IMS-MTP for Consumer Goods IndustryMTP PROGRAM: SUSTAINABLE MANUFACTURING

IMS Manufacturing Technology Platform meeting

Barcelona 19 September 2011

Emanuele CarpanzanoRosanna Fornasiero

Why an IMS Manufacturing Technology Platform on Consumer goods Manufacturing ?

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Global population trends379 Millions people aged 80 or over are expected for 2050Ageing

Currently around 10 per cent of the total world's population live with a disability

Disabled

Overweight In 2008 1,5 billion adults, 20 and older, were overweight

New Workers 23 million persons in the EU27 have a work-related health problem

ChildrenIncreased prevalence of allergy in “westernised” countries. Overweight can range between 21 and 36 %.

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Global lifestyle trends

For the first time in history, the majority of people live in urban areas.

Urbanization

SustainabilityNew consumer market for “green “ product is worldwide increasing.

High performances

New products are expected to be more and more “highly performing”

Products are custom-designed and marketed to ever-smaller segments of consumers, even to individual level.

Individualization

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Consumers Needs are Globally GrowingFootwear Clothing Accessories

Professional Safety

Sport

Childs

Disables

Obese

Eldery

Footwear Clothing Accessories

Professional Safety

Sport

Childs

Disables

Obese

Eldery

Which are the European strategies and actions to face such challenges?

FOOTWEAR P&P ETP

SPORT ETP

TEXTILE ETP

Other Consumer goods sectors …

Consumer Goods Strategic Research Agenda

Technology - Processes

Consumer goods - Products

Co-operation among sectors

Prosumer.Net Initiative

Strategies: development of technology roadmaps

Common socio-Common socio-economic drivers & economic drivers & challengeschallenges

Safety & sustainability in production and consumption

Health, well-being & activity of an aging & individualising population

Satisfying needs & desires of a growing global consumer class

Common Strategic Research ThemesCommon Strategic Research ThemesSRT1 Multifunctional products for specific uses & applications

SRT2 Intelligent manufacturing & the smart value chain

SRT3 New design and product life-cycle concepts

SRT4 Customisation, Personalisation & Consumer Empowerment

European Consumer Goods Research Initiative Networking European Technology Platforms addressing Design-based Consumer Goods Industries and Related Research and Technology Fields

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Actions: running European projects

Towards a common IMS

initiative

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The CoReNet Project

Supply andDistributionNetworksDesign

Collaborative Planning Forecastingand Replanishment

CAD -PDM

Eco - monitoring

Healt medicalSensoring

Digital Printing Laser Engraving

LCA evaluation

Methods, tools and technologies for sustainable small series industrial value creation of health fashionable goods like clothing, footwear and accessories for special categories

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The FASHION-ABLE Project

Product Development ServicesProduct Development Services

Co-design interface

PDM -LCA

(PLM)Process control

and mngt.

New CAD-CAM functionsNew CAD-CAM functions

Automated pattern adaptation (orthotics &

extreme atypical shapes)

Automated definition of 2D/3D areas requiring

treatment

New Flexible Manufacturing Operations and Equipment

New Flexible Manufacturing Operations and Equipment

Final ProductFinal ProductSmall batch supply of high

performing textiles and leathers

Single product finishing in specific functional areas

Medical advisorsMedical advisors

ENDUSERSEND

USERS

Performance optimization

• Functional requiremnts• Morphometric data • Style choices• Real time visualization

• Finishing specs• Material selection• 3D design

Development of new technologies for the flexible and greener production of customized healthy clothing, footwear and orthotics for consumers with highly individualised needs

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The MY-WEAR Project

Production of next generation health, safe and eco-friendly customized work-wear and sports-wear goods for specific target groups, such as elderly, disables, diabetics and obese people.

Which are the main features of the joint IMS initiative?

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TARGET GROUPSHEALTH & SAFETY PROBLEMS(clothing, footwear and orthotics)

PRODUCTREQUIREMENTS

PRODCUTION TECHNOLOGIES ENABLING PRODUCT

CUSTOMIZATION

PHYSICAL AND/OR PHYSIOLOGICAL

BARRIERS

REDUCED MOBILITY

OR WEAKNESS

BODY SHAPE

DIVERSITY

SENSITIVITY DISORDERS

Venous diseases

Higher vulnerability to fire

Increased moisture

Risk of slips, trips & falls

Put in/out difficulties

Restricted movements

Lower energy consumption

Impossible or poor fitting

Hygiene difficulties

Lower durability due to different wear areas

Frequent stains (saliva, mucus, urine, etc.)

Skin ulcers

Skin incompatibilities

UV intolerance

Higher vulnerability to weather conditions

Repellence (e.g. anti-drop)

Pressure control

Adequacy to joint mobility

Anti-entanglement

Shock protect. / reinforcement

Ease of use (e.g. put on/out)

Moisture management

Perspiration control

Thermal insulation

Posture matching

Anthropometry matching

Anti-microbial/bacterial

Alternative feedback

Friction control

UV protection

Anti-allergic / biocompatible

Tissue regeneration

Risk of entanglement

Flame retardant / fire-resistant

Wear resistance

Automated Individual pattern

adaptation for orthotics and

extreme atypical bodies and feet

Flexible manufacturing processes and

machines of high performing leather and

textiles

flexible finishing processes and

cells for treatments of

textiles/leather and finished

products

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IMS initiative structure

Obese

Diabetics

Elderly

Disabled

MARKET NICHES

NEEDS

BODY SHAPE DIVERSITY

REDUCED MOBILITY

SENSITYVITY DISORDER

Childs

…

Con

sum

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Nee

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Prod

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Proc

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Core values driving IMS initiative

• HEALTH, SAFETY AND SUSTAINABILITY OF PRODUCTS: to ensure wellbeing and health to consumers

• PERSONALIZATION AND CUSTOMIZATION OF PRODUCTS: to satisfy consumers specific expectations and needs

• FLEXIBLE PRODUCTION TECHNOLOGIES: for high quality personalised consumers products manufacturing

• INTEGRATION ALONG THE SUSTAINABLE SUPPLY CHAIN: to ensure coordination along networks and to manage and monitor supply chain according to also environmental respect

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To create a framework for consumer goods design, production and distribution in sustainable networks

The IMS-MTP activities will act at the following levels

Product level (CAD-CAM, LCA, Materials)

Process level (automation, machinery)

Network level (SCM, ERP)

IMS R&D activities of the MTP

Customer integration level (web, ICT, PoS)

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Dissemination

P1. Reference Framework for Collaborative Supply Networks

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Inte

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Pilot demonstration for health fashionale shoes

P4. Rapid manufacturing technologies and

processes for small series industrial

production

P3. Sustainable Methods and tools for production

distributed planning

P2. Innovative consumer-cooperative environments

for product design

Market interaction

tools

Co-design(CAD/PDM)

and LCA

Eco Track and trace

Supply network configuration

Advancedlaser

engravingand

marking

Capacity Planning Forecasting and Replenishment

Consumer KB interaction

tools

Tools for co-planning and distribution

Rapidmanufacturing

machinesP5.

IMS Task

IMS Task

IMS Task

IMS Task

IMS Tasks in the EU projects : Project CoReNet

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WP1: End -user productspecifications

WP0: Management activities

WP7: Explotation and dissemination activities

IMS Task

IMS Task

IMS Task

IMS Task

IMS Task in the EU projects : Project FASHION-ABLEIMS Tasks in the EU projects : Project FASHION-ABLE

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IMS Task

IMS Task

IMS Task

IMS Task

IMS Task

IMS Tasks in the EU projects : Project MY-WEAR

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IMS activities Customer-interactive design

The task will be based on the collaboration of European partners with Human Solution, Inc. (USA), a company with large experience in USA market for what concerns basic and applied technologies of human modelling, CAD technologies, ergonomics and industrial science, 3D image processing. In particular it will be possible to integrate their competences and developments in the project for the Development of 3D Scans of obese people in the US and the Integration of the Scans into partner’s process chain for designing clothing

International reference models for collaborative consumer-driven supply networks The task will be based on established collaboration of some European partners with ITESM a.k.a Tecnológico de

Monterrey (Mexico). Thanks to past collaborative experience with European scientific world through projects like ECOLEAD and COIN, the Institute can contribute in the domains of supply chain management, extended enterprises and dynamic virtual enterprises domains, especially in new manufacturing operational models (e.g. build-to-order supply chains). They can provide useful support for implementation of Reference model for Supply Chain Network as well as for the definition of Supply Chain Services according to their previous experience also in other sectors to transfer concepts useful for TCFI.

International demonstration This task will further extend demonstration activities outside Europe thanks to IMS network. In particular some possible

international demonstration will be especially based on existing distribution network of industrial companies in the European project since some partners have shops in Korea and in USA where it could be possible to test cooperative management of product delivery through joint visibility and replenishment of products throughout the supply chain. It will be possible to test with other Korean partners like DGen and Korean i-fashion some of the practices on collaborative design and supply chain management.

IMS Tasks in the EU projects: illustrative examples

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Complementary partners along the value chain

Networks

US Mex KorCHEU

Process

Product

Customer Integration

Structuring the international research

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MTP Activities

Activity 2 - Workshops & Dissemination - International workshops are planned during the period of this initiative once a year. Furthermore, members of the initiative will organize sessions during known relevant conferences like for example CIRP, ICE, APMS and PRO-VE conferences and plan to write conjoint papers on special issues in scientific journals etc. Industrial visits will be programmed during the MTP-initiative.

Activity 1 - Common R&D activities - Common R&D activities on Technologies and Paradigms for Customization and Production of Healthy and Sustainable Consumer centred Products will be identified and addressed among different IMS regions.

Activity 3 - Targeted experts exchanges - This activity involves visits of experts to other’s places with concrete targets, for example: common work on a specific task of a project of the hosting organization, writing of a common paper, preparation of a new project, visit of production and sales facilities, etc.

Activity 4: Promotion of New research initiatives - Identification and formulation of new research requirements and projects. The outcome will be a set of recommendations for future research at IMS level and the launch of new specific R&D initiatives.

Activity 5: International R&D Roadmap for consumer goods industry - develop a full multi-annual roadmap for IMS research programs on Consumer Goods manufacturing, in strict relation ship with the running Prosumer.Net coordination action.

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1 Sem 2012 2 Sem 2012 1 Sem 2013 2 Sem 2013

ACTIVITY 1 COMMON R&D ACTIVITIES

ACTIVITY 2 WORKSHOPS & DISSEMINATION

ACTIVITY 3 TARGETED EXPERTS EXCHANGES

ACTIVITY 4PROMOTION OF NEW RESEARCH INITIATIVES

ACTIVITY 5INTERNATIONAL ROADMAP FOR THE CONSUMER GOODS INDUSTRY

MTP Timeline

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Partners

• Human Solutions, INC (USA)• University of Michigan (USA)

CoReNet, MyWear, Fashion-able & Prosumer.Net EU partners (Synesis, CNR-ITIA, DITF, INESC Porto, IBV, Assyst, Base Protection, …)

• Korean i-fashion center (Korea)• DGen (Korea)

• ITESM a.k.a Tecnológico de Monterrey (Mexico)

• Ergosoft (partner of CoReNet project)• SUPSI (partner MyWear)• Longhi (partner MyWear)

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Contacts

THANK YOU!

Emanuele Carpanzano, Rosanna Fornasiero

Institute of Industrial Technologies and Automation

National Research Council

Via Bassini 15, 20133 Milano (Italy)

Ph. +39 02 2369 9914

Fax. +39 02 2369 9941

E-mail: emanuele.carpanzano@itia.cnr.it; rosanna.fornasiero@itia.cnr.it