Intelligent embedded components for enhanced supply chain observability and traceability: INTELLICO
Lead Research Organisation:
Loughborough University
Department Name: Sch of Mechanical and Manufacturing Eng
Abstract
This project will develop highly innovative ambient intelligence (AmI) software components to increase significantly the
observability and traceability of systems, human operators (HO's) and environments within the automotive and electronics
manufacturing supply chains, thereby leading to more effective control and monitoring throughout the product supply chain
and operational lifecycle based upon higher levels of intelligence. This knowledge generation capability requires the
deployment of a network of integrated, embedded (within the product and processes) Radio Frequency components and
systems with robust, reliable sensors, autonomous operation, proactive reasoning, learning and social abilities (e.g.
communication, co-operation, conflict resolution and negotiation). The objective of INTELLICO is to demonstrate a
prototype generic network at automotive and electronics manufacturing end users.
observability and traceability of systems, human operators (HO's) and environments within the automotive and electronics
manufacturing supply chains, thereby leading to more effective control and monitoring throughout the product supply chain
and operational lifecycle based upon higher levels of intelligence. This knowledge generation capability requires the
deployment of a network of integrated, embedded (within the product and processes) Radio Frequency components and
systems with robust, reliable sensors, autonomous operation, proactive reasoning, learning and social abilities (e.g.
communication, co-operation, conflict resolution and negotiation). The objective of INTELLICO is to demonstrate a
prototype generic network at automotive and electronics manufacturing end users.
Planned Impact
(i) Economic:
The consortium aim to make significant reductions in manufacturing, maintenance and End of Life costs for automotive and
high value electronics products. For example, the consortium will aim to achieve (i) a reduction of 95% of engine mis-builds
due to incorrect parts (a greater than £200M p.a. issue for rework, warranty) (ii) a 95% reduction in losses ( a greater than
£10M p.a. issue for misplaced items) (iii) a 100% improvement on quality (e.g. from cleaning, shocks, temperature) (iv) an
80% improvement on traceability (currently batch level in 10,000's) (v) an 80% reduction in time to solve field issues and,
(vi) an 80% improvement on End-of-Life processing. For industrial adoption, dramatic reductions in lifecycle costs and
business risks are required, allied to significant improvements in reliability and component parts traceability. Additionally the
project will create new business models based upon embedded product service models.
(ii) Social:
The new business models created by the generation of these embedded product service architectures will see job creation in services development, education and up-skilling of human operators (e.g. IMechE Imagineering scheme) and augmented health and safety training for staff. The market opportunities in high value production are also expected to see improved competitiveness in UK manufacturing and provision of a technical lead to exploit further market opportunities that
shall maintain and potentially grow employment opportunities in high value manufacturing industries.
(iii) Environmental
The INTELLICO technologies and services are particularly targeted at delivering significant reductions in rework, waste generation, resource usage (e.g. materials, energy) and throughout life maintenance of products and production resources.
Embedding product knowledge and life-history shall also see significant improvement in the complex decisions regarding recycling vs. reuse vs. remanufacturing activities. Such improvements offered by INTELLICO will enable better informed decisions regarding these decision points, thereby increasing materials and product reclamation and re-use and improving the operating efficiencies of the end of life management businesses. The services provided shall also better integrate OEM and supply chain entities with the manufacturing with end-of-life companies, thereby explicitly extending and closing the
loop on product supply chains.
The consortium aim to make significant reductions in manufacturing, maintenance and End of Life costs for automotive and
high value electronics products. For example, the consortium will aim to achieve (i) a reduction of 95% of engine mis-builds
due to incorrect parts (a greater than £200M p.a. issue for rework, warranty) (ii) a 95% reduction in losses ( a greater than
£10M p.a. issue for misplaced items) (iii) a 100% improvement on quality (e.g. from cleaning, shocks, temperature) (iv) an
80% improvement on traceability (currently batch level in 10,000's) (v) an 80% reduction in time to solve field issues and,
(vi) an 80% improvement on End-of-Life processing. For industrial adoption, dramatic reductions in lifecycle costs and
business risks are required, allied to significant improvements in reliability and component parts traceability. Additionally the
project will create new business models based upon embedded product service models.
(ii) Social:
The new business models created by the generation of these embedded product service architectures will see job creation in services development, education and up-skilling of human operators (e.g. IMechE Imagineering scheme) and augmented health and safety training for staff. The market opportunities in high value production are also expected to see improved competitiveness in UK manufacturing and provision of a technical lead to exploit further market opportunities that
shall maintain and potentially grow employment opportunities in high value manufacturing industries.
(iii) Environmental
The INTELLICO technologies and services are particularly targeted at delivering significant reductions in rework, waste generation, resource usage (e.g. materials, energy) and throughout life maintenance of products and production resources.
Embedding product knowledge and life-history shall also see significant improvement in the complex decisions regarding recycling vs. reuse vs. remanufacturing activities. Such improvements offered by INTELLICO will enable better informed decisions regarding these decision points, thereby increasing materials and product reclamation and re-use and improving the operating efficiencies of the end of life management businesses. The services provided shall also better integrate OEM and supply chain entities with the manufacturing with end-of-life companies, thereby explicitly extending and closing the
loop on product supply chains.
Publications
Sharpe R
(2018)
Cyber-Physical Systems in the re-use, refurbishment and recycling of used Electrical and Electronic Equipment
in Journal of Cleaner Production
| Description | Antennae design: Novel encapsulated antennae design for embedded RFID applications with directional control and reduced interference Use of EI to enhance recycling efficiency: Use of EI technology incorporated into electronics by OEM customers will enable S2S to make more informed choices at end of life about the best options for refurbishment, recycling or reuse and this will enable S2S to generate more revenue for itself and its customers. Transfer of data with product: The innovative element of this result is that the data; process history, batch numbers, materials dates etc. is retained and added to through the value chain and is readily available at each step. Encryptable EI - Sept 2011: a printed circuit board with an encryptable EI embedded within it to record full product details, process results & test results ensuring product quality. Also provided the platform to develop through life controls for recycling. Commercialisation of EI in Board: Incorporation of EI functionality as a solid state device is novel and therefore more reliable and safer than alternative options. Antenna structure in component keep out area of the board. 4 pad layout for chip interconnections (improved stability) Usage of adhesive for interconnection (possible attachment before or after alternative oxide process possible) Usage of under-fill for mechanical stabilisation of the chip on the inner layer. Test and programming of the chip with a probe for defined communication with a specific tag Data structure/organisation with RFID memories. Layered multi-layer structure with recess holes in both pre-pregs/determination of pre-preg layer thickness. Visualisation software to a)read/write to tag b)to track products c)to link additional information (e.g. databases) |
| Exploitation Route | Improved end of life decisions for electronics refurbishment, recycle and reuse leading to improved UK revenue. Encrypted embedded intelligence in products allowing development of through life controls, leading better decisions for end of life. Commercialisation of EI in board provides safer and more reliable functionality. Improved product tracking and tracing will allow manufacturers to reduce loss and increase productivity and record more information about their products and processes. |
| Sectors | Aerospace Defence and Marine Digital/Communication/Information Technologies (including Software) Electronics Energy |
| Description | Antennae design: Novel encapsulated antennae design for embedded RFID applications with directional control and reduced interference Use of EI to enhance recycling efficiency: Use of EI technology incorporated into electronics by OEM customers will enable S2S to make more informed choices at end of life about the best options for refurbishment, recycling or reuse and this will enable S2S to generate more revenue for itself and its customers. Transfer of data with product: The innovative element of this result is that the data; process history, batch numbers, materials dates etc. is retained and added to through the value chain and is readily available at each step. Encryptable EI - Sept 2011: a printed circuit board with an encryptable EI embedded within it to record full product details, process results & test results ensuring product quality. Also provided the platform to develop through life controls for recycling. Commercialisation of EI in Board: Incorporation of EI functionality as a solid state device is novel and therefore more reliable and safer than alternative options. Antenna structure in component keep out area of the board. 4 pad layout for chip interconnections (improved stability) Usage of adhesive for interconnection (possible attachment before or after alternative oxide process possible) Usage of under-fill for mechanical stabilisation of the chip on the inner layer. Test and programming of the chip with a probe for defined communication with a specific tag Data structure/organisation with RFID memories. Layered multi-layer structure with recess holes in both pre-pregs/determination of pre-preg layer thickness. Visualisation software to a)read/write to tag b)to track products c)to link additional information (e.g. databases) |
| Sector | Aerospace, Defence and Marine,Digital/Communication/Information Technologies (including Software),Electronics,Energy |
| Impact Types | Economic |
| Description | End of Life Product Monitoring |
| Amount | £20,000 (GBP) |
| Organisation | S2S Limited |
| Sector | Private |
| Country | United Kingdom |
| Start | 09/2017 |
| End | 10/2021 |
| Description | Ford Motor Company Global Innovation Award |
| Amount | $150,000 (USD) |
| Organisation | Ford Motor Company |
| Sector | Private |
| Country | United States |
| Start | 09/2016 |
| End | 10/2020 |
| Description | Loughborough University Enterprise Project |
| Amount | £20,000 (GBP) |
| Organisation | Loughborough University |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 06/2016 |
| End | 01/2017 |
| Description | Optimisation of Manufacturing Processes by Gamification |
| Amount | £60,000 (GBP) |
| Organisation | HSSMI |
| Sector | Private |
| Country | United Kingdom |
| Start | 09/2017 |
| End | 10/2021 |
| Description | Platform Grant |
| Amount | £1,600,000 (GBP) |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 03/2017 |
| End | 04/2022 |
| Title | Development of system to collect and send asset and environmental data via GSM to a cloud server for storage in a database |
| Description | Data from an instrumented van collected though a number of wireless sensors for environmental conditions and asset presence, sent via GSM. This data is then collected and stored in a relational database with key value pairs to ensure data is kept correctly linked to relevant customers and can only be accessed by relevant personnel. The model utilises a VPN, password protection and user access restrictions to maintain data security. |
| Type Of Material | Database/Collection of data |
| Year Produced | 2019 |
| Provided To Others? | No |
| Impact | Secure data management and advanced traceability of assets, ensuring data integrity for better asset security during transport. |
| Description | Encryptable EI - Sept 2011 |
| Organisation | Invotec Group Ltd |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | To produce a printed circuit board with an encryptable EI embedded within it to record full product details, process results & test results ensuring product quality. Also to provide the platform to develop through life controls for recycling. |
| Collaborator Contribution | access to facilities |
| Impact | Increased product reliability and control through to end of life. |
| Start Year | 2011 |
| Description | S2S Electronics on-site testing of RFID Enabled Van Service |
| Organisation | S2S Limited |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | Discussion over and trial of the development of an intelligent, RFID enabled van service with accompanying web service for the increased security and visibility of assets in transport. Further development of a prototype system with design improvements and changes to increase the robustness and reliability of a solution. Development of a web service, database solution and physical implementation of an RFID enabled van service, tested in real-world conditions. |
| Collaborator Contribution | Discussion of future work and input of company protocols currently in place to secure assets in transport. Supply of transport with built in power supply and sign off for real-world system and application testing. Development of end user requirements and industrial constrains to be imposed on the system. |
| Impact | This collaboration is multi-diciplinary |
| Start Year | 2018 |
| Description | Transfer of data with product |
| Organisation | Ford Motor Company |
| Country | United States |
| Sector | Private |
| PI Contribution | The innovative element of this result is that the data; process history, batch numbers, materials dates etc. is retained and added to through the value chain and is readily available at each step. |
| Collaborator Contribution | access to facilities, data and warehouse. |
| Impact | tracking system in Ford for engine components |
| Start Year | 2012 |
| Description | Use of EI to enhance recycling efficiency |
| Organisation | Sound to Sense (S2S) |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Use of EI technology incorporated into electronics by OEM customers will enable S2S to make more informed choices at end of life about the best options for refurbishment, recycling or reuse and this will enable S2S to generate more revenue for itself and its customers. |
| Collaborator Contribution | access to knowledge, warehouse and facility, information on their internal processes and data gathering. |
| Impact | installation of EI system to improve processing efficiency and tracking of products and record of processes at S2S providing More sustainable approaches to end of life electronics reduced costs and enhanced environmental credentials. Better and more efficient handling of end of life electronics that will enable better choices to be made in terms of materials recovery and individual unit recovery and refurbishment. |
| Start Year | 2012 |
| Title | 3-Dimensional Visualisation |
| Description | Unity game engine development of the visualisation for tracking RTIs. |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Unity game engine development of the visualisation for tracking RTIs. |
| URL | http://eiis.co.uk/3c/3D.html |
| Title | 3Cs Simulation |
| Description | Modelling software respresenting product flow in an automotive manufacturing environment |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Modelling software respresenting product flow in an automotive manufacturing environment |
| Title | A Novel Metal Mountable UHF RFID Tag |
| Description | Design of a novel RFID tag using a high permittivity flexible substrate which operates efficiently on radio-interfering metal objects.The proposed tag is readable up to 8m from the reader antenna when applied to various automotive assets such as stillages and crankshaft separators used in engine assembly plants, and through the supply chain. |
| Type Of Technology | New/Improved Technique/Technology |
| Year Produced | 2014 |
| Impact | A cost-effective metal-mountable RFID tag which will meet the end-user's requirement in a radio-interfering or harsh environment. |
| Title | Data Logging Service |
| Description | Code to log and distribute error information for maintenance and administration purposes |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Code to log and distribute error information for maintenance and administration purposes |
| Title | Electronics Manufacturing |
| Description | Software which runs autonomously on a SMT manufacturing data capturing information unique to each product |
| Type Of Technology | Software |
| Year Produced | 2013 |
| Impact | Novel system which autonomously collects information unique to the manufacture of the product. The granularity of information collected is much higher than currently available in this domain |
| Title | Electronics Recycling Traceability |
| Description | Software for the collection of re-manufacturing data via RFID enabled workstations. Integrated into this are layers of rules which can be easily adapted to changes in product and process |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Information previously un-captured is now being collected to aid process optimisation as well as conformance to newly introduced industry standards. |
| Title | Electronics Recycling Traceability - Web Interface |
| Description | Web interface to represent data, collected real time and visualised in a way which is of most impact to end user |
| Type Of Technology | Webtool/Application |
| Year Produced | 2014 |
| Impact | Web interface displays information, real-time to end user. This information was previously very limited as well as having a high lag. It has also allowed compliance to new industry standards |
| Title | Maintenance Software |
| Description | Software for the detailed interrogation of portal hardware in order to diagnose and fix issues |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Software for the detailed interrogation of portal hardware in order to diagnose and fix issues |
| Title | Performance Improvement of a Label UHF RFID Tag |
| Description | Enhanced Performance of RFID tag using flexible substrate, different printing ink and printing methods. |
| Type Of Technology | New/Improved Technique/Technology |
| Year Produced | 2013 |
| Impact | A cost-effective solution for the manufacturing applications in the automotive and electronics domain using a novel RFID tag antenna substrate, printing ink and printing method. The tag is mountable on various automotive assets such as engine block and crankshaft separators used in engine assembly plants, and through the supply chain. |
| Title | Personalised Logo RFID Tag :On/Off Metal Mountable |
| Description | Design of an efficient EIIS logo RFID tag with a novel substrate and printing ink. The tag performs efficiently on various automotive assets such as engine part separators (off-metal) and stillages (on-metal) used in engine assembly plants, and through the supply chain. The proposed tag can be read efficiently up to a distance of 8m from the reader antenna. |
| Type Of Technology | New/Improved Technique/Technology |
| Year Produced | 2014 |
| Impact | A novel personalised logo RFID tag on/off metal mountable which can perform efficiently in radio-interfering harsh manufacturing environment. |
| Title | RFID Data Collection Service |
| Description | Web service for the collection of RFID data from portals. |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | Web service for the collection of RFID data from portals. |
| Title | RFID Enabled Transport System User Interface - Web Application |
| Description | User interface for real time and historical data relating to product location and transport status for increased visibility of products in transit. Interacts with an RFID enabled asset traceability solution installed in a van. |
| Type Of Technology | Webtool/Application |
| Year Produced | 2020 |
| Impact | There is increased customer interest in a future service however the system is currently still in prototype phase so there is no quantifiable impact. |
| Title | RFID PLC Code |
| Description | RFID software API for use in Programmable Logic Controllers for the detection of RFID tags |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | RFID PLC Code |
| Title | RFID Tag Design and Positioning : 3D Modelling and Simulation |
| Description | Use of 3D modelling and simulation software to determine where and how to attach RFID tags to a range of Stillages and component Separator trays for the use of tracking the items within the automotive domain. |
| Type Of Technology | New/Improved Technique/Technology |
| Year Produced | 2014 |
| Impact | To meet the end-user's application requirements, the RFID tag can be virtually placed on the CAD of a product to be tagged and the tag parameters e.g. radiation efficiency and directivity can be optimised. |
| Title | User Interface for the representation of RFID traceability |
| Description | User Interface for the representation of RFID traceability |
| Type Of Technology | Software |
| Year Produced | 2014 |
| Impact | User Interface for the representation of RFID traceability |
| URL | http://eiis.co.uk/3c/ |
| Title | smaRTI Software Services |
| Description | A set of software services that wrap the smaRTI device to provide realtime data capture, visualisation and analytics. This includes the supporting software architecture, such as MQTT, Websockets and Node-Red. |
| Type Of Technology | Webtool/Application |
| Year Produced | 2016 |
| Impact | - Supports the development of Cyber-Physical Returnable Transit Items, for improved logistical process monitoring and control. |
| Company Name | E.I.I.S. Limited |
| Description | |
| Year Established | 2012 |
| Impact | R&D in manufacturing ICT |
| Description | Exhibition in Productronica, Munich 2013 |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Showcasing the innovative solutions for tracking future of electronics products and production systems. Industrial contacts were made that resulted in further academic collaboration e.g. atg Luther & Maelzer GmbH - Company and Haecker - automation in Schwarzhausen, Germany |
| Year(s) Of Engagement Activity | 2013 |
| URL | http://www.productronica.com/ |
| Description | Factory site visit |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Industry/Business |
| Results and Impact | visit to a manufacturing site at a prospect sponsor company that may be interested in the outcomes of the research and future work. |
| Year(s) Of Engagement Activity | 2020 |
| Description | Presenation at the RSA: The Great Recovery, Tracking and Tracing Workshop |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Professional Practitioners |
| Results and Impact | Presentation of research within the recycling and refurbishment of end of life IT assets. |
| Year(s) Of Engagement Activity | 2015 |
| URL | http://www.greatrecovery.org.uk/ |
| Description | Royal Academy of Engineering Summer Soiree June 2014. Exhibition - 'Manufacturing at the Heart of the Nation'. |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Participants in your research and patient groups |
| Results and Impact | Enterprise Hub Showcase Showcasing innovations in embedded RFID for electronics products implemented in the PCA manufacturing line at the MTC |
| Year(s) Of Engagement Activity | 2011,2013 |
| Description | Visit to present plan of action and initial solution for improving asset traceability in transport |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Industry/Business |
| Results and Impact | Met with an industrial sponsor and an SME to present a system design and plan for prototype system for an improved traceability system for instrumented transport solution. The system was designed to meet the customer specifications and the draft was developed do meet both academic and industrial requirements. |
| Year(s) Of Engagement Activity | 2019 |