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Manufacturing, Scale-up
and Clean Energy
Berkeley – March 2015
Prof. Mike Gregory
Outline
• Changing structures in manufacturing
• Mapping research to value chains
• Emergence and Scale-up
• Tackling the whole manufacturing system
• Implications for clean energy
Changing Patterns of Industry
• Companies increasingly focus on particular stages of value chain
• Stages in the value chain may have different ‘owners’.
• Interfaces and interdependencies poorly understood.
• Implications for industrial competitiveness
R&D Design Supply Production Routes
to Market
After Sales
Services
R&D - Plastic Logic
• ‘Power of electronics with pervasiveness of printing’
• Enables new product concepts including displays & sensors.
• Potential to create new industry via radical change in economics of production
Production - GKN
• 40% of world market for constant velocity joints
• Leadership enabled by production capability linked to advanced design
• Close integration with customers
• Local production facilities worldwide
Service - Xerox
• Pioneered service based business models
• Service offering now includes business improvement
• Re-manufacturing a growing strength
• Example of product-service systems
So what can research do…?
• Ensure take up of new knowledge
• Marshal research across value chain
• Support & capture “emerging industries”
• How can research help keep industrial systems healthy, efficient, competitive and evolving?
R&D Design Suppy Production Routes
to Market
After Sales
Servics
Identify Societal / Market Needs & define system requirements & barriers
Develop Useful Insights from Fundamental Knowledge
Integrate Fundamental Knowledge into Enabling Technology
Research Systems Interacting research activities
(E O’Sullivan: Adapted from NSF ERC Strategy Framework)
Research & Industrial Systems
(Eoin O’Sullivan & Mike Gregory)
Linking research to industrial needs
Physical Production Engineering • Advanced Manufacturing • Manufacturing Machines & Equipment • Materials Process & Performance Control • Fabrication & Processing Technology • Advanced Processing & Packaging • Production scale-up (emerging industries)
Decision Systems Engineering • Reconfigurable Manufacturing Systems • System Design & Simulation Engineering • Product Development Innovation • Visualizing & virtual prototyping systems • Sensors and Sensing Systems • Control Systems
Industrial Innovation Systems • Innovation Systems & Design Eng • Operations Systems research • Logistics & Distribution • Value chain research • Product-service systems • Industrial Organizational Systems
Applied science & Technology • Materials science • Device physics • Applied chemistry • Biotechnology •
Industrial Systems-Market/Society Interface • Innovation Systems & Design • Service Enterprise Systems • Industrial Economics • Industrial policy
ECONOMIC & SOCIAL SCIENCE
RESEARCH
APPLIED SCIENCE
RESEARCH
ENGINEERING RESEARCH
Industrial Innovation and Research Fields
(Eoin O’Sullivan)
Physical Production Engineering • Advanced Manufacturing • Manufacturing Machines & Equipment • Materials Process & Performance Control • Fabrication & Processing Technology • Advanced Processing & Packaging • Production scale-up (emerging industries)
Decision Systems Engineering • Reconfigurable Manufacturing Systems • System Design & Simulation Engineering • Product Development Innovation • Visualizing & virtual prototyping systems • Sensors and Sensing Systems • Control Systems
Industrial Innovation Systems • Innovation Systems & Design Eng • Operations Systems research • Logistics & Distribution • Value chain research • Product-service systems • Industrial Organizational Systems
Applied science & Technology • Materials science • Device physics • Applied chemistry • Biotechnology •
Industrial Systems-Market/Society Interface • Innovation Systems & Design • Service Enterprise Systems • Industrial Economics • Industrial policy
ECONOMIC & SOCIAL SCIENCE
RESEARCH
APPLIED SCIENCE
RESEARCH
ENGINEERING RESEARCH
Research fields and their positioning
Emergence map – CT Scanners
(Eoin O’Sullivan)
Misalignment & leakage SCIENCE
Dominated Emergence
TECHNOLOGY Dominated Emergence
APPLICATION Dominated Emergence
MARKET Dominated Emergence
Mature ”emerged”
market
Precursor Embryonic Nurture Growth
(E. O’Sullivan)
Leve
l of F
undi
ng
Basic Research Development / Scale-up Commercial Operation Mature Industry
Navigation of industrial emergence (barriers, enablers, inhibitors) depends on understanding of industry-level factors, e.g.:
• Industrial design • Manufacturing strategy • Production scale-up • Supply networks • Investment • Regulation & standards
Time Valley of
Death
Funding from public sector
Private sector sales
Scale-up New science ideas & technology opportunities into new industries, new jobs
(Eoin O’Sullivan)
Leve
l of F
undi
ng
Time
Scale-up Different value chain configuration for different emergence phase
(Eoin O’Sullivan)
Leve
l of F
undi
ng
Time
Scale-up Different research for different innovation needs Different research for different phases of scale-up
(Eoin O’Sullivan)
Leve
l of F
undi
ng
Emerging Industries
(E O’Sullivan & L. Dodin)
Science lab-grown human tissue
Time
Regenerative Medicine
Leve
l of F
undi
ng
Emerging Industries
(E O’Sullivan & L. Dodin)
Seeding of stem cells on
engineered structures
Science lab-grown human tissue
Time
Regenerative Medicine
Leve
l of F
undi
ng
Emerging Industries
(E O’Sullivan & L. Dodin)
Seeding of stem cells on
engineered structures
GMP manufacturing & automation processes
Science lab-grown human tissue
Time
Regenerative Medicine
Leve
l of F
undi
ng
Emerging Industries
(E O’Sullivan & L. Dodin)
Seeding of stem cells on
engineered structures
GMP manufacturing & automation processes
Advances in logistics & distribution technologies
Science lab-grown human tissue
Time
Regenerative Medicine
Canadian Manufacturers & Exporters (2005)
[Manufacturing is] a business system encompassing all activities required to deliver products that meet customer needs... [The system extends] from R&D, design, engineering, to production, finance, sales, marketing, after-sales service... extends beyond any single enterprise, across increasingly global supply chains and business networks.
Definitions of ‘Manufacturing’ People can mean very different things...
The manufacturing sector... a wide-ranging number of different industries, technologies and activities, varying significantly in terms of the economic value they generate, reflecting differences in their use of particular factors of production (raw materials, physical capital, intangible investment, skilled and non-skilled labour, knowledge)
The manufacturing sector comprises establishments engaged in the mechanical or chemical transformation of materials substances, or components into new products. Establishments in the manufacturing sector are often described as plants or factories, and characteristically use power-driven machines and materials-handling equipment...
North American Industry Classification System (200
BIS Economics Paper 10A (2010
transformation of materials plants or factories
business system ...extends from R&D, design, engineering, to production, finance, sales, marketing, after-sales service
industries, technologies and activities
factors of production
machines and materials-handling equipment
“Entrepreneurship”
Energy
“Knowledge”
Land /resources
Dis
tribu
tion
Sub
-as
sem
blie
s
Par
ts
Com
pone
nts
Production
Pro
cess
ed
mat
eria
ls
Supp
ly
man
agem
ent
Dev
elop
men
t
Des
ign
Production
Res
earc
h
Production Fa
ctor
y eq
uipm
ent
Ada
ptiv
e m
achi
nes
• Production capability
“Manufacturing” Production
Mec
ha-
troni
cs
Raw materials
Product idea
Capital equipment
/ tools
Dis
tribu
tion
Afte
r-sal
es
Serv
ices
Eng
inee
ring
tool
s
“Manufacturing” Production
Perspectives on ‘Manufacturing’ / ‘Production’ What we talk about when we talk about ‘manufacturing’...
• Factory-based activities
• Production function
• Material transformation & assembly/supply
• Product development & delivery
Integrated Conceptualisation of Manufacturing A Systems Perspective
Knowledge
Natural resources
Capi
tal
Enterprise
Production
Integrated Conceptualisation of Manufacturing A Systems Perspective
Product/ service
Dis
tribu
tion
Knowledge
Natural resources
Capi
tal
Enterprise
Production
Fact
ory
equi
pmen
t
Mec
ha-
troni
cs
Adap
tive
mac
hine
s
Production capability configuration
Capital equip / tools
So what about clean energy?
• Manufacturing has focussed on energy reduction
• Opportunities at process, system and network levels
• Good practice and load scheduling undervalued
SO…
• Low cost clean energy the goal
• Modern manufacturing offers integrating approach
• Identification and mapping of ‘ecosystems’ a first step
A manufacturing perspective
• Consider energy systems as manufacturing systems • Seek to lower cost of ‘production’ processes - through process efficiency - and radical product design • Consider system and network opportunities • Explore cross sectoral learning • Map and manage the manufacturing ‘ecosystem’