DMDII

DMDII (5)

McKinsey & Company and the Digital Manufacturing and Design Innovation Institute (DMDII), a UI LABS collaboration, announced the launch of the North American Digital Capability Center (DCC) – a unique digital manufacturing learning center offering company leaders and their workforces hands-on experience and workshops in next generation technology to help them advance their operations, design and productivity.

“Digital manufacturing will disrupt every business in every industry, pushing leaders to reinvent their operations and retrain their workforces,” said Enno de Boer, McKinsey partner and digital manufacturing leader. “The North American Digital Capability Center joins McKinsey’s global network of 15 Model Factories, which bring together more than 15,000 leaders every year to ask and solve their businesses’ toughest questions around transformative technological change and the benefits their companies and workers can recognize from the latest digital technologies.”

The North American DCC brings McKinsey’s deep expertise in digital manufacturing, automation and business transformation to Chicago, at the crossroads of America’s manufacturing base. It aims to not only help America’s leading manufacturers adapt to new technologies but also to help the next generation grow - preparing smaller and mid-size companies to innovate, while nurturing start-ups.

The facility offers:

Digital showcases: Over time, companies will be able to explore more than 20 themes related to digital manufacturing, including showcases dedicated to digital performance management, digital standard work, predictive maintenance, and wearables and augmented reality.

Experiential capability-building workshops:
Leaders from companies of all sizes can sign up for one-day workshops designed to build awareness of digital manufacturing, and managers and their teams can take advantage of multi-day workshops to equip them with necessary skills to undertake digital transformations within their organizations.

The DCC mock line transforms in stages from a current, non-digitized line into a higher-performing, digitally driven production line of the future that includes advanced analytics, augmented reality and digital assistance for the operators. In the coming months, it will include collaborative robots (cobots) and artificial intelligence.

The DCC is digitally connected to four additional McKinsey DCCs in Singapore, Aachen (Germany), Beijing (China), and Venice (Italy). The Chicago-based McKinsey and DMDII partnership benefits from the collaboration of more than 300 manufacturers, technology companies, academic institutions and other organizations dedicated to bringing manufacturing enterprises into the 21st century.

“Access to the necessary tools and training is essential for U.S. manufacturers to benefit from the rapid technological change currently underway,” said Thomas McDermott, Executive Director of DMDII. “Housing the North American Digital Capability Center at DMDII – a neutral collaboration platform – ensures companies of all sizes can tap into the resources they need to adopt advanced manufacturing technologies and remain competitive on the global stage.”

The technologies featured at the DCCs are provided by a growing list of technology partners that bring to life the benefits of digital manufacturing through a functioning production line that makes refrigerator compressors. Microsoft, a key partner, enabled advanced analytics capabilities like Artificial Intelligence and Machine Learning using Microsoft Azure along with Microsoft HoloLens and Microsoft Surface Hubs to power industrial applications such as digital performance management, predictive maintenance and mixed reality for field force. Tulip, another key partner, has created a technology ecosystem to provide digital operator assistance, analytics and feedback across the assembly line. Additional contributors include OSIsoft, Scope AR and equipment donor Bulova Technologies Machinery LLC.

The center draws upon UI LABS’ state-of-the-art facilities, a 94,000 square-foot collaboration studio and manufacturing floor with a real-world factory for experimentation and research and development. DMDII and its partners are currently engaged in more than 50 technical projects along with workforce development initiatives to prepare U.S. workers with the skills required for digital manufacturing jobs. Leaders from 50 UI LABS partner organizations are participating in trainings at the North American DCC this month alone. UI LABS also plans to engage small and medium-sized manufacturers within the DCC to ensure that organizations across the supply chain can access the tools and training needed to adopt digital manufacturing technologies.

The Digital Manufacturing and Design Innovation Institute (DMDII), a UI LABS collaboration, announced the release of its second 2016 Project Call, which requests proposals for four topics across three DMDII Technology Thrusts: Intelligent Machines (IM), Advanced Manufacturing Enterprise (AME), and Advanced Analysis (AA).

The title and goal of each Project Call Topic are listed below:



Low-Cost Robotics and Automation (IM)


This Project Call Topic seeks robotics and automation solutions that are affordable, reconfigurable, and adaptable, and that exhibit the precision, repeatability, and productivity of conventional automated solutions. They must also exhibit flexibility at a cost that makes them accessible to small and midsize businesses.

Real-Time Optimization of Factory Operations (AME)

The objective of this Project Call Topic is to improve factory decision-making by transforming raw data into meaningful and useful information for analysis and decision recommendations. Example analytical tools include online analytical processing, data mining, complex event processing, text mining, predictive and prescriptive analytics, and active performance management.

Seamless Work Flows from Design to Fabrication (AA)

The goal of this Project Call Topic is to develop software solutions that significantly reduce the manual input and expertise required to rapidly translate designs into fabricated parts during manufacturing, and thus to fully utilize the capabilities of available machine tools.

Human Systems Integration (AA)

This Project Call Topic aims to develop digital and physical technologies to improve human systems integration through data collection and analysis to reduce the costs and inefficiencies that stem from industrial workers performing tasks in environments that do not adequately take into account human size variation or capabilities.



To convey additional information to interested stakeholders, DMDII will host a Project Call Workshop at the UI LABS Innovation Center on September 8, 2016. Workshop attendees will hear from the DMDII leadership team about the institute’s mission, vision, and goals, as well as how to do business with DMDII. Attendees also will have the opportunity to network throughout the course of the workshop to enable teaming for responses to the Project Call Topics.

To facilitate the formation of project teams, DMDII encourages manufacturing businesses, manufacturing services providers, technology companies (hardware and software), and academic institutions to register their capabilities and interests through an online survey in advance.

For more information, visit: dmdii.uilabs.org/events/september-project-call-workshop

The Digital Manufacturing and Design Innovation Institute (DMDII), a UI LABS collaboration, announced that it has issued seven national applied research, development, and demonstration awards. These projects address several digital manufacturing and design topics, including augmented reality for use on manufacturing shop floors and on wearable and mobile devices.

“We are excited to continue to advance applied R&D within our core technology focus areas,” said Dr. Dean Bartles, Chief Manufacturing Officer of UI LABS and Executive Director of DMDII. “With each project call, we bring additional researchers, global industry leaders, and small companies into our consortium and move closer to making technologies related to ‘smart manufacturing’ and ‘brilliant factory’ applicable to manufacturers across the country.”

The projects involving augmented reality (AR), Manufacturing Work Instructions on Wearable and Mobile Devices with Augmented Reality, led by the Rochester Institute of Technology, and Authoring Augmented Reality Work Instructions by Expert Demonstration, led by Iowa State University, reflect the tremendous potential that AR holds as related technologies transition from consumer applications to the industrial sector.

“Our project will enable the creation of instructions for an augmented reality-based training system that mimic the actual part manipulations of an expert,” said Eliot Winer, Associate Professor of Mechanical Engineering at Iowa State University. “This project builds upon successful research from our project team, which we anticipate turning into real-world applications for manufacturers through the perspective provided by our industry partners.”

Embedding visual instructions in an individual’s environment through projection, wearable elements, or handheld devices can reduce training time and errors at multiple stages of the manufacturing process. AR also allows companies to redeploy experts to other tasks rather than time-consuming training sessions.

“A critical element to driving manufacturing competitiveness is delivering work instructions to our skilled workforce,” said Craig Sutton, Manager of Advanced Manufacturing at Deere & Company. “Given the amount of complexity that this workforce manages, written instructions remain a challenging medium. A tool like augmented reality will enable us to improve our productivity and quality measures in our operations.”

DMDII’s projects bring together teams with expertise in a variety of manufacturing disciplines and include major multinational corporations, small- and medium-sized enterprises (SMEs), government entities, and university researchers. Each project is managed by a lead organization that coordinates work among other organizations on the team. For example, Iowa State University is spearheading a project that includes Purdue University, John Deere, Boeing, Daqri, and Design Mill. Facilitating connections among its diverse consortium to create unique solutions is an important aspect of the UI LABS process.

DMDII’s seven new contract awards are as follows:

Manufacturing Work Instructions on Wearable and Mobile Devices with Augmented Reality – 15-04-01
Lead Organization: Rochester Institute of Technology
Other Organizations on the Team: Harbec, Optimax, OptiPro

This project aims to move shop floor instructions off of paper and into interactive, easy-to-use wearable technology. Using augmented reality technology, users will be able to see how to complete a task in real time, with virtual guides showing them what—and what not—to do. At the same time, the system will collect valuable real-time shop floor data that is not typically captured and harness it to improve future manufacturing processes. The system will be based on open standards to achieve another key goal of the project: the creation of technology that is cost-effective for SMEs.

Authoring Augmented Reality Work Instructions by Expert Demonstration – 15-04-03
Lead Organization: Iowa State University
Other Organizations on the Team: Boeing, Daqri, Design Mill, John Deere, Purdue University

This proposal seeks to create work instructions for augmented reality systems by developing the Augmented Reality Expert Demonstration Authoring (AREDA) product. The end product will be a simple and intuitive method to quickly create augmented reality work instructions using 3D cameras with advanced image processing and computer vision algorithms. The cameras will track experts as they manipulate parts to complete a project, capturing minute details and translating them into virtual instructions. AREDA stands to benefit companies like project team partners John Deere and Boeing by making assembly line training more cost-effective through augmented reality. 

FactBoard: Real-Time Data-Driven Visual Decision Support System for the Factory Floor – 15-02-08
Lead: Iowa State University
Other Organizations on the Team: Boeing, Factory Right, John Deere, ProPlanner

This project will develop FactBoard, a shop floor decision support system that will convert thousands of data inputs from logistics and production systems into a collection of visual dashboards—all in real-time. The dashboards will consist of mobile support displays that can be accessed by a variety of users, from plant managers to factory floor foremen. FactBoard will enable manufacturers to make quick adjustments to respond to resource changes, saving them time and money. Many companies are often not in a position to make major upfront investments in shop floor data collection, so FactBoard would ultimately enable manufacturers to use existing data effectively while increasing the quality of information and decision-making as additional data sources become available in the future.

Elastic Cloud-Based Make: Supply Chain Configuration Use Case – 14-09-02
Lead Organization: GE Global Research
Other Organizations on the Team: Rochester Institute of Technology

The initial Elastic Cloud-Based Make (ECBM) project will transition multiple manufacturing tools developed under the Adaptive Vehicle Make (AVM) program to DMDII. It will create a use case report that will be available on the open source manufacturing resource the Digital Manufacturing Commons (DMC) and will function like a road map for SMEs looking to incorporate AVM tools across their supply chains. This project extends the scope of the original project to further demonstrate paths to commercialization for additional AVM tools throughout the supply chain, from SME suppliers through large manufacturers. These commercialization pathways will be demonstrated through supply chain configuration for new products and for remanufactured products.

SPEC-OPS: Standards-based Platform for Enterprise Communication enabling Optimal Production and Self-awareness – 15-03-02
Lead: Palo Alto Research Center (PARC)
Other Organizations on the Team: ITAMCO, MTConnect Institute, System Insights

SPEC-OPS aims to provide a first-of-its-kind platform to tightly integrate machine tools and the multiple systems involved in the total manufacturing process, such as manufacturing execution systems, enterprise resource planning systems, dynamic planning and scheduling and process analytics. The capability to integrate multiple systems to transfer data back and forth does not exist today, and SPEC-OPS is the first major effort to address the challenge. The final platform will result in savings in planning, scheduling, execution, and maintenance time for manufacturers.

Automated Manufacturability Analysis Software “ANA” – 14-01-07
Lead Organization: Iowa State University
Other Organizations on the Team: American Foundry Society, John Deere, The Lucrum Group, MFG.com, North American Die Casting Association, Pennsylvania State University Applied Research Laboratory, Steel Founders’ Society of America, Tech Soft 3D, University of Alabama at Birmingham

This project will create a manufacturability analysis package that can work on any platform to provide real-time feedback on critical manufacturing issues. The ANA project builds upon work from the AVM project to develop commercially viable software that will provide feedback to designers at the conceptual design phase. The resulting analysis software will enable conceptual designers to receive immediate feedback on their designs early in the manufacturing process, cutting down the often lengthy conceptual design phase of components. The outcomes of this project will enable significant reductions in manufacturing costs, product launch costs, and time to market.

Integrated Manufacturing Variation Management – 14-07-02
Lead: Caterpillar Inc.
Other Organizations on the Team: Missouri University of Science and Technology, University of Illinois Urbana-Champaign

Incoming stock from casting and forging suppliers can vary to the point that standard machine tools cannot adequately respond to the existing material condition in the as-programmed state. The goal of the project is to generate a system by which a manufacturer, in an automated fashion, can compensate for machine tool workspace (machine tool) errors induced due to part, fixture, tooling, or machine tool errors. This should allow for large reductions in setup times for new parts, new fixtures, or parts that see a large variation in the rough condition as delivered to the machining operation while minimizing human interaction in the machining setup process. The innovation over the present state of technology will yield significant improvement in process reliability and efficiency in the entire value stream.

For more information, visit: www.dmdii.org/projects

The Digital Manufacturing and Design Innovation Institute (DMDII), a UI LABS collaboration, announced the release of its first 2016 Project Call addressing two of the three DMDII Technology Thrusts: Advanced Manufacturing Enterprise (AME) and Intelligent Machines (IM).

The title and goal of each Project Call Topic are listed below:

Analytical Solutions for Lifecycle Feedback (AME)
The goal of this Project Call Topic is to reduce total lifecycle costs of complex systems by collecting data from different parts of the product lifecycle, allowing data to flow across the product lifecycle and to use this information to improve decision-making.

Industrial Internet of Things Retrofit Kit for Legacy Manufacturing (IM)
This Project Call Topic aims to develop an affordable means to retrofit legacy production systems with a wide array of sensors, and to provide the capability to securely and rapidly collect, store, and transmit the data, enabling participation in the digital enterprise.

To convey additional information to interested stakeholders, DMDII will host a Project Call Workshop at the UI LABS Innovation Center on March 29, 2016. Workshop attendees will hear from the DMDII leadership team about its mission, vision, and goals, as well as how to do business with the Institute. Attendees also will have the opportunity to network throughout the course of the workshop to enable teaming for responses to the Project Call Topics. To facilitate the formation of project teams, DMDII encourages manufacturing businesses, manufacturing services providers, technology companies (hardware and software), and academic institutions to register their capabilities and interests on an online survey in advance.

DMDII plans to issue additional Project Calls over the next several months, covering the Technology Thrusts mentioned above as well as Advanced Analysis (AA). Upcoming project topics will include Low-Cost Robotics and Automation (IM), Real-Time Optimization of Factory Operations (AME), Seamless Work Flows from Design to Fabrication (AA), and Human Systems Integration (AA). Specific dates for these releases will be announced separately.

For more information, visit: dmdii.uilabs.org/events/spring-workshop

The Digital Manufacturing and Design Innovation Institute (DMDII), a UI LABS collaboration, announced that it has issued six national contract research awards, including funding to test and aid compliance with the nation’s cybersecurity standards for digital manufacturing. The projects span several digital manufacturing disciplines, but each reflects the core mission of DMDII: propelling the field of American digital manufacturing and design forward.

“These project awards sponsor research that will change the way that manufacturers in all segments of the supply chain are able to engage in business,” said Dr. Greg Harris, DMDII’s program manager through the U.S. Army Aviation and Missile Research, Development, and Engineering Center. “The investment in cybersecurity research is particularly exciting, as the U.S. manufacturing sector lacks the compliance pathway and workforce development plan to comply with current standards. This award is part of DMDII’s commitment to moving American manufacturing beyond the 21st century.”

The projects bring together teams with expertise in a variety of manufacturing disciplines and include major multinational corporations, small enterprises, government entities and university researchers. Each project is managed by a lead organization that coordinates work among other organizations on the team. For example, Rolls-Royce Corporation is spearheading a project that includes Microsoft and 3D Systems, top tier engineering school Georgia Tech, the National Center for Supercomputing Applications at the University of Illinois at Urbana-Champaign, and leading research institutes Pennsylvania State University Advanced Research Laboratory and Southwest Research Institute. Facilitating connections among diverse project teams is a key aspect of the UI LABS approach.

“This cohort of awardees shows what DMDII and UI LABS are all about: smart cross-sector collaboration that is going to enhance competitiveness for the entire industry,” said Dr. Dean Bartles, Chief Manufacturing Officer of UI LABS and Executive Director of DMDII. “Through these projects, we are lowering cost and access barriers to implementing digital manufacturing practices for small manufacturers across the country.”

Assessing, Remediating, and Enhancing DFARS Cybersecurity Compliance in Factory Infrastructure is the first DMDII project focused specifically on cybersecurity. The project seeks to test and validate a uniform cybersecurity standard for manufacturing, with the goal of improving the cybersecurity of the supply chain across the manufacturing industry. It reflects feedback from DMDII’s large manufacturing partners who have expressed the need for improved supply chain management security.

The project will review Department of Defense (DoD) cybersecurity standards for contractors and conduct a series of case studies to assess the costs and capabilities manufacturers need to meet them. Ultimately, more manufacturers will be able to become DoD cybersecurity compliant, adding more potential contractors into the DoD and manufacturing pipeline. While this merely scratches the surface in addressing the cybersecurity needs of small- and medium-sized enterprises (SMEs) and the manufacturing industry as a whole, it is an important initial step in enhancing the cybersecurity of the U.S. supply chain.

“Companies of all sizes, as well as federal and state governments, must be concerned about the security of the other organizations that make up their supply chain, as their security could be compromised by an insecure partner. This project will help understand cybersecurity issues in a critical supply chain segment – manufacturing – and ultimately propose an enhanced cybersecurity standard that is tailored to the industry,” said Jim Henderson, Vice President of Cyber, Engineering, and Technology at Imprimis, Inc., the lead organization on DMDII’s first cybersecurity project.

The contract awards continue DMDII’s investment in digital manufacturing, building on 2015 contracts valued at over $7 million. The research and tools generated from all projects will be available on the Digital Manufacturing Commons, DMDII’s open-source online platform that allows manufacturers to access data and tools that can improve efficiency and productivity across the entire manufacturing cycle.

“DMDII’s research will ultimately make America’s manufacturing industry more competitive and secure, while strengthening our workforce and the economy in the process,” said U.S. Senator Dick Durbin. “Chicago’s flagship digital manufacturing institute has brought together teams with diverse brainpower and expertise to address the critical need to boost cybersecurity capabilities. I was an early advocate of DMDII, have fought for a steady stream of federal funding in the face of potential cuts, and am proud to support its new focus on cybersecurity research.”

DMDII’s six contract awards are as follows:

Integration of AVM iFAB Tools for Industrial Use
Lead Organization: Pennsylvania State University Applied Research Laboratory
Other Organizations on this Team: aPriori, Oshkosh Corporation, Parametric Technology Corporation (PTC)

Part of the U.S. Defense Department’s Defense Advanced Research Projects Agency (DARPA) Adaptive Vehicle Make (AVM) program, this project will develop tools and standards for advanced adaptive manufacturing of complex vehicles.

This project seeks to create “design assist tools”– tools that help manage data from design through manufacture and potentially service life –that will increase speed and efficiency and cut down costs. The tools will allow designers to analyze manufacturability and assemblability by creating a simulation that enables them to work on a virtual prototype, rather than a costly real-world one. Ultimately, the tools will be added to the Digital Manufacturing Commons, DMDII’s open-source online platform.


Elastic Cloud-Based Make
Lead Organization: GE Global Research
Other Organizations on this Team: Iowa State University, Northwestern University, Oregon State University, Pennsylvania State University Applied Research Laboratory, Quad City Manufacturing Laboratory, Rochester Institute of Technology, Rolls-Royce Corporation

Many SMEs lag behind larger manufacturers in adopting new technologies. A key challenge for these businesses is the adoption of information technology—particularly advanced modeling, simulation, and analysis (MS&A) tools, which is increasingly important to manufacturing competitiveness but can be cost-prohibitive for SMEs.

Through the Defense Advanced Research Projects Agency (DARPA) Adaptive Vehicle Make (AVM) Tool Integration project, the GE Global Research-led team will directly address these technical challenges by enabling SMEs to access the AVM MS&A tools via the Digital Manufacturing Commons.


Supply Chain MBE/TDP Improvement
Lead Organization: Rolls-Royce Corporation
Other Organizations on this Team: 3rd Dimension, Anark Corporation, ITI-Global (International TechneGroup Incorporated), Lockheed Martin, Microsoft, Purdue University

This project seeks to push Model-Based Enterprise (MBE) technologies forward by using MBE technology to streamline the design stage of the manufacturing process. This involves the use of intelligent 3D models to eliminate the need to translate to different formats, including 2D drawings, when transferring information between original equipment manufacturers (OEMs) and other companies within the supply chain.

Using MBE ties data related to tolerance, life of product, and other product specs to the 3D model during the design phase and allows it to be used for all stages of the process, eliminating issues of unclear or inaccurate drawings. The combination of the 3D model and accompanying information is referred to as the technical data package (TDP).

As a framework and best practices for MBE/TDP are standardized and disseminated more widely, they will become more useful and accessible to SMEs. As a greater percentage of the supply chain embraces MBE, the number of potential suppliers to the DoD and other major manufacturers will increase.


O3 – Operate, Orchestrate, and Originate
Lead Organization: STEP Tools, Inc.
Other Organizations on this Team: ITI-Global (International TechneGroup Incorporated), Mitutoyo America, System Insights

The O3 project will develop a web environment that will enable users to orchestrate machining and measurement processes from tablets and smart phones. Time and money are wasted when a machining program creates a part that does not conform to the design requirements of the customer. O3 will allow users to check machining programs for conformance from remote locations. When conformance is not met, the service will allow the process to be adjusted using apps.

The servers that will be used to host O3 tools will be located at DMDII, and the tools will be available to all manufacturers through the Digital Manufacturing Commons. 


Advanced Variance Analysis & Make
Lead Organization: Rolls-Royce Corporation
Other Organizations on this Team: 3D Systems, Georgia Institute of Technology, Microsoft, National Center for Supercomputing Applications (NCSA), Penn State University Applied Research Laboratory, Southwest Research Institute (SwRI)

The Advanced Variance Analysis & Make project uses high-performance computing to demonstrate how data coming off of a machine relates to the part made by that machine. It will indicate whether an anomaly in the data is, in fact, related to an anomaly in performance and/or adherence to a design specification for the part.

The analyses will form the basis of a database of production anomalies available through the Digital Manufacturing Commons. Manufacturers will use the resulting data in real time to correct an anomaly if it will affect a part’s performance, or to ignore the data anomaly if there is no evidence of impact on the part’s capabilities, saving time and money during the manufacturing process.


Assessing, Remediating and Enhancing DFARS Cybersecurity Compliance in Factory Infrastructure

Lead Organization: Imprimis, Inc. (i2)
Other Organizations on this Team: SPIRE Manufacturing Solutions, Western Cyber Exchange

This project seeks to create, test and implement a uniform cybersecurity standard for DMDII, with the goal of improving cybersecurity and supply chain security across the manufacturing industry. It reflects feedback from DMDII’s large manufacturing partners who have expressed the need for improved supply chain management.

The project will review DoD cybersecurity standards for contractors, assess the costs, capabilities, and training manufacturers need to meet them, then develop a case study to aid manufacturers in meeting them. Ultimately, more manufacturers will be able to become DoD cybersecurity compliant, adding more potential contractors into the DoD and manufacturing pipeline.

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