on the “Full Traceability of refurbished material/products/parts” through the use of Blockchain as well as the use of new 3D modelling as well as material usage for 3D printing of products/pieces using composite focusing on the future refurbishment of the product/pieces. But these are just two examples of the work being done ensuring a real progrees ebyond the SoTA.