Optimised machining processes leveraging cyber-physical systems

 Machining industry in Europe is a large market that accounted for 16.6 billion € in turnover in 2013. Computer Aided Process Planning systems providing simulation for machining process optimisation have been increasingly adopted by European SMEs, still they do not leverage cyber-physical systems information to a large extend.

 

Challenge
The goal of this Application Experiment is to cloudify a Process Planning System as a CloudFlow-enabled service, hence offering cost-effective and flexible Process Planning to machining companies, especially SMEs. Technically, the dynamics of machining processes challenge the CloudFlow infrastructure with respect to reliability and integration of streamed data. The experiment is expected to lead to improved product quality, productivity and sustainability, shorter and more accurate quotations. Economically, the experiment will enhance the productivity, quality and sustainability of Powerkut – the end user in this experiment. The estimated targets are: a) cost savings in production: 20 percent - 30 percent (it is expected to save about € 200,000 per year for Powerkut when the system has been fully implemented in the company) and b) time reduction for process planning: 3-4 times faster (e.g., from 2 hours to about 30 mins for a reference part) (Powerkut is mainly for customised production and its current capacity is to process 300 customised orders per year. Using the CUSTOMISE solution, the capacity will be increased to over 1,000 orders per year).

Benefits
Powerkut is expecting cost savings in the production in the range of 20 - 30 percent (e.g., energy saving, less scrap material, etc.). It is anticipated that € 200,000 will be saved per year for Powerkut when the system has been fully implemented in the company. The time for process planning is expected to be shrunk by more than 70 percent (3-4 times faster than today). Powerkut is mainly for customised production and its current capacity is to process 300 customised orders per year. The process plan for each order will be 2 hours in the current practices. With the CUSOTMISE solution, the efficiency will be increased 3-4 times higher to be within 30 mins for planning each order. As thus, the capacity will be increased to over 1,000 orders per year. Meanwhile, the quality of the produced orders will be improved from minimum 20 micro level to 5 micro level, and 20 percent-30percent of production cost will be reduced for each order, it should to motivate higher numbers of items sold/produced in markets. For the services developed by University of Coventry a commercial solution shall be brought to the market offering these CloudFlow services especially to machining companies in aerospace and automotive sectors. 5 years after the experiment more than 100 new customers (>400 licenses) shall be acquired resulting in a revenue stream of more than 1 Mio. €.

Organizations involved
CU - Coventry University - United Kingdom
PKT - Powerkut Ltd. - United Kingdom
Arctur - Slovenia