MANUFUTURE

MANU
FUTURE 2011 CONFERENCE
WS1 -New emerging Manufacturing Science and Technologies

Desktop Factories
Actual Knowledge Status and
Experiences from Far East
Prof. Reijo Tuokko
Tampere University of Technology
Department of Production Engineering
October 24, 2011

Outline
1. Introduction
2. Overview: Europe
3. Overview: USA
4. Overview: Japan
5. Overview: Korea
6. Discussion

Trends in

Miniaturized
Products

io
t
a
z
i
r
u
t
a
Mini

Miniaturized
Production
Equipment

Desktop Lorch Lathes for

Watchmakers in 1930

Miniaturized
Factories

Surroundings for Manufacturing Industry

Minimizing energy
consumption and use of natural
resources

Fast supply/manufacture/delivery
of customized and personalized
product of varying volumes
Easy and fast re-configurability

Cut initial/running costs

Space utilization

Micro and Desktop Factories

Small desktop-size production
systems suitable for fabricating
and manufacturing of small size
parts and products

Case 1:

Energy
saving
98%

Case 1:

Space
saving
95%

Case 2:

Case 2:

Material
saving
99%

Space
saving
90%

Paradigm Change
Towards Environmental Friendly, Agile and
Point-of-Need Manufacturing

Benefits of the Approach

Remarkable savings in investment, space, energy, and
resources
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

Europe

Desktop Factory Technology from Festo

Desktop Factory by Bosch Rexroth

Year
2007

tio
a
z
i
r
u
t
a
i
in

Desktop Factory Technology from

Switzerland
PocketDelta Robot

PocketDelta line: 4 Robots,

Footprint: 0.5 x 1.2m2

Asyfeed Pocket for palletizing,

sorting & assembly

DesktopDelta Robot

22

TUT-Microfactory
Concept & Applications

Modular TUT Microfactory

Ear implant fabrication

Laser marking

MEMS spring assembly

CO2 Sensor asembly

Mobile phone assembly

Desktop Factory Technology from

Finland

Master Automation Group Oy

Biohit Oyj

Wegera Oy

USA

Commercial US Desktop Machinery

Atometric, Inc
Atometric,
Inc.,
., 4-Axis Micro
Milling Machine

Medical Murray Inc., MicroInjection Moulding Machine

SmalTec Int., Micro-EDM

and Grinding
Microlution Inc.,
3-Axis Micro
Milling Machine

Micromachines Int., 3-Axis

Micro Milling Machine

ExOne Inc.,
Micro--ECM Machine
Micro

Japan

1996-2000

2010

Portable Microfactory

Courtecy: Dr. Okazaki, AIST, 2004

1996

Lathe

Milling machine

2000

Press machine

Transfer arm

Two-fingered hand

Developments in National Projects

www.enomoto-net.co.jp
Desktop Micro CNC Milling
Machine. Size (mm): 370L x
374W x 642H

Achieved Benefits of Desktop Factories

Space saving 95%

Total energy saving 98% (incl.
assembly processes, cleaning,
compressed air & air controlling
units)

Conventional Turning Machine

Machining of precision watch

parts

Desktop Turning Machine

Workpiece material saving

up to 99%
Space saving 90%

Takashima Sangyo Co., Ltd.

DTF Research Consortium (Japan)

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 small
systems
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"

22 Member Companies
INDUSTRY NETWORK Co.
ENGINEERING SYSTEM Co., Ltd.
OLYMPUS Co.
KEC Co.
KOGANEI Co.
CKD Co.
CERATEC JAPAN Co., Ltd.
CENTRAL ENGINEERING Co., Ltd.
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., Ltd.
HIRAIDE PRECISION Co., Ltd.
BOSCH Co.
MIKUNI KOGYO Co., Ltd.
MISUZU INDUSTRIES Co.
SHINKO SELLBUC Co., Ltd.
TECHNO Co., Ltd.

DTF Manufacturing Line with Wireless

Communication

2009 SUWA AREA

INDUSTRIAL MESSE

Desktop Multi-Process Machine with

Exchangeable Tool-Heads

Takashima Sangyo Co., Ltd.

Desktop Minakiro Factory

Takashima Sangyo Co., Ltd.

Takashima Sangyo Co., Ltd.

300+ Desktop machines already in use

Desktop Machine Tools from Japan

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

iModela iM-01 - Affordable 3D Hobby Mill is

Designed for the Craft and Hobby Markets
www.rolanddg.com
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 and
patterns 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 a
dedicated 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 by
joining the online community at
http://icreate.rolanddg.com

Korea
National Programme 2004-2011:

Development of Micro
Micro--Factory System
Technology for Next Generations

Development of Micro-Factory System

Technology for Next Generations
Project Coordinator : Korea Institute of Machinery and Materials (KIMM), Dr. JongKweon 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 organizations
2004 -2007: Development of Core
Machine Element Technology
2007-2009: Development of Unit
Machine System and basis for Field
Applications
2009 -2011: Micro-factory for Future
High Tech Industry

Machine Tool Elements and Machine

Tools
Results from Development of Micro
Micro--Factory System Technology for Next Generations

IT-Microfactory System for Cellular

Phone Camera Module
Results from Development of Micro
Micro--Factory System Technology for Next Generations

Manual: 4 persons, cycle time 3 min

Automated: Cycle time appr. 10 sec

Footprint: 820 (W) 700 (D)

Developed Commercial System for

Dental Restorations
Results from Development of Micro
Micro--Factory System Technology for Next Generations

Final
5-axis Milling
Machine for CMA
CMA Custom Implant Abutment

31

Discussion (1)
Economical and ecological opportunities and
challenges
Desktop size supports better lean production and
automation assisted manual production
Smaller production facilities or more production in the
same space
Lower investments in production systems
Reduced material costs, less waste. Reduced energy
consumption and lower running costs.
Improved portability of the production equipment.
Distributed production and delivery

Point-of-Need Manufacture

Minakiro Desktop Factory, Takashima Sangyo Co., Ltd.

300+ desktop machines in the factory

Takashima Sangyo Co., Ltd.

Comparison to a traditional factory:

Production capacity: 1:1
Investment:
1:5
Running costs:
1:5

FoF Workshop 25 November 2010

33

Discussion (2)
A lot of research is behind of the first
commercialized desktop factory
products
Further joint research (from manufacturing
processes and machines to business models
and value chains) is still needed for a real

breakthrough in the manufacturing

industry in order to utilize the whole
potential of the desktop approach and
to respond fully to the existing and
developing market and society need.

34

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)

35

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

Welcome to IWMF 2012 & its Industry Forum!

www.tut.fi/iwmf2012

Industry Forum on Innovation and Entrepreneurship

in Micro and Desktop Factories
&
IWMF Innovation Awards

THANKS
Q&A
reijo.tuokko@tut.fi