STRATEGUS · STRATEgic GUide to Smart manufacturing

STRATEgic GUide to Smart manufacturing

Manufacturing is undergoing a major digital transformation. Over the last decade, advances in low-cost sensors, high-performance computing, and artificial intelligence have made it possible for factories to become smart, adapting to changing demand, integrating new processes, and cooperating with human operators. Initiatives such as "Industry 4.0" in Germany and Italy's "Piano Nazionale Industria 4.0" have encouraged this transition. The next step, "Industry 5.0", focuses on human-machine collaboration and worker well-being. Many European small and medium-sized enterprises (SMEs) still face difficulties in using the large amounts of data now collected on their shop floors. Integrating advanced scheduling, automation, and control technologies into existing production lines can be complex and carries the risk of reduced productivity, lower quality, or safety issues. At the same time, market trends are pushing a shift from make-to-stock to make-to-order production, which increases the need for agile and reliable manufacturing systems. The STRATEGUS project aims to address these challenges by developing intelligent scheduling and control methods that coordinate machines and human workers in flexible manufacturing systems. The core concept is a digital twin, a detailed virtual replica of a production line that is built from mathematical models and real-time sensor data. The digital twin is used to predict performance, optimise operations, and respond to unexpected events. The project will design and integrate three main components into an open-source software platform: - Digital twin: models the physical and operational behaviour of manufacturing equipment and workers, using both physics-based and data-driven approaches. - Scheduler (strategist): uses the digital twin to create optimal schedules, balancing cost, energy use, deadlines, safety, and worker capabilities. - Analysis tools: monitor performance, detect bottlenecks or failures early, and adjust plans automatically to minimise disruption. The work will be carried out by the University of North Carolina (USA) and the University of Verona (Italy). It will be tested on advanced industrial demonstrators and through partnerships with both multinational companies and SMEs. STRATEGUS will produce an open-source framework for digital-twin-based production simulation, scheduling, and analysis. The framework will help manufacturing companies to: - Reduce production time, energy consumption, and operational costs - Increase flexibility in fulfilling customised orders - Improve worker safety and well-being by taking human factors into account - Reduce downtime by detecting and mitigating problems earlier In the longer term, the methods can be extended to predictive maintenance and other optimisation tasks. STRATEGUS will enhance the competitiveness of European manufacturing, particularly for SMEs, and contribute to achieving EU goals in digitalisation, sustainability, and a human-centred industry. It will also train researchers in combining advanced modelling, optimisation, and industrial collaboration, ensuring long-term benefits.

Data: CORDIS, © European Union