Presentation given at PrefabAus 2014. http://www.prefabaus.org.au/conference/ The material has been sourced from a number of researcher, including: Nico Adams, Robert Zlot, Paul Flick, Alberto Elfes, Laurent Lefort, Sarah King, Peter King, Peter Kambourios, Craig James, Leila Alem, Swee Mak.

1. Next Generation Manufacturing
FUTURE MANUFACTURING FLAGSHIP

2. Who am I?
1. CSIRO Research Scientist
 Autonomous Systems Program (80+)
 QLD Centre for Advanced Technologies
2. 9 years in Manufacturing
 Low Pressure Die Casting
3. 4 years Machine Reliability
 Predictive Maintenance
 Machine Vision
4. 9 years Mining Robotics
 Robot Navigation
5. 5 years Robotic Perception
 3D LiDAR Mapping
6. 1 year Manufacturing
 High Performance Workplace

3. Autonomous Systems Program
Vision: A world in which humans and autonomous systems are
able to seamlessly, reliably and safely collaborate.

4. Robot navigation
Dynamic, difficult environments

5. Remote Collaboration
Robots, vision and broadband

6. Pervasive Computing
Platform technology

7. Robots in Mining
Dragline Swing Automation Shovel Automation Tele-robotic Rock-breaker
LHD Automation (Caterpillar) Explosive Loading (ORICA) Longwall Automation (CESRE)

8. CSIRO - Snapshot
62%of our people hold university
degrees
2000 doctorates
500 masters
Wodonga
Armidale
2 sites
CSIRO undertakes $~500M
of externally funded R&D each
year
Partners = 1300+
Top 1% of global research institutions in 14 of 22
research fields
Top 0.1%in 4 research fields
Highest number of citations per scientist in
Australia
Darwin
Alice Springs
Bakers Hill
Atherton
Townsville
2 sites
Rockhampton
Toowoomba
Gatton
Myall
NarraVbrai le
Mopra
Parkes
Griffith
Belmont
Geelong
Hobart
Sandy Bay
Werribee
Newcastle
Perth
3 sites
Adelaide
2 sites
Brisbane
6 sites
Sydney 5 sites
Canberra 7 sites
People = 6000+
Locations = 57
Budget = $1B+
Murchison
Cairns
Melbourne 6 sites
Infra = $3.5bn
Patents = 3000+

9. Our track record: top inventions
4. EXTENDED
WEAR CONTACTS
2. POLYMER
BANKNOTES
3. RELENZA
FLU TREATMENT
1. FAST WLAN
Wireless Local
Area Network
5. AEROGARD 6. TOTAL
WELLBEING DIET
7. RAFT
POLYMERISATION
8. BARLEYMAX 9. SELF TWISTING
YARN
10. SOFTLY
WASHING LIQUID

10. We are in the world’s Top
10 institutions for
2 research fields.
We are the only Aussie R&D
organisation in the world’s
Top 10.
We have 14 research fields
in the top 1% of global
research organisations.
CSIRO global positioning
45
40
35
30
25
20
15
10
5
0
Columbia
UC San
Diego
U Michigan
U Wisconsin
Yale U Penns
Chinese Acad
Sci
1 2 3 4 5 6 7 8 9 10 11 12 13
NO. OF INSTITUTIONS
NO. OF FIELDS IN TOP 10 GLOBALLY
CSIRO
CNRS
Cornell
Georgia Inst
Tech
INRA
NASA
Nat U
Singapore
NCI
NIAID
Princeton
U Toronto
USEPA
USGS
U Illinois
U Tokyo
USDA
Wageningen
U
UCSF
Johns Hopkins
UCLA
MIT
U
Washington
UC
Berkeley
Harvar
d
Max
Planck
Standford
CSIC
U Carolina
UC Davis
Oxford
Based on total citations. Source: Thomson-Reuters/ISI Essential Science
Indicators

11. China Australia Alliance for
New Energy Vehicle
Innovation
Global connections
80+
countries

12. World-class
science and
technology
CSIRO - the roles we play
1 2 3 4 5
Trusted advisor
to government
Leveraging
Australia’s
Innovation
System
Innovation
supporting the
creation of new
businesses
Helping existing
companies
transition to the
future

13. Where does CSIRO operate?
http://erc-assoc.org/book/export/html/745

14. Innovation
Ecosystem
National Innovation Networks
CSIRO
CRC
HUBS
Universities
SME’s

15. How does CSIRO do this?
CSIRO
Innovation
Partnerships
Research
Agreement
Operator OEM
License
Agreement
Purchase
Agreement

16. National Research Flagships
BIOSECURITY ENERGY TRANSFORMED
DIGITAL PRODUCTIVITY
AND SERVICES
CLIMATE ADAPTATION
WEALTH FROM OCEANS
FOOD FUTURES
SUSTAINABLE
AGRICULTURE
MINERALS DOWN
UNDER
FUTURE
MANUFACTURING
PREVENTATIVE HEALTH
WATER FOR A
HEALTHY COUNTRY
Mission
Oriented
Research

17. The Australian Situation
~1m jobs
Generally
high wages 29% of
exports
Dominated
by SMEs
Highly
productive?
30% of trade
apprentices
8% of GDP
and more in
service
industries
20% of
output as
input into
other sectors
25% of
Business
Expenditure
in R&D
• Under pressure from high Australian dollar
• Ageing workforce
• Operating in high cost environment
• Largely SME based
• Remoteness and small local market
• Skills shortage: losing capabilities to other sectors
• Need to lift up productivity
• Transitioning to a resource constrained future

18. National thought leadership in manufacturing
The combination of forces currently putting pressure on many Australian businesses
threatens to undermine the capacity of the (manufacturing) sector to take advantage of
future opportunities. If manufacturers are not in a position to capitalise on emerging
opportunities, the Australian economy as a whole will be weaker and more vulnerable now
and over the longer term.
Prime Minister's Manufacturing Taskforce, Report of the Non-Government Members, 2012

19. Towards a
competitive,
productive
and
sustainable
future for
manufacturing
The 7 “S” of Manufacturing
Sustainability - License to operate,
Sustainable products, Resource efficient
Speed and agility
Responsiveness, Customisation, Speed to market
Scalability
Low volume, reconfigurable, Scope vs scale
Smart - Materials and processes,
Information systems, Design led
Services
Solutions vs product, Moving up value chain
reSources
Natural assets, Human capital
Supply chains
Globally connected

20. •New Workflows
•New Business
Models
•New Enterprises
Next Generation Manufacturing ?
•New Processes
•New Materials
•New Production
•Mass
Customization
•Maximize
Flexibility
•Mass Production
•Minimize Waste
Great
Expectations
Lean Agile
Information
Driven
Advanced
Virtually here
More from
Less
• Additive
• Titanium
• Nano
• Bio
• Flexible

21. What’s in a Name?
Industrial Internet (GE)
Industry 4.0 (Germany)
Network Enabled
Manufacturing (Boeing)
Manufacturing 2.0
(European)
IoT – Internet of
Things
Cloud Computing
Big Data
Semantic Web

22. iManufacturing Architecture
FUTURE MANUFACTURING FLAGSHIP

23. Layered Architecture
External Forces
Virtual Factory – Executive Layer
• Simulation of factory and the world around it.
• Interactive and collaborative user interface
• Decision support (simulated scenarios)
Digital Factory – Strategic Layer
• Live (Real-time) digital model of factory
• Fully Integrated across the production cycle - Data Fusion
• Optimization of production based upon demands
Smart Factory – Tactical Layer
• Smarter sensing and actuation around each process
• Reconfigurable / Adaptive / Responsive processes
• Improved situational awareness - QA/QC
Demands
Demands
Demands
Data
Intelligence
CRM
Customer
Relationship
Management
PLM
Product
LifeCycle
Management
SCM Supply Chain
Management
ERP
Enterprise
Resource
Planning
MES Manufacturing
Execution System
SCADA

24. Connected Architecture
CRM
PLM
SCM
ERP
MES
SCADA
CRM
PLM
SCM
ERP
MES
SCADA
CRM
PLM
SCM
ERP
MES
SCADA

25. subcontracting process
Engineer at company A
defines product specification
in in-house ERP A
raises purchase order
and generates further
specifications in ERP A
Engineer at
company B retypes
specification in in-house
ERP A ERP B
ERP B
Engineer at
company B retypes
specification in in-house
ERP C
ERP C
Status Quo

26. Bridging the Information Gap
• Bespoke solution are not scalable.
• Previously required installation of software on-site.
• Too expensive for SME.
• The cloud can provide off-load the software
• But still have a problem with inter-connections.
Solution
• Objects with relationships to other objects across strata exist.
• Management by Semantic Web
• Deliver information flows to the supply chain to allow secure, fit for purpose,
interoperability across various platforms and processes

27. What are the information flows At the nodes, we need Informatics
Client
data
Human
Services
Material, Products
and Processes
Supply chain
events
Supplier
data
ICT Automation,
IoT, Robotics
Factory
events
Factory
data
End to end
data
Product
data
Process
data
Supply chain
management
Nodes
Assistive
technologies
Design,
customisation
Direction of
data flow
Sustainable
Relationship manufacturing
Management
Informatics
Workforce skills

28. Apple Treatment Process – Knowledge Representation
Chemical
Processing
Engineers
Informatics
Engineers

29. Example:
Knowledge Representation of Apple Processing

30. “eManufacturing Cloud”
subcontracting process
Engineer at company A
defines product specification
in in-house ERP A
raises purchase order
and generates further
specifications in ERP A
ERP A
ERP B
Machine-comprehensible
specifications translated into
data format for ERP C and
automatically ingested by
ERP C
ERP C
Machine-comprehensible
specifications translated into
data format for ERP B and
automatically ingested by ERP
B
Proposal

31. High Performance Workplace
FUTURE MANUFACTURING FLAGSHIP

32. LAMS – Lightweight Assistive Manufacturing Solutions
• Low-cost, from purchasing price and installation costs, to
reprogramming and maintenance costs
• Easy to use, without the need of technical expertise to deploy,
• Support mass customisation, ideal for small runs of multiple
Guardian Angel
•Monitors environment
• Tracks people and assets
•Make work safer for humans
Guardian Mentor
•Worker augmentation
• Provides skills and training
•Make work easier for human
Guardian Helper
• Provides physical assistance
• Robotic co-workers
•Works with humans
Guardian Worker
• Provides remote assistance
• Tele-operated robotics
•Work for humans
High Performance Workplace
operate and reconfigure the systems
types of products
Augmentation
• Collaboration
• Interface
• Observatory
Assistive
• Navigation
• Manipulation
• Cooperation
Awareness
• Monitoring
• Modeling
• Management
Worker Centric:
Increase productivity, safety and adaptability
of future workforce through virtual and
assistive automation technologies
Social Science
Human Factors
Informatics
Communications
Sensors
Robotics
Engineering
Investment Innovation Impact

33. Changing Manufacturing Paradigms
Current automation
in manufacturing
Rigid
Bulky
Expensive
Unsafe
Lightweight
Assistive Solutions
Flexible
Affordable
Lightweight
Human-centered
Easy-to-use

34. Lightweight Assistive Manufacturing Systems
Multi-Sensorial
Augmented Reality
Human/Robot
Collaboration
Augmented Human
Worker
Robot/Robot
Collaboration
Worker Safety: Always
Aware
Telesupervision

36. HMI
LAMS
ICT
Perception
Consumer
Devices
Robotics
Mobile
Tele-presence
Lightweight
Robotics
Social
Networking
Mirror
Worlding
Sensing in
Unstructured
Dynamic
Environments
Dependability
Robustness
Field
Robotics
Military/Mining
Collective
Intelligence
Cloud
Services Big Data
Internet of things
Cheap sensor,
processors
and actuation
Immersive
Interfaces
Gaming
Additive Manufacturing
Intuitive
interfaces
Mobile
Devices
Ubiquitous
Connectivity
Location based service
Technology / Trends to
Develop Assistive Robotics

37. Autonomous Safety Zones
1. Create 3D Model
2. Monitor environment
3. Track people and robots
4. Measure risk
5. Detects hazards
6. Alerts participant
7. Creates Safety Zone
8. Alerts bystanders
9. Monitors task
10. Alerts help if required.
Bystander walks into factory
Guardian Angel
•Monitors environment
•Tracks people and assets
•Make work safer for humans
Person starts to change tyre! Vehicle wants to move

38. Construction
FUTURE MANUFACTURING FLAGSHIP

39. Prefab Challenges
1. Site Preparation
 Green Field / Brown Field
– 3D Surveying
– Mobile Mapping
2. On-site Assembly
 Skills
– Remote Training
3. Certification / Inspection
 Remote Monitoring
– Robotic Inspection

40. Mobile Mapping
FUTURE MANUFACTURING FLAGSHIP

41. Zebedee
• Hand-held Mobile 3D mapping system
• Commercial system licensed to 3DLM
• Formed JV to create company called GeoSLSAM

42. Lean Tower of Pisa Scanning

43. Scanning of the Leaning tower of Pisa

44. The Opera-Theatre of Clermont-Ferrand

45. Anzac Square
Information Driven Manufacturing

46. Tele-Maintenance
FUTURE MANUFACTURING FLAGSHIP

47. Capabilities in Remote Collaboration
Gesture Tracking Vehicle Tracking People Tracking Face Tracking
Security and Trust High Bandwidth Comms Quality of Service Haptics
Augmented Reality Augmented Virtuality Panoramic Display Collaborative Environments
Situational
Awareness
Communications
Human Machine
Interface

48. Assembly and Remote Assistance
Assisted Human Worker
Autonomous Navigation
Lightweight Robot
Assistant
Remote Instruction +
Augmented Reality
Remote Expert

49. Remote Maintenance
Remote Expert
Virtual Collaboration Space
Local Resource
ReMoTe is hands-free, wearable, and is operational in various environmental conditions
and designed so operators can operate it without any training or prior skill.

50. Confined Space Robotics
FUTURE MANUFACTURING FLAGSHIP

51. Capabilities in Field Robotics
Dragline Shovel LHD HMC
Rock Breaker Explosive Loading Cleanup Agriculture
Helicopter Submarine Ground Boat
Haulage
Manipulation
Navigation

52. Hexapod Robots

55. Information Driven Manufacturing

56. IMCRC
Information Driven Manufacturing
McFarlane for MIICRC to re-submit a combined bid with AMCRC by the end of
May. He said:
“In addition to this funding, the Advanced Manufacturing and Manufacturing
Industry Innovation CRCs are well positioned to assist the Australian
manufacturing industry to adapt to new, high tech manufacturing processes
and will assist in opening new markets. These applications displayed merit
and are proposing to address issues of national importance. As such I have
asked these CRCs to submit a combined proposal for my consideration.”

57. Some Videos
1. ETHZ Construction Robots - https://www.youtube.com/watch?v=rl7u2pPf-ak
2. Hundegger Robot Drive https://www.youtube.com/watch?v=MnwVd7A-mtk
3. Contour Crafting https://www.youtube.com/watch?v=c8Dhdf6eheg
4. IAAC Minibuilders https://www.youtube.com/watch?v=G1iT8_QyP0M
5. 15 Storeys in 30 days https://www.youtube.com/watch?v=rwvmru5JmXk
6. Brick laying robots https://www.youtube.com/watch?v=0s6OF5awJKs
7. Swarm Robots https://www.youtube.com/watch?v=pxLfzWDs3HA
8. Collaborative Robots https://www.youtube.com/watch?v=4JNJ1LHSAwA
Information Driven Manufacturing