Industry Day Forum

Industry 4.0: Present and future challenges


Organized and co-chaired by

Carlos Sagüés
University of Zaragoza, Spain
csagues@unizar.es
Armando Walter Colombo
University of Applied Sciences Emden, Germany
awcolombo@ieee.org

Download the Call for Participants in PDF format


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We cordially invite you to the ETFA‘2019 Industry Day Forum that is dedicated to the subject of “Industry 4.0 Present and future challenges”. It features presentations by industry experts from various sectors of Home Appliances and Car Automation Industry and Logistic. This Forum will offer an opportunity to exchange views with researchers and practitioners from academia and industry. The Industry Day can be visited without attending the conference. We are pleased to welcome you at Aula Magna of Paraninfo building, on September 10th, 2019.


Program

Tuesday, September 10, 2019

08:00-08:45 Room: Josefa Amar y Borbón
Registration
08:45-09:00 Room: Aula Magna
Industry Day Opening Session
Session 1.
Present and future challenges in Home Appliances Industry: products and processes
09:00-09:20 Room: Aula Magna

Connected Products and Processes at the service of people

José Juste

Talk title. Connected Products and Processes at the service of people

The household appliance sector is immersed in an evolution similar to that of other industrial and consumer sectors. The implications of globalization, the disintermediation of channels, the digitalization of products and services, are generating changes that will transform the model of the sector for the benefit of client-users and the advantage of companies that are able to adapt or, better, that are the main actors of evolution.

There is much talk of today’s world as volatile, uncertain, complex and ambiguous (VUCA), which implies that it is difficult try to make predictions of what is going to happen. This is an excellent excuse to do nothing, but also the quick way of being irrelevant. What to do then? To be the generators of change or, at least, to be very agile and flexible acting at the first signs of change.

The BSH response to all these challenges is: Connected Products that users will love, produced in Excellent Factories where people want and enjoy to work. Our connected products will make users’ lives easier and more enjoyable, offering not only task solving devices but also providing value-added services. In the supply-make side BSH has focus on improving its Production System and nowadays this has a lot to do with adopting the best technologies of the so-called Industry 4.0 , in an intelligent and appropriate way. It’s not about fashion, it’s about competitiveness. BSH is implementing in Spain an Industry 4.0 strategy based in four main fields: Data Analytics, Adaptive Robotics, Cognitive Support and Automated handling.

José Juste's biography

José Juste, is Chief Operations and Technology Officer at BSH Electrodomésticos España S.A. since 2010.

BSH currently has four factories in Spain and several R&D and Technology centres, occupying a top position as patent applicant in Spain. We collaborate closely with technology centres and universities and especially with UNIZAR, on research projects in relevant fields of mutual interest.

BSH is leader in Home Appliances market in Europe and Spain, with global brands Bosch and Siemens and other special and local brands.
José Juste is Industrial Engineer by the University of Zaragoza, has a postgraduate degree in business administration and management by IESE Business School and for ten years was teaching Operations Management at Escuela Europea de Negocios de Aragón.

José has an extensive experience of more than 30 years in production and technology, having been for the last 18 years director of several factories and business units.

José Juste represents BSH in various technology centre councils and in bodies of other organisations.

09:20-09:40 Room: Aula Magna

Current and foreseen use cases at BSH

Andrés Escartín

Talk title. Current and foreseen use cases at BSH

The pressure from competitors and the increasing availability of digital solutions and tools pushes our factories to become Excellent Factories, where Industry 4.0 plays a very relevant role. BSH Spain is focusing in four main areas: Data Analytics, Adaptive Robotics, Cognitive Support and Automated handling.

Data analytics.We collect a lot of data from our equipment and processes, but make little use of it. We use them more to report and explain what happened, than to understand why it happened and therefore learn and improve. On the other hand, data analytics has many aspects to consider: capture, cybersecurity, storage, accessibility, quality, etc. , all necessary to finally analyse them by means of appropriate algorithms. Use cases arise daily, but it is necessary to develop mastery to identify those that have the maximum benefit-effort ratio.

Adaptive robotics. The path of automation encounters huge barriers of profitability, when the activities are of low volume, diverse and complex. The use of new collaborative robots, lightweight, low-cost, easily integrated into work environments, are a new paradigm to extend automation in labor-intensive processes. But en extensive use of these will only be possible by including adaptive capabilities. Evaluating the context as humans do and acting consequently is the challenge to further develop automation.

Cognitive support. In those working places where automation is not the right solution and is carried-out by people, in addition to eliminating physical fatigue, we aim to reduce as much as possible mental fatigue of tedious activities with little added value. Augmented reality, image recognition systems, RFID, … are coming to the scene to support humans to do their work better, faster and more reliable.

Automatic handling. Moving and handling loads and elements are necessary operations but of null added value. Many of them are made by automatic mechanical systems when they are repetitive (conveyors, transport chains, … ), but there are many others made and/or assisted by humans. Automatic guided vehicles are not new, but are recently more accessible, more flexible and easier configurable to specific needs.

All these systems, connected, interoperating and interacting are configuring, step by step, our factory of the future. We will present to you some use cases.

Andrés Escartín's biography

Andrés Escartín is member of the Corporate Innovation division in BSH Home Appliances Group. Industrial Engineer by the University of Zaragoza, he started his professional career in that University working in research projects in collaboration with BSH Electrodomésticos España SA.

Laser technology was the focus then as a promising tool for improving decoration processes in BSH factories. Following the evolution of this technology, Andrés joined BSH in 2011 as part of the engineering team developing the industrial application, and later joined the Corporate Innovation team for industrial processes. During this period worked in the design of this industrial process, the adaptation of the technology to BSH industrial requirements and the evaluation of the potential for the end users.Nowadays BSH counts with more than 100 laser systems for digital decoration.

As part of this trajectory, Andrés was coauthor of some papers and several patents, coordinated the public funded project UV Marking under FP7 (2012-2015, ID 314630), and is currently coordinating Laser4fun under H2020 (2015-2019, ID 675063), as well as participating in others (TresClean, LAMPAS, CARES).

Following the evolution of these digital techniques, Andrés turned his trajectory towards innovation of other digital processes as part of the Industry 4.0 ecosystem. Since 2017, he is working in the coordination of Industry 4.0 activities in BSH in Spain, is part of the global I4.0 community of BSH and is leading some of the Corporate Innovation initiatives.

09:40-10:00 Room: Aula Magna

IoT as engine of Data-Driven Transformation: New business models

Fernando Sánchez

Talk title. IoT as engine of Data-Driven transformation: New business models

Internet of Things is being especially crucial to accelerate the innovation in OEMs (Original Equipment Manufacturer), this technology working together with others like Big Data, Cloud Computing and Artificial Intelligence has allowed the machine builders to create connected systems which place the data in the center as a key asset. Technology can bring multiple benefits from an operational point of view, reduce maintenance cost, improve the performance and the quality. The first step comes with IoT, connecting the machines and aggregating. Technology is also having an impact in the way companies monetize their value proposals. The movement from ownership to access is more than a trend, and OEM segment is especially suitable to adopt new business models. Machine as a Service means recurring revenue for OEMs, more predictable and measurable. On the other side, end users need less investment at beginning but especially, they get a strong commitment from the OEM to deliver the best service,the new relationship force OEMs to be excellent. Machine as a service model have some roadblocks related to the complexity of the agreements, data privacy and financial risks. In a world in constant and fast movement, data will play a key role, companies who get the most value of data and take their decisions based on data will have competitive advantage.

Fernando Sánchez's biography

Fernando Sánchez Miravalles received in 2011 his degree in Electrical Engineering from Zaragoza University. After graduating he started in the same university an internship in the maintenance department to deploy a supervisor and control system.

In 2012 he started working in Barcelona for BlauLabs, an IoT cloud solution focused on energy management where he participated in the development life cycle and software architecture design. He collaborated in transforming the company from a license on premise model to a SaaS model ( Software as a service) by designing the pricing and go-to market strategies.

After that, he joined Schneider Electric Company in Barcelona as a solution architect. He has used his experience in IT-OT convergence, PaaS model (Platform as a Service), and advanced analytics to implement data solutions for Schneider customers as well as help them to join membership economy models.

10:00-10:30 Room: Aula Magna
Panel Discussion.
Moderator: Carlos Sagüés
Panelist: Sergio Gómez, Andrés Escartín, Fernando Sánchez
10:30-11:00 Room: Josefa Amar y Borbón
Coffee Break
Session 2.
Industry Car Automation
11:00-11:20 Room: Aula Magna

Industry 4.0 applied Smart in Automotive

Hans Grundig

Talk title. Smart Factory applied in automotive. 'Use the right tool for the right purpose'

I will talk about the process from the idea creation to the implementation of smart factory innovation. How to get to the right agility ensure that the concepts are validated. Will talk about the key of business engagement. Will show some real implemented ideas with success and without. Giving some ideas of inflight ideas and challenges.

Hans-Juergen Grundig's biography

Education
1987-1991 Dipl. Ing. Electronic

Professional path:
October 1991 Start at Opel at the technical development center in Rüsselsheim
1991-2000 Planning engineer in Manufacturing
2000-2003 Project lead for electrical package Leanfield plant Rüsselsheim
2003-2008 Project lead in international projects in the assembly and powertrain plants
2008-2012 Department head IT manufacturing systems
2012-2013 Department head innovation and strategy IT O/V
2013-2014 Technology field lead IT / manufacturing Opel / Vauxhall
2014-2017 Global Lead of the Smart Factory Innovation Program at GM for IT
2017 Smart Factory and Migration to PSA Systems

Some achievements:
Developed and harmonized GM globally RFID
Giving global service in Asia, Russia, USA and Europe
PM for 75 Mio project in Ruesselsheim
300 Mio cost avoidance project developed for MES and shop floor
Became Global taxonomy lead in manufacturing
Excellent business process knowledge in all assembly areas incl. stamping
Leading role in business transformation
Globally managed all IT manufacturing innovation
Expert in IoT and Industry 4.0
4 years leader of the smart factory program manufacturing GM globally.

Current role:

Leading role in the PSA group to harmonize business processes and IT systems. Smart Factory expert in manufacturing and giving guidance on technologies and principles in that area. Responsible for the sustain of the manufacturing IT systems in OV and leading the plant production monitoring space in the PSA group.

11:20-11:40 Room: Aula Magna

Business Intelligence; real use cases with ROI

Fernando Espiau

Talk title. Business Intelligence; real use cases with ROI

Modern industry uses a great amount of controllers such as PLCs, robots, weld controllers or motor drives. On top of their controlling function, many of them are also able to generate, store and transmit data about their condition or about the result of the process they control. Such datasets make up a precious asset that, if properly managed and analyzed, can provide valuable benefits.

Predictive maintenance, quality tracking, energy consumption measurement or maintenance work order monitoring are just a few examples of applications that can be developed with this data. The range of achievable benefits is very wide depending on the kind of industry and the level of automation.

The presentation will cover some real examples of such applications developed by a European car manufacturer, Opel-Vauxhall (Groupe PSA), within the last three years:

  • Welding Wizard, a predictive analytic application for spot welding process.

  • Eagle Eye Reports, based on data from an automated paint inspection system. It helps paint engineers to improve quality.

  • Drive Wizard, a predictive maintenance system based on data extracted from motor drives.

  • Bottleneck Reports, that help supervisors to find the main bottlenecks on the assembly line.

Fernando Espiau's biography

Fernando Espiau received the Industrial Engineering degree from the University of Zaragoza, Spain. In 1985 he started at General Motors Spain (later Opel Spain) as automation engineer within the Manufacturing Engineering Automation area. There he worked with several brands of PLCs, robots, weld controllers, motion controllers, machine vision systems, electronically controlled torque tools, field buses and a wide variety of automation material. Among others, his field of work included welding cells, paint installations, automated assembly processes, error-proofing systems as well as the communication with Manufacturing Execution Systems (MES).

Between 1997 and 2000 he acted as the Y2K team manager in Opel Spain (to minimize the Y2K effect on manufacturing installations).

In 2007 he moved to Manufacturing IT in Opel Europe Holdings, where he has managed several MES projects. Since 2016 he is the Functional Lead of Business Intelligence and Data Analytics (BI&DA) for Opel-Vauxhall Manufacturing, currently within the Groupe PSA after its acquisition from General Motors.

Within the Manufacturing scope he leads all initiatives, proofs of concept and projects related with Business Intelligence, Data Analytics, Industrial IoT, Machine Learning and Big Data for all Opel and Vauxhall plants, either Assembly, Component or Powertrain.

He belongs to the core team member of CORTEX, a group that aims for the convergence of BI&DA architectures and tools and looks for synergies on such fields among all companies within Groupe PSA.

11:40-12:00 Room: Aula Magna

Smart Manufacturing for Battery Production Scaleup

Robert Harrison

Talk title. Smart Manufacturing for Battery Production Scaleup

This presentation aims to give an insight into WMG’s approach to Smart Manufacturing in the context of the provision of R&D facilities to support the creation and scaleup of battery production in the UK. It will discuss WMG’s experiences in the creation and use of its Energy Innovation Centre for battery cell production in cylindrical and pouch formats, the realisation and evolution of pilot production facilities for modules and packs on the AMPLiFII and H1PERBAT projects, and our role in the creation of smart production systems for the UKBIC. Industry needs agile, scalable, production methods for battery systems, applicable to multiple manufacturers and varying volume builds, together with longer-term support to de-risk the wider ambition for full-scale, high-volume battery manufacturing.

The WMG Energy Innovation Centre is a national facility for battery R&D from materials and electrochemistry through to application integration, recycling, and reuse. The AMPLiFII (Automated Module to pack Pilot Line For Industrial Innovation) project aims to make production viable at relatively low initial volumes of battery packs for hybrid and electric vehicles. The H1PERBAT project is addressing the need for high-performance electric vehicle (EV) batteries by realising a novel flexible production line adaptable to various modular battery architectures and related manufacturing processes. The UK Battery Industrialisation Centre (UKBIC) is establishing a new national facility for battery manufacturing development, which will open in 2020, with the aim to transition the UK into a leader in battery design, development, and manufacture for vehicle electrification. These activities involve consortia of partners from large companies to SMEs, including JLR, Nissan, Aston Martin Lagonda, JCB, Unipart, Williams Advanced Engineering, Productiv, Delta Motorsport, Ariel, and many others.

Robert Harrison's biography

Professor Robert Harrison is head of WMG’s Automation Systems Group at the University of Warwick, with a focus on systems engineering and industrial automation through a wide range of R&D programmes from the EU, EPSRC, Innovate UK, HVM Catapult, and industry. His work spans two main areas of research and development: (1) cyber-physical systems methods, tools, and technologies and (2) their application to production systems, typically by user-driven applications engineering projects, in an area of expertise now commonly referred to as Industry 4.0. His expertise is underpinned by a lifetime’s experience of working in systems integration and engineering tools and methods for automation systems realisation in very close collaboration with industry. He has conducted collaborative research programmes with a wide range of companies and has more than 150 peer-reviewed publications and a wide network of academic collaborators, nationally and internationally. Previously a founding member of the MSI (Manufacturing Systems Integration) Group at Loughborough University, a Research Fellow at the National University of Singapore, Ford Motor Company and Schneider Electric, and recipient of a Royal Academy of Engineering Global Research Award in the field of Modular Reconfigurable Manufacturing Automation. Robert has also played a major role in the UK and Europe in research related to the realisation of service-oriented distributed systems for embedded devices and the integration of business systems with SoA-based automation systems, with his focus of expertise being particularly related to the creation of lifecycle engineering tools and related data models, which are now often referred to as digital-twins.

12:00-12:30 Room: Aula Magna
Panel Discussion.
Moderator: Carlos Sagüés
Panelist: Hans-Juergen Grundig, Fernando Espiau, Robert Harrison
12:30-14:30 Restaurante Idílico
Lunch Break
Session 3.
Intelligent Distribution Systems and Logistics
14:30-14:50 Room: Aula Magna

New technologies for urban mobility

Susana Val

Talk title. New technologies for urban mobility

In the framework of the activities that ZLC carries out as a research center on logistics and supply chain management, the conference will tackle different European initiatives (national and international) related to urban mobility. Particularly speaking, the topic of urban mobility will be addressed in terms of the future mobility scenarios, that is, how we envision those future mobility scenarios of cities in Europe, acording to our perception of technology, convictions, regulations and trends observed. Then we will quickly move to the Smart-city concept, as this is closely related to some ideas such as sustainability, interoperability and technologies. The Smart-city will be defined as the integration between freight plus citizens and the speech will focus on freight distribution and the innovative solutions to build better sustainable cities.

The above will lead to illustrate through several examples the reality of most of the cities and what new technologies may provide in terms of social, economical and environmental impact. For instance, physical internet will be a topic that may help to improve the supply chains and last mile distribution. Examples of some other innovative solutions will also be discussed during the talk

Susana Val's biography

Susana Val is the Director of Zaragoza Logistics Center (ZLC). She is also Principal Investigator for the Transport Research Group, Associate Research Professor at MIT-Zaragoza International Logistics Program and Research Affiliate at the MIT Center for Transportation and Logistics. She completed both a PhD and MSc degree in Industrial Engineering at the University of Zaragoza. Her doctoral thesis was awarded as the first CEL (Spanish Logistics Center) University Prize in 2008. Furthermore, she studied the Master of Engineering and Logistics at MIT (Massachusetts Institute of Technology).

In her research activity at ZLC he has led more than 20 research projects, collaborating with companies and entities such as Halliburton, Panalpina, P&G and the Inter-American Development Bank, among others. Her field of research focuses on urban logistics and distribution; specifically in the best practices, new development policies, innovations and modeling of urban areas for the distribution of goods. He has also participated in several projects and studies related to multimodal transport and ecological corridors, with special emphasis on rail promotion and carbon footprint. Finally, she also collaborates in research related to logistics infrastructures and air freight, and its relationship with the supply chain.

As a result of this research, he has published chapters in books such as Springer and articles in different journals such as Supply Chain Management Review, Transportation Planning and Technology, and International Journal of Procurement Management.

14:50-15:10 Room: Aula Magna

Challenges for supply chains of the future

Carolina Ciprés

Talk title. Challenges for supply chains of the future

Market trends are creating the urgent need for companies to significantly adapt the way they are organised and interlinked within supply chains. Customisation, climate changes, scarcity of resources, acceleration of the technological development bring threats and opportunities for the European manufacturing sectors, as well as for the distribution and logistics sector and lead to the need of new and reconfigured supply chains and collaboration mechanisms that shift from cost competitiveness to striving for the highest value. This talk will show:

  • industrial scenarios for 2030, based on the analysis of trends at social, economic, environmental, technological and political level and the way they may impact on SCs, in order to define how future SCs could be designed to answer the specific challenges

  • Strategic Research Agenda for the SCs of the future, where research and innovation priorities are identified for each future scenario

  • Action plan with policy recommendations and timeline for the implementation of the research priorities of the Strategic Research Agenda.

All of the above is the outcome of European project NEXT-NET, based on a top-down and bottom-up approach by involving different stakeholders: companies from process industry, discrete manufacturing, distribution and logistics, ICT providers, and consumers.

Carolina Ciprés's biography

Carolina Ciprés is Director of Research at ZLC and Chair at CNC-LOGISTICA. She is a graduate from the MIT-Zaragoza International Logistics Program with a Master of Engineering in Logistics and Supply Chain Management. She also holds an MSc degree in Chemical Engineering by University of Zaragoza. Prior to joining ZLC she worked in industrial companies from different areas such as plastic manufacturing, foodstuff, ICT and environmental engineering. She has participated in R&D projects on a national and European level in the fields of supply chain security and risk management, logistics clusters, sustainability, urban mobility and new trends in supply chains.

15:10-15:30 Room: Aula Magna

SmartDriving: Development of a real-time intelligent driving assistant for the Grupo Sese road transport

David Escuin Finol

Talk title. SmartDriving: Development of a real-time intelligent driving assistant for the Grupo Sese road transport

Grupo Sese and ITANNOVA, (Technological Institute of Aragon) have the pleasure of presenting the SmartDriving project, an innovative solution aimed at the drivers and traffic managers. The solutions, already in a production environment with more than 100 vehicles, facilitate the decision making thanks to the development of real time smart systems that leverage of the huge amount of telemetry data (speed, position, fuel consumption) generated by tractors and trailers apart from other relevant information such as business agreements and external data.

These real-time decision support systems gives recommendation of speed, timing and stops to the drivers in concordance with the time windows of delivery and always seeking a global reduction of fuel consumption. SmartDriving analysis periodically the telemetry data, perform multiple processes to remove outliers and get valuable information and maps the geographic coordinates with a geographic information system.

With the help of a customized navigation software, drivers receive information of traffic instructions, radar warnings and estimated time of arrival (ETA). In addition to this, Grupo Sese has set up a personalized reliable path network to ensure that trucks move on low consumption and cost zones (avoiding tolls) and drivers have their resting time on stops with security cameras.

David Escuin's biography

David Escuin Finol is PhD and Computer Engineer at the University of Zaragoza since 2005. He is working at ITAINNOVA (Technological Institute of Aragon) as technical and researcher in areas such as logistics, transportation and process optimization within the line of the industrial processes. His main areas of interest are transportation optimization, dynamic vehicle routing problems, scheduling and planning, intelligent transportation systems. Following the evolution of the digital techniques, David drives the innovation of blockchain as part of the Industry 4.0 ecosystem. David also collaborates in UNIR (International University of La Rioja) as a teacher in the Master of Software Engineering and Computer Systems and Master of Logistics Management.

15:30-16:00 Room: Aula Magna
Panel Discussion.
Moderator: Carlos Sagüés
Panelist: Susana Val, Carolina Ciprés, David Escuin Finol




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