The open innovation thanks to the Smart Factory 4.0 from ALTEN

All the more since the pandemic from Covid-19, the industry must become flexible and agile with on-demand production for increasingly personalized products. The key ? Data, in order to adapt all possible configurations, whether in terms of resources, design, logistics, quality monitoring … in “mode” end to end »In an integrated logic from the supplier to the end customer. This is the whole point of the smart factory or factory 4.0 which relies on technologies such as IoT, digital twin, the AI, the augmented reality or the robotic. However, there is no question of accumulating innovations to achieve this. The program set up by ALTEN insists precisely on the use of new technologies and the associated gains in the integration of these solutions into an existing environment, which is often not conducive to changes.

The fourth industrial revolution for the benefit of man

The concept of Industry 4.0 appeared at the beginning of the 2010s. It corresponds to the fourth industrial revolution after that of mechanization, electrification and then automation. Today, it is therefore that of digitization with the contribution of artificial intelligence most ” which must be for the benefit of that of humans, to provide them with all the information useful for forecasting and decision-making, of which they remain in control », Specifies François Portier, director of the Smart Factory 4.0 research program for ALTEN. In 2021, it is no longer a question of choice: those who will not take this turn will lose a lot of ground on the competitors. Especially since this 4.0 revolution integrates the challenges of sustainable development for a greener factory, a green factory which optimizes its energy resources and waste generated for zero or even positive environmental impact.

Gray matter and the black gold of data

ALTEN’s innovation department has therefore set up the “ Smart Factory 4.0 ». For this, it has forged partnerships with startups, large companies, research laboratories and schools. ” Our wealth is our matter gray and black gold of data, the fuel of the digital economy. It all starts with a good analysis of the client’s needs and context. We then rely on a network of experts gathered within Labs on innovative solutions », Explains François Portier. The approach was intended as a “test and learn” approach to make co-creativity a reality thanks to proactive ideation loops on projects before validating them using POC (Proof of Concept), de POV (Proof of Value) and MVP (Minium Viable Product).

9 Smart Factory 4.0 projects

The nine projects of the program address the technological challenges of the transformation of Industry 4.0:

• the maintenance predictive in real time (with gains of 20 to 30% on the duration machine life);
• intelligence managementenergy ;
• the distributed intelligence of AGVs (Autonomous Guided Vehicles) ;
• the digital twin of the factory of the future processes;
• the digital twin of the internal logistics of the factory of the future;
• robotics: universal gripper;
• digital continuity for additive manufacturing;
• the prediction of accidents professionals;
• the convergence of production and business management networks.

In prospective mode, a digital twin, a digital twin, allows for example to model projects with ramp-up to make them viable according to indicators such as the OQD (on quality delivery) and OTD (on time delivery) without impact on production. Of course, the cybersecurity is omnipresent at all project levels.

The adaptation of new technologies to the existing

According to François Portier, “ the earlier it is triggered, the more effective the transformation will be. The hardest part is getting started and managing the change “. It is for this reason that ALTEN is counting on adapting new technologies to existing ones so as not to have to make excessive investments and promote gradual adoption. ” We are progressing little by little, first on a defined perimeter which makes it possible to measure the impact and the gains before gradually expanding it. »Advice is also given on financial aid opportunities, in particular from the state when the project makes it possible in particular to gain energy sobriety.

The example of an AI solution in the edge computing

A striking example concerns a major player in the aeronautics sector. For the drill bits used on very expensive parts, the wear or the slightest failure of which can therefore have significant consequences, ALTEN called on a technology developed by the start-up. Cartesiam, recently acquired by STMicroelectronics. The solution called NanoEdge AI Studio makes it possible to incorporate an AI and its functionalities of machine learning directly in the C code of the microcontroller present in the device. It processes millions of combinations in a few hours algorithmiques to define which one is optimal and thus be able to detect the slightest anomaly. The solution tested on a production line was won over by its efficiency to the point that it will be deployed in all of the company’s factories.

According to Joël Rubino, director of Edge AI – STMicroelectronics, “ l’artificial intelligence suffers from over-communication which can confuse some on how to use it wisely without too much investment or development time. This kind of solution has a very simple and rapid prototyping capacity, for a gradual generalization thereafter. This makes it possible to demystify AI, to evangelize teams, with limited investments and above all to be ready when all technologies mature. “. A necessary and beneficial approach that he likes to sum up in one sentence: ” If you want to go on the Moon, you have to go to Houston first! “

Article produced in partnership with ALTEN