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Closed-Loop Digital Pipeline

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Penelope Manager

Interview with PeneloPe´s Coordinator, Félix Vidal Vilariño

PeneloPe is a H2020 Funded project launched in November 2020 and born as a new Industry 4.0 solution to develop a novel closed-loop digital pipeline based on the development of modular and reconfigurable production approach for the manufacturing of high-precision large-scale parts. This initiative is key to bring forward the future of the European manufacturing industry, as it is a strong asset for the European economy and an important driver of employment and prosperity. 

We had the opportunity to chat with the PeneloPe´s coordinator, Félix Vidal Vilariño, Head of Robotics and Control Unit at AIMEN Technology Centre based in Galicia, Spain. 

PeneloPe´s coordinator, Félix Vidal Vilariño, Head of Robotics and Control Unit at AIMEN
  • What does the idea of PeneloPe come from?

Manufacturing of large-scale components is facing important challenges because current manufacturing methodologies rely on complex, highly manual, time-consuming and imprecise/inaccurate processes characterised by i) An increasing complexity in design and manufacturing setup representing up to 20-25% of total costs; ii) Limited production efficiency and product quality that impose recurrent reworks with subsequent longer operations; iii) Preservation of the industry-specific knowledge and skills.

As a result, novel approaches for a more precise, accurate, flexible and responsiveness manufacturing or large-scale components are needed in order to maintain competitiveness of EU top-class manufacturing supply chain in strategic sectors, such us aerospace, shipbuilding, metalworking, transport.

PENELOPE aims to develop a novel methodology for a more precise manufacturing of large-scale parts based on holistic data management and integrated worker-centric solutions to develop an end-to-end manufacturing solution across the entire manufacturing chain.

  • What does PeneloPe bring to the EU manufacturing industry?

PENELOPE will support and enhance the transformation of EU industry, especially for the manufacturing of large-scale components. Therefore, we are offering to the European companies dealing with the manufacturing of large-scale components the opportunity to stay at the leading edge. Let me explain: to reach the EU excellence in the manufacturing of large-scale parts, products’ performance, quality or zero-defect manufacturing, customization (specially for low-volume/one-of-a-kind manufacturing schemes, that are the typical in the manufacturing of large-scale components), delivery time and lifecycle services —i.e. in situ maintenance and repair— must be ensured.

For that, PENELOPE will implement a digital manufacturing approach leveraging the potential of Internet of Things (IoT), simulation models, digital twins, heterogenous data-exchange, Artificial Intelligence (AI) algorithms, robotics and user-centric tools for developing a data-driven pipeline, linking product-centric data management and production planning and scheduling, for defining a more precise, responsiveness and productive manufacturing strategy from initial design.

Apart from, for a flexible and responsive production, one of the key-pillar is related with the development of user-centric solutions in which skilled workforce remains as key driver. To do that, PENELOPE takes advantage on the latest developments on VR/AR, exoskeletons, mobile and/or collaborative robots, etc., building a modular and flexible workshop.

  • What do you hope the EU will learn from this project?

PENELOPE will be built upon advancing and innovative technological solutions. The developments resulting from PENELOPE project relies on cutting edge technologies such as simulation models, Digital Thread, Digital Twin, online control & inline inspection, data analytics and AI tools, a broad range of worker-centric tools (VR/AR tools, exoskeletons, mobile robots, etc.) towards the future module, flexible factory 4.0.

  • What are the big challenges that the PeneloPe consortium is facing/is going to face during the project development?

You should think that manufacturing and repairing of large-scale components is a complex process. PENLOPE will develop an integrated methodology ensuring the manufacturability, quality and high-precision for the manufacturing of large components from the initial concept design. The goal is to link heterogenous data from both process and product lifecycle by gaining knowledge from the manufacturing to obtain a continuous model of the process, as well as assisting in a more precise design and manufacturing of the next large-scale components.

  • PENELOPE encompasses representative large-part manufacturing in four EU strategic sectors, addressing both one-of-a-kind (Oil&Gas, Shipbuilding) and low-volume manufacturing (Aeronautics, Bus&Coach). Why these specific sectors where selected?

Energy/Oil&Gas, Shipbuilding, Aeronautics and Transport are strategic sectors in Europe. In this regard, these sectors are represented by worldwide and top-class manufacturing companies such us AIRBUS, FOKKER, MV WERFTEN, ALSTOM… as well as linked supply chain companies. European companies are able to achieve superior quality and precision, while the integrated design and process development allows the fast deployment of products highly customized for unique customer needs. However, increasing complexity on the design of these large-scale components, regulation compliance, together with increasing quality and accuracy requirements are pushing the limits on the EU manufacturing sectors, and often customers are seduced to choose standard products from foreigner competitors, mainly Asian, due to lower manufacturing costs. In this regard, the future of these EU companies relies on the development of modular and flexible equipment together with the development of holistic data management by connecting engineering, management and production for a more responsiveness and precise manufacturing of these large-scale components. Thus, digitalization, knowledge and innovation are key pillars in which EU companies must invest if they want to maintain competitiveness against other foreigner competitors, such us Asia and US.

Finally, this manufacturing approach would be applied to other strategic value chains for European economy such us energy, railway, metalworking, and construction.

  • Has the current situation with the COVID-19 crisis, affected the development of the project?

No yet, even though some Partners have explicitly informed us about the impact from the COVID-19 outbreak, as PENELOPE is just starting, and we hope this situation will return to a normal point there is no delay or affectations. Apart from that, PENELOPE has two different branches: the physical in which we test the developments and solutions (affected with the restrictions) and the digital one (even with a potential lockdown we can progress in this part).  But we hope we’ll recover a normality very soon.

  • Who can benefit from the PeneloPe solution?

If the questions is how this new technology will affect our daily life:

1. Regarding the citizens, PENELOPE will change the way in which ships, planes, buses, etc. are made. It will even change the energy sector. It could trigger a shift of paradigm in the society. Actually, the expected results are:

  • Reinforcing Industrial Competitiveness, growth with better jobs and new skills
  • Leveraging private investment and innovation capacity
  • Reduction of the environmental impact and the safety hazards
    • 20% reduction of scrap generated by the industrial process
    • reduction of up to a 22% of energy consumption.
    • 25% on scrap reduction,
    • better usage of raw materials (up to a 15%) and reduces waste management

2. Thinking in the SMEs, they can also benefit from: PENELOPE contemplates the creation of a network of technological centers which will offer services oriented to SMEs or Mid-caps. Before being market, it will be offered and managed a network services by free through an Expression-Of-Interest Call (EOI) by FBA: to validate the network operation, services and acceptance. These services will be offered at no cost for the selected applicants. These services will be served on a revenue-basis (guaranteeing sustainability beyond the project). The expected SMEs which will apply to the EOI Call and the success results, will be used to convince authorities in the added value that their co-investment may generate. 

  • What are the next steps to be taken for the project development?

PENELOPE is developing and implementing this technology at the same time. The results will be tested implementing a two-fold approach:

  1. First level: deployment of a network of Didactic Factories (DF) at RTOs providing services in the European industry ecosystem.
  2. Second level: deployment of application-driven pilot lines at four industrial End-users in oil&gas, shipbuilding, aeronautics and bus&coach.

At this stage, we are in M9, all workpackages are active. We are starting to develop the solutions and exploring the most adequate approach to tackle all the challenges. The solutions will be implemented at the Didactic Factories first. This will reduce the gap with the final pre-industrial demonstration in real-scale pilot lines, validating the PENELOPE developments and ensuring the interoperability to produce an agnostic, flexible and modular solution.

  • Final question: Is it challenging to be the project coordinator of such a big EU project?

Yes, of course. To align efforts and resources to accomplish the PENELOPE project itself is the biggest challenge. So, we really need to perform their job in the most efficient way. But, it is also an opportunity to put together all this expertise in achieving a common objective and the results will be implemented and validated at industrial level. So, it will be relevant for the industry and for the society as well. In terms of management, the project PENELOPE is the biggest challenge that I had to face so far: a European flagship project, involving 31 partners from 9 countries of more than 20 million euros. So, it is challenging, demanding and time-consuming but also very, very stimulating.

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Filed Under: Featured

Welcome to the PeneloPe website!

Welcome to PeneloPe! In this site you will find all the relevant information regarding the project, its development, and the consortium working together to make it possible.

On the section ´The PeneloPe project´ you can learn about the overall objectives of the project, an introduction to the challenges and the project´s methodology and the partners forming the consortium.

On the section ´Tech and Demonstrators´ you will find everything you need to know about the project’s innovation potential, the technology advancements proposed and the demonstrators of the PeneloPe solution.

On the section ´Didactic Factories´ you can read about PeneloPe´s pan-European network of Didactic Factories and showrooms and access the subsections dedicated to each one of them.

On the section ´Community´ you will be accessing directly the PeneloPe Community and join an online platform for networking and mentorship with diverse industrial peers who will support, challenge and inspire one another!

To keep up with the latest progress of the project, publications, news and events, please take a look at the section ´events´ and ´media´.

If you have any question or request, please fill free to contact us here. You can also follow us on out twitter account and LinkedIn Profile!

Filed Under: Featured

Penelope EU industrial initiative officially kicks off to european improve large-scale parts manufacturing in the EU

Manufacturing of complex large-scale parts is a challenging subject matter in Europe. It must ensure high product quality through high-precision manufacturing and repairing processes across all stages of the value chain whilst remaining competitive in the global scenarios. It is a key part of industry in Europe since it affects strategic sectors such as oil and gas production, shipbuilding, aeronautics and bus/ coach assembly.

Nowadays, manufacturing methodologies still rely on manual, time-consuming and inaccurate processes however there is good news for the future of EU industry. To increase competitiveness of its SMEs, Mid-caps and corporates, Europe is leading this battle developing cutting edge technology on increasing products’ performance, quality, customization, delivery time and lifecycle services. As part of this strategy, PENELOPE will develop a specific methodology and vision focused on manufacturing of large-scale parts of several value chains.

PENELOPE main challenges involve: increasing complexity in design and manufacturing setup, Limited production efficiency and product quality, Raw materials scarcity is a major issue that increases production cost and preservation of the industry-specific knowledge and skills. In order to tackle these issues, innovation resulting from PENELOPE project will rely on developing and adopting technologies such as simulation models, Digital Thread, Digital Twin, online control & inline inspection, data analytics and AI tools, a broad range of worker-centric tools (VR/AR tools, exoskeletons, collaborative robots, etc.) towards the future modular and flexible factory 4.0.

These innovations will be built upon advancing existing “Made in Europe” technical solutions developed from previous EU multinational research projects that will allow taking the results to the next level. INTEGRADDE and MAYA projects in automotive and additive manufacturing; DIMOFAC, FAR-EDGE, AUTOWARE or OPENMOS projects to demonstrate a modular and decentralised manufacturing; SHERLOCK project developed AR tools and exoskeletons in real manufacturing fields; H2020-QU4ALITY for achieving Zero-defect manufacturing strategies; AI4EU project that develop an AI platform to build a cognitive Factory and to exploit the potential of artificial intelligence with advanced manufacturing.

All previous innovations and technical solutions will be reflected by the deployment, validation and demonstration of 4 industrial-driven pilot lines in strategic manufacturing sectors in EU tier one companies facilities: IDESA, MVW, FOKKER Aerostructures and VDL. The transformations brought about by PENELOPE need to be replicated, thus, it will be also supported by a pan-European network of Didactic Factories and showrooms, providing workforce training and skills development to industry. It is expected that PENELOPE will develop training methods, enabling the EU industrial workforce to transition towards Industry 4.0. ensuring safety, accuracy and precision on manufacturability in all stages from design to the final product for the overall benefit of the EU manufacturing sector.

More information can be found extensively at: https://penelope-project.eu/

About PENELOPE project: This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 958303.

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PENELOPE´s extensive and multinational partnership is leaded by AIMEN TECHNOLOGY CENTRE as project coordinator, and it is composed of 31 organizations all across Europe. Know more about the consortium here.

Filed Under: Uncategorized

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    This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 958303

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