e-Science

1. e-Science e-Manufacturing: Fundamentals, Applications and Potentials Professor Kai Cheng Advanced Manufacturing & Enterprise Engineering (AMEE) Group School of Engineering & Design, Brunel University Uxbridge UB8 3PH, UK Tel: 08195-267255 Fax: 08195-269703 email: kai.cheng@brunel.ac.uk Dr Richard Bateman CERAM Research Ltd Queens Road, Penkull Stoke-on-Trent, UK. ST4 7LQ Tel: (0) 1782 764349 email: richard.bateman@ceram.com

2. Outline of the presentation e-Science • Background • - Why e-manufacturing? • - What is e-manufacturing? • e-Manufacturing fundamentals • - Internet enabled technologies • -Advanced technologies for e-manufacturing • - Internet and manufacturing knowledge management • - Computing infrastructure for e-manufacturing • e-Manufacturing applications and potentials • - Collaborative design and product development • - Mass customization and customer oriented e-manufacturing • - Remote control and condition monitoring • - Virtual manufacturing and systems • - e-Supply chain management • - e-Enterprise and global manufacturing • Conclusions and the future ‘standing’

3. e-Science Why e-Manufacturing? • The characteristics of e-manufacturing emphases the new philosophy through which manufacturing will be operated in integration with Internet technology. e-manufacturing philosophy results from that the way people work is being changed by the Internet, for instance: • Digitisation • Globalisation • Mobility • Collaborative work • Immediacy

4. e-Science Manufacturing globalization - e-Manufacturing (1) Manufacturing Design Sale

5. e-Science Distributed manufacturing - e-Manufacturing (2)

6. e-Science Development of manufacturing technology Manufacturing e-Manufacturing Agile Manufacturing Digital enterprise Technology CAX & Concurrent Engineering engineering tools TQM, MRP II & Just-In-Time engineering tools • High precision • Automation TQM & Lean Manufacturing engineering tools Computer Integrated CAD/CAM, DNC Manufacturing & robotics Group technology Flexible Manufacturing & CNC, robotics Production line Mass Production & automation Towards 21st Century

7. e-Science Transformation by e-Manufacturing • Mass production • Long pipeline • Sale from stock • Sequential processes • Cost of inventory • Wait in line • Mass customisation • Shrinking supply chain • Make to order • Simultaneous processes • Capital working • First available slot • - Manufacturing 2020 Foresight Report

8. UK e-Science research program (2001 onward) e-Science • What is meant by e-Science? In the future, e-Science will refer to the large scale science that will increasingly be carried out through distributed global collaboration enabled by the Internet. Typically, a feature of such collaborative scientific enterprises is that they will require access to very large data collections, very large scale computing resources and high performance visualisation back to the individual user scientists. • The Core Program has been structured around 6 key elements: • A national e-Science centre linked to a network of regional grid centres • Generic grid middleware and demonstrator projects • Grid ‘IRC’ research projects • Support for e-Science testbeds • Participation in international grid projects and activities • Establishment of a grid network team • - http://www.rcuk.ac.uk/escience/

9. EU 6th Framework - IST program (2004 onward) e-Science • Applied IST research addressing major societal and economic challenges: • Towards a global dependability and security framework • Networked business and government • e-Safety for road and air transport • e-Health • Technology-enhanced learning and access to cultural heritage • Applications and services for the mobile user and worker • Cross media content for leisure and entertainment • Grid-based systems for solving complex problems • Improving risk management • e-Inclusion • Products and services engineering 2010 • - http://www.cordis.lu/ist/activities/activities.htm

10. e-Science What is e-Manufacturing? - (1) e-manufacturing covers a range of online manufacturing activities for products and services, including product design, production control and conditions monitoring, supply chain management, maintenance and sale services, etc., through the Internet/Intranet/Extranet and grid computing infrastructure.

11. e-Science What is e-Manufacturing? - (2) e-manufacturing is the complete electronic (computer systems and networks) integration of all factory components. Users range from operators to technicians to engineers to managers. - UK Industrial White Paper (2002)

12. e-Manufacturing fundamentals e-Science • Internet Enabled Technologies • - HTML • - Java programming • - XML • - Client/server architecture • - Java database connectivity • Advanced Technologies for e-Manufacturing • - Agent technology • - Multi-agent systems • - Data mining and knowledge discovery • - Grid computing • Internet and Manufacturing Knowledge Management • - Internet characteristics • - Design agility and the Internet • - Manufacturing responsiveness and the Internet • - CBR and web-based computational intelligence • Computing Infrastructure for e-manufacturing • - Software tools • - Hardware • - Networking • - Implementation

13. e-Science e-manufacturing applications Application (1) - case studies - Web-based bearing design support systems - Web-based manufacturing assembly simulation - Web-based intelligent (CBR) selection of cutting tool inserts - Modelling and simulation of the extended enterprise operations based on dynamic Petri nets - Remote condition monitoring and control of manufacturing systems - Creative design search engine - RFID application for diamond cutting tools’ tooling service Application (2) - devolved manufacturing

14. Web-based Intelligent (CBR) Selection System for Cutting Tool Inserts e-Science A proposed system architecture… Main CBR loop Standard e-Catalogue search CBR validation loop Language selection

15. Modelling and Simulation of the Extended Enterprise Operations Based on Dynamic Petri Nets e-Science INTERNET ORGANISATION MODELS PROCESS MODELS CO-ORDINATOR DESIGN MANAGEMENT MANUFACTURING ENTERPRISE INTRANET/ INTERNET REAL-TIME VISUALISATOIN JAVA SIMULATION DATABASE INTRANET/ INTERNET RESOURCES PRODUCTS EVENTS EVENTS

16. Remote Condition Monitoring and Control of Manufacturing Systems e-Science

17. Creative Design Search Engine … e-Science A search engine for innovative/creative … • 3D models • …… • …… • …… • …… • …… • …… • …… • …… • …… • …… • …… Creative Design & Innovative Manufacturing

18. Look up Geometric images Specification User information Re-sharpening records …… Read Host System with Tool Database Reader Tagged Cutting Tools T1…TN Update Identify Reading Successfully Host system with Tool Database Reader Tagged Tools Antenna Diamond tools tracking and servicing support sys RFID Application for Diamond Cutting Tools’ Tooling Service e-Science

19. Selected ‘Milestone’ Publications (in e-manufacturing) from the AMEE Group e-Science Books: (1) K. Cheng, D. Webb and R. Marsh, Advances in e-Engineering and Digital Enterprise Technology I (Editors), Professional Engineering Publishing, London, September 2004. (2) K. Cheng, e-Manufacturing, Fundamentals and Applications, WIT Press, London, February 2005. Journal Papers: (1) K. Cheng, P.Y. Pan and D.K. Harrison, Internet as a tool with application to agile manufacturing: a web-based engineering approach and its implementation issues, International Journal of Production Research, Vol.38 No.12, 2000, pp.2743-2759. (2) K. Cheng, P.Y. Pan and D.K. Harrison, Web-based design and manufacturing support systems: implementation perspectives, International Journal of Computer Integrated Manufacturing, Vol.14 No.1, 2001, pp.14-27. (3) K. Cheng, M.L. Yang, G.E. Taylor and A. Dow, Petri net as a tool with application in modelling an Internet based virtual manufacturing enterprise, International Journal of Agile Manufacturing, Vol.4 No.2, 2002, pp.100-109. (4) J. Toussaint and K. Cheng, Implementation of design agility and manufacturing responsiveness on the web: two case studies, Integrated Manufacturing Systems, Vol.13 No.5, 2002, pp.328-339. (5) R. Bateman and K. Cheng, Devolved manufacturing, Concurrent Engineering: Research and Applications, Vol.10 No.4, December 2002, pp.291-297. (6) K. Cheng and Y. Popov, Internet enabled modelling of extended manufacturing enterprises using the process based techniques, International Journal of Advanced Manufacturing Technology, Vol.23 No.1, 2004, pp. 148-153. (7) J. Toussaint and K. Cheng, Web-based CBR (case-based reasoning) as a tool with the application to tooling selection, International Journal of Advanced Manufacturing Technology, Vol. 26, 2006. (8) R. Bateman and K. Cheng, Extending the product portfolio with ‘devolved manufacturing’: methodology and case studies, International Journal of Production Research, Vol.45, 2006.

20. Current developments in e-manufacture are generally ‘factory-centric’ Transport/logistics problems increasing (‘gridlock Europe’) New technologies are available or emerging New possibilities … Need to ‘Think outside the box’… e-Science Devolved Manufacturing – (1) Key areas for integration

21. e-Science Devolved Manufacturing – (2)

22. e-Science Mass Customisation MASS PRODUCTION Outcome of industrial revolution Driven by production and cost needs Concept developed in 1980’s Increases product range by allowing customers to choose from range of options Needs to be set up with care to avoid extra overheads associated with increased product variety MASS CUSTOMISATION MASS ‘INDIVIDUALISATION’ Ultimate goal of MC ?

23. e-Science Rapid Manufacturing (RM) 1. The CAD model is sliced into layers 2. RM machine ‘creates’ model 3. Finished Object

24. e-Science End-user & Practitioner Surveys Breakdown of Systems by Type Rise in Annual Sales of RP/RM machines (000’s) Number of Patents Issued for RP/RM Technology Global RP/RM Installations

25. e-Science Case One – CAL system Typical Race Clutch Construction Central Splines in Friction Plate Hub

26. e-Science Case One – CAL system System Menu Search Existing Products Input Spline Dimensions View 3D Model Send files for manufacture Test Mfg at Brunel

27. e-Science Case Two – wydiwyg.co.uk Use mini-CAD program Home page Details Download mini-CAD program View model in 3D Stage ONE Stage TWO

28. e-Science Case Two – wydiwyg.co.uk Home Page Upload CAD file Make payment Register Find outlet Confirmation Outlet details Test part Stage THREE

29. e-Science Case Three – Creatorium Portal Stakeholders in the CREATORIUM Portal

30. e-Science Case Three – Creatorium Portal CREATORIUM relationship with Cases One and Two

31. e-Science Discussions • Implementation key issues • Start points and direction • Organisational issues • Technology adoption • Strategies for DM • Design, legal and ethical issues • Control and management of a DM venture

32. e-Science Acknowledgements • EPSRC • Royal Society • DTI TCS / Faraday Schemes • NATO Scientific Program • HEFCE • SHEFC

33. e-Science Thank You!