RRI International Symposium 2020
Manufacturing policy in the world of post COVID-19
October 13, 2020

Designing resilient manufacturingwith versatile human interaction in the world of post-COVID-19
Fumihiko Kimura
Professor Emeritus, The University of Tokyo

Contents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Contents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Current issues towards the Future of Manufacturing• Achieving high Quality-of-Life (QoL) is still an issue in the global world,
especially in developing countries.
• High value creation with less resource consumption is a key for success.
• The advanced manufacturing is an infra-structural enabler.
• Efficient usage of resources is a basis: natural resources, materials & products,
technology, human, market and environment, etc.
• Resources and demands are unevenly distributed in the world, and in-balanced.
• “Optimized” global life cycle network of production and products is required.

Designing the Future of Manufacturing in the world of post-COVID-19• In COVID-19 crisis, unforeseen and disruptive changes in various aspects ofmanufacturing• How to maintain the global life cycle network in the world of post-COVID-19• Comprehensive Digitalization is a basis for the future of manufacturing• From “AS-IS” to “TO-BE” innovation based on digital infra-structure• Dynamic decoupling and re-integration of “cyber world (knowledge)” and“physical world”• Resolving the boundary of traditional industries and creating new ones
• Dynamic re-assignment of human resources to activities• Complete automation vs. autonomy with versatile human involvement

Contents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Resilient manufacturing based on model-based approach• Resilience in manufacturing• adaptability, flexibility, agility, efficiency, high-value-creation, human involvement ,sustainability, etc.

• How to introduce resilience in manufacturing• Business process (activity) innovation : from AS-IS to TO-BE• Enabling environment: technology, natural & social environment• Mapping: business process vs. enabling environment• Enabler: importance of “Digitalization”• Model-based approach• CPS in narrow sense: modelling of physical world• CPS in wide sense: modelling of physical world + designing of business processes

Resilient manufacturing based on model-based approach
Model-based approach
Traditional approachbusiness
process: 2
business
process: 1

business
Processn:nflexibly
connected

Design for Resiliencebusiness
process: m

1:1
tightly
connected
physicalobject

model ofphysical object: A
Cyber
World
PhysicalWorldmodel ofphysical object: B

model ofobject: Z

1:1

1:1

1:1

physicalobject: A

physicalobject: B

object: ZResilient manufacturing based on model-based approach
Business
Process: m
1..nNetwork
relationship1..mmodel ofobject: X
Cyber
World
Physical
World

10..1

object: X

Design of processes- engineering, production, management, service, society, etc.
- dynamism and autonomy- process for whole life cycle- modularity and standardization
Mapping among processes and models- various mapping according to thedesign objective- Prerequisite: comprehensive
semantic inter-operability amongprocesses and models- digitalization as a basis

Design for Resilience- risk reduction under unforeseen anddisruptive changes- from cost-competitiveness to riskcompetitiveness- traditional approach: design for
productivity: cost reduction

Modelling of objects- physical objects, including natural environment- non-physical objects: human, information, knowledge, etc.
- dynamism and autonomy- appropriate accuracy, precision and granularity- comprehensive approach- modelling of whole life cycle

New value creation activities including “manufacturing” as a basis
Physical world
object:5

object:4

Cyber world
object:3transport

model:3

object:2

model:2

model:1

object:1

model:5

model:4

newactivity:1
city

new
activity:2

manufacturing

energyagriculture

healthComprehensive semantic inter-operability
among models and activities

model:nobject:nContents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Active human role in resilient manufacturing• Characterization of human capability is mandatory in the model-basedapproach.
• Human as a resource• Reduction of traditional human work
• Possibility of new roles• Adapting to human diversity become possible by the model-based approach.
• Design and dynamic re-configuration of work sharing and division according to change ofenvironment• Leading role, supporting role or …

• Decision and design must be done by people and society.
• Technology is almost ready, and how to motivate the change of people’s “mind-set” is akey.

Human-to-Human and Human-to-Machine Interactions• Modelling of diversified roles of “human”, “machine” and “environment”• Change of basic thinking: from “cost-competitive” to “risk- competitive”• complete automation of “low-value-additive” and “simple”, but “un-organized” works ”→ Disruptive changes of the employment structure !
• gradual replacement of human roles in highly sophisticated physical and logical works• New technologies available for Human-to-Human and Human-to-Machine Interactions• Physical distance does not matter !
• Innovative technologies of VR/AR• Deep re-thinking of human roles strongly required• human-machine co-existence/separation• New works need to be created: disappearing the boundary of manufacturing and services• Diversity of human and machine must be recognized. Therefore the solutions are diversified.
No general solution !

“TO-BE” Mapping of Roles to Human/Machine

KPI:
Quality of Life

ActivityResourcesProcessHuman◎◎☆

Sustainability◎

Risk- Competitiveness

☆

etc.

◎☆

◎☆

●●●●●●☆

●●Mapping◎

Machine☆

〇◎: Role☆: Process element

〇

〇
〇

〇

〇
〇

Contents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Research example in Japan toward resilient manufacturing• Many research and development activities are emerging.

• Establishing comprehensive modelling environment and semantic interoperability requires long-term endeavor.
• Long-term planning and agile implementation should go in parallel.
• Feasibility study is effective for changing people’s “mind-set”.

17

The Image of Digital Triplet(Prof. Yasushi Umeda: The University of Tokyo)
Integrated support of engineering activities throughout a product life cycle
Design ⇔ Mfg. ⇔ Use ⇔ Maint. ⇔ Reman. ⇔ Circulation

Digital Triplet

Taking mfg. stage as an example
Intelligent Activity World: Creating values from data by human knowledge

Intelligent Activity
WorldValue
Industrial AI

Intelligent
Activity World:Interpretation
DT construction/updateDecision
Creating values
from data by humanknowledge
Analysis
ControlCyber World

Product Info.

Cyber World

Design
Info.

設計
情報

Digital Twin
Physical World

Physical World
製品Physical World

Cyber Physical SystemProduct
製品情報

Cyber World

18Acquiring Process Knowledge of Engineering Activities on Digital Triple⚫

From now: Engineers should execute engineering activities mainly with the cyber world
Describe these engineering
cycles as the process
knowledge

Knowledge
Experience
Return to Design
Selection of
Evaluation
Methods

EngineerTechnician

Decision
Evaluation

Execution

Selection ofAnalysis Methods
and Tools
Selection ofData to Be
Collected

Cyber World

Info. Analysis- AI tools- Simulators- CAE
DesignInfo.

- Actuators- Reprogramming- Revamping

Knowledge &experience onexecution

Value

Product Info.

Data Collection- Sensors- Loggers- IoT- Actuators

Product

Physical World-To the next stage

Formalizing, collecting, and archiving the process knowledge
Supporting human activities by reusing and deploying the knowledge
Employing the knowledge to education

Targets:- Inconsistency between
objectives and achievements- Continuous improvements- Changes of physical systems- Changes of environment

19Concept of Engineering Support by D3⚫ We represent know-how and tacit knowledge in engineersArrows: Human thought process
Analysis
Represent an “Engineering cycle”
as a combination of digital twinand process model on D3

Tool A

Tool C

Tool B
Decision
Execution

Tacit Knowledge

Traditional AI
Experts

Data Collection

Supporting an engineer inproblem solving and value
creation based on themodel of engineering cycle

Task is substituted by AI

20

Extraction of Engineering Cycle of Mold Processing for Injection Molding
Failures
Experts

Historical Records

Knowledge
Systematization
with AIHearing

人が頭の中で考えている部分

CAMで表現している部分

一般面中仕
上げ方向のイメージ

一般面荒削り方向のイメージ

壁荒削りパス生成

壁中仕上げパス生成

壁仕上げ
パス生成

一般面仕上げのイメージ

一般中仕上げピッチのイ
メージ

一般面荒削りピッチのイ
メージ

上向き面荒削りパス生
成

上向き面中仕上げパス
生成

上向き面
仕上げパス
生成

際仕上げのイメージ①

際中仕上げ方向のイ
メージ

際荒削り方
向のイメージ

際荒削りパ
ス生成

際中仕上げ
削りパス生
成

際中仕上げ
ピッチのイ
メージ

際荒削りピッチのイメージ

仕上げ工具の選定

際仕上げのイメージ②

Engineering Cycle Model（for Mold Processing）

際仕上げ削りパス生成

Contents• Designing the Future of Manufacturing in the world of post-COVID-19• Resilient manufacturing based on model-based approach• Active human role in resilient manufacturing• Research example in Japan toward resilient manufacturing• Actions to be taken

Actions to be taken• Technology for new manufacturing is already there or being ready !
(Still need more investment !)• Technology can be a common infrastructure to be shared by all.

• How to design systems and to implement technology in our life depend
on vision and intention of individuals, society and countries.
• Therefore the new manufacturing paradigm must be selected andexplicitly designed by individuals, society and countries.
• Even though the actual design could be different in society and countries,
we can share the common technology basis, and collaborate towards thefuture society.

• Key message is: Future is not given, but it can be designed.