Annual Meeting 2019

Technical Day Abstracts

Breakout Session

CAM-I Presents: Readiness Indicators for Technology Adoption and Costing for Manufacturing Competitiveness

CAM-I is an international consortium of manufacturing and service companies, government organizations, consultancies, and academic and professional bodies who have elected to work cooperatively in a pre-competitive

environment to solve management problems and critical business issues that are common to the group. Working with IMS, the CAM-I session will focus on three areas of importance to manufacturers; (1) core change

requirements for Industry 4.0 technology adoption, (2) cost management and target costing for improved competitiveness, and (3) leveraging data as a strategic asset and cost optimization in supply chains.

Keynote: Ashok Vadgama, President, CAM-I

 

This brief introduction will include a history of CAM-I, its membership, and an overview of its body of knowledge and relevance to manufacturing.​

Assessing Change Readiness

Oliver Bridge, Head of UK Operations Consulting

David Bovis, Associate Director, Operations Consulting, Grant Thornton UK LLP

This session will discuss the core change requirements for a manufacturing enterprise to prepare new operational, manufacturing, automation and/or management transformations. The participants will learn about CAM-I change readiness assessment framework and its applicability to help manufacturing enterprises gear up for changes and drive cultural adoption of intended transformation.

 

Understanding, Managing & Optimizing Costs

Natasha Teeling, Associate Director, Business Consulting

Ruth Brunskill, Manager, Business Consulting, Grant Thornton UK LLP

This session will include CAM-I’s work in the area of cost to serve and target costing. Participants will learn how cost management and target costing can help manufacturing enterprises be more competitive in their chosen markets. Case studies on customer, product and channel profitability will be discussed in this session. Participants will also learn about tools and techniques that leading organizations are employing to optimize costs and maximize profitability

Breakout Session

ASM Presents: Harnessing Materials Information for Manufacturing

Designing New Materials

Anders Engström, CEO, Thermo-Calc Software

Aziz Asphahani, Chairman & CEO, QuesTek Innovations

 

The Fraunhoffer Institute states that to ensure the digital networking of production systems and the optimization of material-specific requirements, we need to measure, analyse and replicate the changes in material properties in a process in which “digital twins” of materials are created.  To achieve this, we need to understand the process-structure-property relationships of the materials, as highlighted in the publication of the National Academies Report on “Integrated Computational Materials Engineering,” in 2008.

 

The Materials Innovation Infrastructure outlined in the Materials Genome initiative report published in 2011 also highlights the synergy between measured (experimental and physical test data), computational models (simulation) and data repositories. Indeed, to simulate the design of parts, and also the manufacturing process, requires good materials data. These data can be obtained from two sources – measured and predicted, and both are needed.

 

A challenge is that the properties of materials depend on both their chemical composition and processing conditions. Handbook data and data repositories alone tend to be limited in the scope of materials covered (their compositions) or the temperature ranges (processing conditions) or lack of time dependence. As such, the engineering simulations which depend on these data are limited, especially for cases involving novel materials and often it becomes necessary to go and measure the needed data or live with the uncertainty.

 

The CALPHAD approach captures the composition and temperature dependence of properties, as well as their temporal evolution, for industrial multi component alloys. As such, data can be simulated for materials or conditions where there are gaps in the measured data. Additionally, location specific properties can be predicted and optimized for a part, which means that manufacturers will no longer be restricted to design minimums.

 

CALPHAD simulations can be used to complement database repositories of measured data, improve machine learning models, and can also be used as input into engineering codes that require more robust materials property data.

 

Dr. Anders Engström, CEO of Thermo-Calc Software AB, the market leader in computational materials engineering software, will exemplify how their CALPHAD based tools are efficiently used to aid materials design and process optimization in a range of different industry segments.

Materials are the backbone of key industrial sectors (e.g., Aerospace, Automotive, Energy), and novel materials are needed in support of manufacturing innovations.  Reciprocally, innovations in manufacturing are presenting challenges in the materials field that require the use of informatics (due to the need for more data acquisition, management, analysis, and usage).


Within the Materials Informatics, there is a keen pursuit of High-Throughput / Big Data, Artificial Intelligence, and Machine Learning, with the view that novel compounds will be discovered by computers.  At the same time, there are ongoing successes with the Integrated Computational Materials Engineering (ICME) technologies, harnessing the use of computer power, vetted materials data, and science-based models (i.e., CALPHAD simulation tools) to design and Accelerate the Insertion of Materials (AIM) in support of manufacturing and competitiveness.

 

Successful ICME-designed and deployed novel materials (supporting competitiveness in the traditional materials manufacturing) will be highlighted with illustrations related to shortening processing time, reducing energy usage, improving performance, and providing alternative environmentally-friendly products.

 

In addition, property predictions of manufactured products, based on AIM methodologies, will be explored in support of innovative Additive Manufacturing (AM) processes.  An AIM-based Accelerated Qualification and Certification (AQC) approach for printed parts will be highlighted.  Such AQC software should successfully address the issues of AM reliability, qualification time reduction, and certifications of “minimum” design properties of AM built parts.

 

QuesTek is a global leader in the design and deployment of novel advanced materials, based on its in-depth expertise in AIM methodologies and its vast experience in ICME technologies.

Material Intelligence in Product Design and Development

Ajei Gopal, CEO, ANSYS, Inc

Dave Cebon, CTO & Co-Founder, Granta Design Ltd. (now part of ANSYS, Inc.)

Effective digital transformation is a critical corporate goal for most manufacturing enterprises.  We see this, for example, in the pervasive use of simulation technologies throughout product development, in the drive to develop Digital Twin strategies, and in the Industrial IoT and Industry 4.0 trends, which are converging the physical and digital aspects of products.  Yet, if we examine the fundamentals of what it takes to make a product, we find one area in which digitalization lags: materials.  To define a material, connect it to a product design, and track its progress through the product lifecycle requires many varied and complex datasets and associated processes. Yet comparatively few enterprises have a systematic approach in place to manage any one of these datasets, let alone to connect them to one another and to their wider engineering and business data infrastructure.  In this presentation, Ajei Gopal, ANSYS CEO (NASDAQ: ANSS), the market leader in engineering simulation technology, will discuss digital transformation in engineering enterprises, and why ANSYS sees materials as a critical missing link. This analysis led to the recent acquisition by ANSYS of material intelligence pioneer, Granta Design.  Granta CTO Professor David Cebon will review Granta’s work in sectors such as aerospace, automotive, and healthcare, which has resulted in multi-million-dollar benefits and avoidance of critical business risks through effective materials information management.  He will discuss what comes next – particularly the vision of ‘Materials 4.0’: what is needed, from a materials information perspective, to support the Industry 4.0 era? Practical examples will include how to speed up adoption of Additive Manufacturing.  The conclusion will provide a checklist of issues for executives to consider when plotting their materials digitalization strategies.

How Materials Information and Design Results Integrate with Manufacturing

Ray Fryan, Vice President, Technology & Quality, TimkenSteel Corporation, Bill Mahoney, CEO, ASM International

Integrated Computational Materials Engineering (ICME) tools are advancing component designers’ effectiveness by improving the speed and sophistication of component and system-level optimization, much like power tools have advanced the cause of homeowners tackling do-it-yourself improvement projects with greater speed, broader scope, and higher confidence.  Current state-of-the art ICME tools treat materials as homogeneous; a paradigm that, for now, places limitations on component designs that can have significant (and high) stress concentration.   For applications that experience cyclical fatigue, component damage often occurs at material inhomogeneities, such as nonmetallic inclusions in engineering steels.  To optimize the load-carrying capability of an engineering material in-application requires a much more thoughtful and sophisticated approach.  Designers will benefit from tools that help find the design with maximum power density at minimum total mass that still meets fatigue life expectations.  For existing designs, being able to assess load increase potential also provides the benefit of avoiding major redesigns via the appropriate engineering definition of materials needed.

Such sophistication requires quantification of the fatigue behavior at a local level based on realistic representations of material inhomogeneities.  For example, in engineering steels carrying high cyclical loads, the nonmetallic inclusion population is a primary source of such ‘material uncertainty’.  These nonmetallic inclusions can lead to fatigue damage and an earlier-than-intended fatigue life limit.  Because current ICME tools lack the quantitative analytics to predict when such material uncertainty risks are being designed-in (or designed around), most high cycle mechanical components are over-designed – intentionally, or otherwise.  TimkenSteel has created an analytical model that pragmatically frames how highly loaded, highly cycled component can be optimized for total cost of the design-in-use; avoiding both overdesign and higher-than-intended risk created via material uncertainty.  This method leverages the wealth of quantitative empirical nonmetallic inclusion data TimkenSteel has generated as realistic inputs to that analytical model.  Ray will describe a successful case study using these analytical methods that frames a significant value proposition in the arena of power-densified, high performance components manufactured from premium clean steels.

Breakout Session

SAP Presents: Advanced Methods and Best Practices for a Connected Reality. Design, Manufacturing, Delivery and Operate

The session will explore challenges and solutions toward transforming a factory to become digital, open, collaborative, and smarter. Follow SAP and some of its most experience partners in a passionate journey, sharing a digital view of the end-to-end process from design to operate within the Intelligent Enterprise.

 

We aim to support companies in thinking about how to connect the business processes digitally, so they can introduce speed to decision making and really focus on the customer, provide total visibility with a digital twin of the entire supply chain to predict outcomes, and drive business innovation by turning data into insights that feed new business models.

SAP will also present new technologies to move to demand driven production with a customer focus to enable smart factories that sense and respond to changes in supply and demand, moving from continuous production lines to adaptive production cells that can deliver individualized products. Participants will leave with a better understanding of new digital technologies, how they are implemented, and results that can be achieved.

Among the topics to be discussed are:

• Intelligent Manufacturing for the Intelligent

Enterprise: Digital Trends and Digital Challenges

• Customers references and digital cases on product

engineering, planning and scheduling, manufacturing

operations, data analysis and predictive technology

• Customer round tables

INDRA Empower the Intelligent Factory Through SAP MII - Implementation & Case Studies

Andrea Ferramosca, INDRA

Santi Maisano, INDRA

Through the sharing of successful implemented cases, the main advantages of SAP MII solutions will be illustrated with particular reference to the Intelligent Factory. The speech will focus on real case studies to show how integration and automation across the supply chain processes in steel and consumer goods industries are empowered, thus obtaining the simplification of procedures and reporting both for the end user and business management team.

Innovative Math Model For Production Optimization
Altea UP Robochain | VIBRAM Success Story

Virginio Basilico, Group IT Manager at VIBRAM SpA

Roberto Gemma, CEO ALTEA UP

 

Vibram is the most well-known brand of Made in Italy in the sector of technical, sporting and luxury soles.
The case is a concrete example of how the digital transformation can provide the best answer to personalized production requests. Altea UP Robochain, the solution part of “ Altea UP Intelligent Factory Suite”, is the personalized math model based on Customizable Variables that was  implemented in Vibram (it’s based on Sap Cloud Platform).

Vibram objectives was aimed to optimize the production process, to provide the optimal use of the soles’ production and moulding lines to obtain a Time to market competitive advantage to customer’s requests. Altea UP Robochain enable the simulation of different production scenarios based on the different market needs, Increasing the production volume, reducing the Time to market, costs and improving the company know-how sharing . Come and see the positive outcomes of Vibram experience. 
 

Altea UP Robochain is the  outside the box  solution | Where the rigidity of the scheduling algorithms fails, comes its flexibility

 

Integration, Traceability and Predictive Quality in the Steel Industry

Nicola Segnali, Business Innovation Manager, Clarex       

Alessandro Milan, Group Quality Manager, Feralpi Group  

Feralpi Group is one of the main steel producers in Europe, specialized in steel for constructions as well as special steels and cold rolling.
One of its key challenges in the products’ quality is represented by traceability.

Clarex has supported Feralpi Group in the development of a bespoke solution which guarantees a complete traceability along the whole supply chain. Clarex is a SAP Gold Partner and provides its customers with end-to-end digital solutions for their business development. 

Digital Transformation Made from Experience

Espedia Consulting

Espedia, SAP Partner, supports companies in the Digital Transformation process, proposing innovative solutions

and applications for aligning business strategies with business priorities. Since 2003, Espedia has a consolidated experience in SAP projects thanks to a highly specialized team with solid know-how in different industries and it is a reference partner for companies that choose to deal with new scenarios with innovative technologies able to

integrate the Manufacturing Execution with the Product Development Processes (PLM), in the field of Smart Manufacturing, Intelligent Asset Management, Internet of Things and Industry 4.0.

The innovative companies - which want to run innovative and intelligent tools to Think, Design, Produce, Delivery

and Maintain products and services for their customers - find in SAP the technological platform and in Espedia the

partner at their side, who offer and implement world-wild efficient solutions.

Keynote Session Led by KPMG

Carmelo Mariano, Customer and Operations, KPMG

Legendary exotic car maker Lamborghini decided to shift gears on production and build a new smart factory from

the ground up for its new Urus – the world’s first “super sport utility vehicle.”

 

The famous auto manufacturer turned to KPMG’s experts for their guidance and collaboration as it set out to build what would be its first factory of the future. The Industry 4.0 journey began with a targeted customer market in

mind for the new model. And with a clear understanding of the needs and preferences of the targeted market

segment, the client and KPMG collaborated on a comprehensive Industry 4.0 strategy that defined how the factory, its technology and its processes should work.

 

With a strategic Industry 4.0 roadmap and its precise objectives in hand, KPMG developed and implemented the complex IT platform that manages manufacturing operation in the entire assembly and finishing halls. The factory features an unprecedented modular design, using digital sensors and robots in a collaborative environment.

 

Boasting the most-advanced Industry 4.0 standards, the futuristic facility merges virtual worlds and live production by integrating robotics and machine-to-machine collaboration with Lamborghini’s skilled production workers. Each vehicle moves along the production floor via automatic guided vehicles (AGVs) that autonomously transport each car to the appropriate work island.

 

Electronic monitoring, data collection and reporting from

every corner of the shop floor are available instantly and workers can control every aspect of production on site–or remotely from any location – using tablets that fully eliminate reliance on paper documents.

Connect Digitally to Perfect Manufacturing

Customer Roundtable

Moderator: Mike Lackey, SAP

Breakout Session

PDES, Inc. Presents: Standards Enable Effective Implementation of Industry 4.0 Solutions for OEM's and their Supply Chains 

Keynotes:

Standards Enable Effective Implementation

Dr. Michael R. Jahadi, President & Chairman, PDES, Inc.

This discussion will address the question from both an OEM and supply chain perspective. Effective digital transformation and having an integrated Supply Chain is a critical corporate goal for most manufacturing enterprises. The Fourth Industrial Revolution is an interconnected group of technology enabled functions that can provide increased sustainability and growth opportunities within Advanced Manufacturing Enterprises. To improve Industry 4.0 interconnectivity, technical standards act as key enablers. The aerospace value chain is becoming increasingly global in nature, with suppliers in many countries supporting manufacturers in the US and Europe, across many home markets. This implies the use of global standards and the value of exploiting such standards.

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Importance of Standards, Targeted at Specific Industry 4.0 Pillars

Robert E. Mansfield, Strategic Director, IMS International

 

Standards organizations like PDES are important enablers to achieving the promise of I4.0. The importance of standards, targeted at specific Industry 4.0 pillars; i.e. IOT, Systems Integration, Augmented Reality and Autonomous Systems.  The complexity of harmonizing the standards needed to move forward means some serious thinking outside stove pipes.  This will be likely very difficult as the mind-sets of varying constituents in the pillar stovepipes needs to be addressed.  

 

Keynote: Interoperability Standards Synergise Industry 4.0 for Value creation in the Aerospace Industry

Jean-Pierre Souzy, VP Engineering Methods & Tools, Airbus

 

The Aerospace Industry faces unprecedented challenges, in terms of quality, reliability and costs of the new products.

The safety exigency remains at the top, together with the respect of all certification requirements. The customers –

the airlines – expect at the same time a reactive delivery of their orders, with the ability to customize the aircraft till the very last steps of the production process and an excellent operational reliability of the product. The pressure on cost is higher and higher, together with the request to integrate to the product the latest technologies

and lower the environmental footprint. In this context, the seamless continuity of the information throughout the information systems backbones of the Company is of high importance. The PLM (Product Lifecycle Management), the ERP (Enterprise Resource Planning) and the Support and Service Information Management Systems need to share and manage the same data in configuration not only in the different Functions of the Company at the different steps of the Product Lifecycle, but also with the Extended Enterprise encompassing the overall Supply Chain. Interoperability Standards and associated Interoperability Forums, aiming at speeding up the deployment of interoperable solutions based on these standards, are a key value creation lever to support the digital

continuity. They enable to propagate from Design to Operations, going through Manufacturing and simplify the interconnection and automation of the different components of the Production chain, mobilizing architecture frameworks, modelling languages, smart manufacturing components, IoT, and building on emerging 5G networks capabilities. The way Airbus considers the development of Interoperability Standards will be presented and discussed.

 

Panel Discussion

 

Panel of industry experts will talk about the utilization of technical standards to reinforce and improve business performance.

 

MODERATOR: Rebecca Taylor, Senior Vice-President National Center for Manufacturing Sciences

PANELISTS:

Dr. Michael R. Jahadi, President & Chairman, PDES, Inc.

Robert E. Mansfield, Strategic Director, IMS International

Jean Pierre Souzy, Vice-President Engineering Methods & Tools, Airbus SE

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