Reijo Tuokko

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Desktop Factories Actual Knowledge Status and

Experiences from Far East

Prof. Reijo Tuokko

Tampere University of Technology

Department of Production Engineering

October 24, 2011

MANUMANUFUTUREFUTURE 2011 CONFERENCE2011 CONFERENCE

WS1 -New emerging Manufacturing Science and Technologies


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Outline

1. Introduction

2. Overview: Europe

3. Overview: USA

4. Overview: Japan

5. Overview: Korea

6. Discussion


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MiniaturizedMiniaturizedFactoriesFactories

MiniaturizedMiniaturizedProductionProduction

EquipmentEquipment

Trends in

MiniaturizedMiniaturizedProductsProducts

Miniaturization

Desktop Lorch Lathes for

Watchmakers in 1930


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Surroundings for Manufacturing Industry

Minimizing energy

consumpt ion and use of naturalresources

Fast supply/manufacture/delivery

of customized and personalizedproduct of varying volumes

Easy and fast re-configurabil ity

Cut initial/running costs

Space utilization


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Benefits of the Approach

Remarkable savings in investment, space, energy, andresources

Special savings in clean room

Easy to change the production (layout, reconfiguration, )

Shorter ramp-up time

Production and customization closer to the customer

Change the long-established image of factories

Ubiquitous manufacturing (on-site, mobile,)

Better performance

Less mass to move

Shorter distances to travel

Smaller force loops -> high natural frequency

Smaller dimensions -> smaller deformations


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Europe


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Desktop Factory Technology from Festo


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Year

2007

Miniaturization

Desktop Factory by Bosch Rexroth


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Desktop Factory Technology from

Switzerland

Asyfeed Pocket for palletizing,

sorting & assembly

PocketDelta line: 4 Robots,

Footprint: 0.5 x 1.2m2

PocketDelta Robot

DesktopDelta Robot


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TUT-Microfactory

Concept & Applications

Laser markingLaser marking

Modular TUTModular TUT MicrofactoryMicrofactory

Mobile phone assemblyMobile phone assembly

Ear implant fabricationEar implant fabrication

CO2 SensorCO2 Sensor asemblyasembly

MEMS spring assemblyMEMS spring assembly

2

2


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Desktop Factory Technology from

Finland

Master Automation Group Oy

Wegera Oy

Biohit Oyj


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USA


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AtometricAtometric, Inc, Inc.,., 44--AxisAxis MicroMicro

MillingMilling MachineMachineMicromachinesMicromachines Int.,Int., 33--AxisAxis

MicroMicro Milling MachineMilling Machine

MicrolutionMicrolution Inc.,Inc.,

33--Axis MicroAxis Micro

Milling MachineMilling Machine

Commercial US Desktop Machinery

Medical Murray Inc., Micro-

Injection Moulding Machine

SmalTec Int., Micro-EDM

and Grinding

ExOneExOne Inc.,Inc.,

MicroMicro--ECM MachineECM Machine


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Japan

1996-20002010


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Portable Microfactory

Lathe Milling machine Press machine Transfer arm Two-fingered hand

1996 2000

Courtecy: Dr. Okazaki, AIST, 2004


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Developments in National Projects

Desktop Micro CNC Milling

Machine. Size (mm): 370L x

374W x 642H

www.enomoto-net .co .jp


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Achieved Benefits of Desktop Factories

Space saving 95%

Total energy saving 98% (inc l.

assembly processes, cleaning,

compressed air & air controlling

units)

Takashima Sangyo Co., Ltd.

Conventional Turning Machine Desktop Turning Machine

Workpiece material saving

up to 99%

Space saving 90%

Machining of precision watch

parts


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Target

Joint research work on Desktop Factory (DTF) in order to

promote the SUWA area to become a center for aggregation of

DTF machines and modules, which forms the basis of overall

industrial activation

Concept

Flexible and efficient production of small items with smallsystems

Small lot production of various kinds of items

Speedy production, short delivery time and low production cost

Production at an optimal allows smoother work and closer

relation to users, promoting creative approaches and values

Earth Friendly and ecology

conscious "MONOZUKURI"

DTF Research Consortium (Japan)

22 Member CompaniesINDUSTRY NETWORK Co.

ENGINEERING SYSTEM Co., Ltd.

OLYMPUS Co.

KEC Co.

KOGANEI Co.

CKD Co.

CERATEC JAPAN Co., Ltd.

CENTRAL ENGINEERING Co., L td.DAIYA SEIKI Co., Ltd.

TAKASHIMA SANGYO Co., Ltd.

TAMAGAWA SEIKI Co., Ltd.

TOYO SEIKI KOGYO Co., Ltd .

NAGATA SEISAKUSHO Co., Ltd.

NIDEC SANKYO Co.

NOMURA UNISON Co., Lt d.

HIRAIDE PRECISION Co., Ltd.

BOSCH Co.MIKUNI KOGYO Co., Ltd.

MISUZU INDUSTRIES Co.

SHINKO SELLBUC Co., Ltd.

TECHNO Co., Ltd.


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DTF Manufacturing Line with Wireless

Communication

2009 SUWA AREA

INDUSTRIAL MESSE


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Desktop Multi-Process Machine with

Exchangeable Tool-Heads


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Desktop Minakiro Factory



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300+ Desktop machines already in use

Takas

himaSangy

oCo.,

Ltd.


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Desktop Machine Tools from Japan

http://vcad-hpsv.riken.jp/


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iModela iM-01 - Affordable 3D Hobby Mill is

Designed for the Craft and Hobby Markets

Roland iModela iM-01 Features:

Precisely mills 3D shapes, patterns and

designs out of foam, wax, balsa wood and

plastic

iModela Creator, Rolands 3D design

software, is included, allowing users to

accurately mill shapes, holes, textures andpatterns right out of the box

Affordable, easy-to-use platform for

exploring creativity

Easy to setup and operate, with just a

power switch, simple LED display and

external control panel for adjusting

computer settings

Compact, desktop device stores in adedicated carrying case and travels easily

A specially designed spindle motor*1 unit

supports a variety of milling tools*2

commonly available at model shops and

do-it-yourself (DIY) retailers

iModela artists can share projects and

learn from others around the world byjoining the online community at

http://icreate.rolanddg.com

www.rolanddg.com


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Korea

National Programme 2004-2011:

DevelopmentDevelopment of Microof Micro--Factory SystemFactory System

Technology for Next GenerationsTechnology for Next Generations


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Development of Micro-Factory System

Technology for Next Generations

Project Coordinator : Korea Institute of Machinery and Materials (KIMM), Dr. Jong-

Kweon Park

Duration : Sept. 2004 ~ Aug. 2011 (3-phases, 7 years)

Total budget : 21 million USD

Funding: 78% MKE (Ministry of

Knowledge and Economy,Korea), 22% Industry

Participating organizations:

9 industries

15 Universities

3 Research Institutes

6 Foreign organizations2004 -2007: Development of Core

Machine Element Technology

2007-2009: Development of Unit

Machine System and basis for Field

Applications

2009 -2011: Micro-factory for FutureHigh Tech Industry


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Machine Tool Elements and Machine

ToolsResults from DevelopmentResults from Development of Microof Micro--Factory System Technology for NextFactory System Technology for Next GenerationsGenerations


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IT-Microfactory System for Cellular

Phone Camera Module

Manual: 4 persons, cycle time 3 min

Automated: Cycle time appr. 10 sec

Footprint: 820 (W) 700 (D)

Results from DevelopmentResults from Development of Microof Micro--Factory System Technology for NextFactory System Technology for Next GenerationsGenerations


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Developed Commercial System for

Dental RestorationsResults from DevelopmentResults from Development of Microof Micro--Factory System Technology for NextFactory System Technology for Next GenerationsGenerations

FinalFinal

55--axisaxis MillingMilling

Machine for CMAMachine for CMA

CMA Custom Implant Abutment


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Discussion (1)

Economical and ecological opportunities and

challengesDesktop size supports better lean production and

automation assisted manual productionSmaller production facilities or more production in the

same space

Lower investments in production systems

Reduced material costs, less waste. Reduced energyconsumption and lower running costs.

Improved portability of the production equipment.

Distributed production and delivery

Point-of-Need Manufacture


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FoF Workshop 25 November 2010

Minakiro Desktop Factory, Takashima Sangyo Co., Ltd.


300+ desktop machines in the factory300+ desktop machines in the factory

Comparison to a tradit ional factory:Comparison to a tradit ional factory:

Production capacity:Production capacity: 1:11:1

Investment:Investment: 1:51:5

Running costs:Running costs: 1:51:5


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Discussion (2)

A lot of research is behind of the first

commercialized desktop factory

products

Further joint research (from manufacturingprocesses and machines to business models

and value chains) is still needed for a real

breakthrough in the manufacturing

industry in order to utilize the wholepotential of the desktop approach and

to respond fully to the existing and

developing market and society need.


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Discussion (3)

How to promote and accelerate R&D and

utilization of desktop factory technology in

industry?

Status:

Commercialization of technology and implementation

in industry has started

Gaps:

Vast supply base of technology, machine components

and equipment from multi suppliers (COTS -

Components Off The Shelf)


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Discussion (4)

How to promote and accelerate R&D and

utilization of desktop factory technology in

industry?

Opportunities:

Increase industrial interest through killing applications

to show the benefits and business potential

Strengthen international cooperation and knowledge

sharing and build a global desktop factory community

Promote industrial participation in the community


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Welcome to IWMF 2012 & its Industry Forum!Welcome to IWMF 2012 & its Industry Forum!

www.tut.fi/iwmf2012

Industry Forum on Innovation and Entrepreneurship

in Micro and Desktop Factor ies

&

IWMF Innovation Awards


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TH NKS

Q

reijo tuokko@tut fi

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