Sustainable upscaling through digitalization of manufacturing processes

Danish manufacturing requires flexible and agile production systems to enable new products and components to be implemented faster with less waste to follow.

By developing virtual models of the manufacturing system through so-called digital twins, companies can simulate and optimize production and production equipment designs prior to and during real-time production. This saves time and materials in the ramp-up of production and at the same time eliminates costly errors or flaws before production begins. Digital twins can also assist companies with better decision-making regarding new ideas and concerns about maintenance and design.

Listen to the leader of the strategic effort Sustainable Upscaling Through Digitalization of Manufacturing Processes Jesper Henri Hattel explain the effort.

This strategic initiative will focus on:

  1. Digital twins and real-time digital “shadows” of production processes
  2. Offline and online optimization of production processes through the digital twins and ”shadows”.

Purpose

The purpose of workstream 4 Sustainable upscaling through digitalization of manufacturing processes is to optimize production processes and improve product quality by applying digital tools and data driven models that reduces the time to ramp-up a new production and ensures “first time right” for new products.

”It is about improving the production equipment and production of products using digital tools. For example, LEGO Group and Beckhoff are collaborating with DTU on using data analytics to rapidly prototype new, high precision production moulds for the production of eco-friendly polymer components,” explains Jesper Henri Hattel, Workstream Leader and Professor at the Technical University of Denmark.

It is about improving the production equipment and production of products using digital tools

Jesper Henri Hattel, Leader of the strategic initiative and Professor at the Technical University of Denmark

Contact:

Jesper Henri Hattel

Professor

Mail: jhat@mek.dtu.dk

A tool for decision-making

”Digital twins provide manufacturing companies with a snapshot of the conditions in the production line. More advanced versions will help companies evaluate, whether the conditions are good or bad and subsequently present a plan for action,” Jesper Hattel says.

There are fundamentally two methods regarding data analysis: Data-based or model-based. ”The data-based method looks at previous data and utilizes machine learning with the goal of discovering useful information, informing conclusions and supporting decision-making.. Model-based analysis is a method of analysis that uses mathematical and software-based modeling to perform simulated analysis of many conditions and designs,“ the Workstream Leader explains.

The goal is to combine the data-based and model-based methods of analysis through the use of digital twins in order to create a system that helps companies improve their decision-making processes.

”I very much look forward to following the projects in Workstream 4. The approach of combining these methods by the use of digital twins and benefitting from them in the physical world is exciting. In the future, we will witness more solutions like this,” Professor Jesper Hattel adds.

Parties in the strategic initiative

Companies

Addifab
Beckhoff Automation
C.C. Jensen
CIM.AS
Haldor Topsøe
JP Air Tech
LEGO Group
NIL Technology

Nordic Foam Group            
Novo Nordisk
Plus Pack
Rockwool
Siemens
Technicon
Universal Robots
Vestas

Universities

AU
DTU
SDU

RTOs

Teknologisk Institut
FORCE Technology
Alexandra Instituttet

SME development projects

The Sustainable upscaling through digitalization of manufacturing processes initiative contains five development projects where the Danish Technological Institute is assisting Danish SME’s in the development and application of digital manufacturing processes.

The SME Addifab has been a part of the MADE collaboration for several years and has successfully completed a demonstration project in 2017. This time around, Addifab has intensied their involvement with theinitiation of  an advanced research project to continue the development of their unique 3D printing process and ensure that the SME maintains a strong competitive advantage:

”Addifab is an industrial partner in the workstream. They have developed Freeform Injection Moulding (FIM) and together we will create a prototype for a UV light projector,” Jesper Hattel explains.

The light projector is a vital component in Addifab’s additive manufacturing process: The projector selectively shines ultraviolet light on a fluid that reacts to the ultraviolet light and hardens as a result. Afterwards, it is possible to build on top of that layer by layer. The goal in this project is to improve this innovative manufacturing process and drastically cut costs associated with it.

Virksomheder samarbejder i MADECompanies join forces in MADE

”The MADE approach where companies work closely together is unique. We strive towards knowledge sharing – even between companies. The MADE network is something quite special and not possible in many other countries, “ Professor Jesper Hattel says, and he adds: ”Some companies will test the innovative research results directly on the factory floor which was not possible before. This kind of validation is second to none.”

The biggest benefit for the companies?

”Companies wish to save time and material resources and initiate proactive improvement actions, driving productivity and reducing costs. They will be capable of correcting when necessary and this will entail a new way of optimizing resources,” Jesper Hattel concludes.

Thematic leaders

  • Peter Gorm Larsen, professor Aarhus Universitet
  • Christoffer Sloth, lektor Syddansk Universitet
  • David Bue Pedersen, Senior researcher DTU
  • Murat Kalachi, Associate professor DTU
  • Matteo Calaon, Senior Researcher DTU

Jesper Henri Hattel

Professor

Mail: jhat@mek.dtu.dk