FUTURE-PROOFING the automotive industry - FP7-Mode

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FUTURE-PROOFING
the automotive
industry
utt
université de technologie
Troyes
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RFID Solutions to Identify & Manage

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INNOVATION:
a key driver
for change

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It’s an exciting, if challenging, time
for the automotive industry…
When it comes to vehicle quality, safety, and reliability,
customer expectations are at an all time high. There’s
also an ever-widening choice of vehicles for buyers to
choose from. Overcapacity is putting pressure on the
industry to keep prices low. And with environmental
concerns growing, the need for sustainable
automotive solutions is a must.
In short, success depends on pioneering product
development coupled with an ongoing commitment
to innovation that breaks new ground in automotive.
The Maintenance on Demand (MoDe) project is one
example of this – of key players coming together to
future-proof the automotive industry.
For car manufacturers, enticing customers has never
been more dependent on being able to differentiate
products from the competition. And that means
coming up with increasingly inventive and innovative
solutions.
Innovation is usually focused on design and
functionality. But genuinely cutting edge development
is rare. And it usually involves creating entirely new
vehicle lines – think Ford’s original Mustang or
Renault’s first ever multi-purpose vehicle (MPV).
So what does success look like for the automotive
industry, now and in the future? Simple. It’s all about
a company’s ability to spot new opportunities and
launch new products…
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Driving innovation forwards
“We have to extend our focus beyond products
and services. We need to focus on business model
innovation…to collaborate with partners from suppliers
to customers and non-industry players and dealers.
It’s only by embedding innovation in the processes,
culture, structure and financing models of a company that
businesses can really improve performance…”
IBM, “Driving Innovation”
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1829
Stephenson’s Rocket
ushers in the era of the
railway. The economic
geography of Europe
and the USA is
changed forever.
1885
Karl Benz invents the
first ever automobile
1899
Camille Jenatzy’s
“Jamais Contente” is
the first car to exceed
100km per hour.
It is electric.
A HISTORY OF INNOVATION
Pioneering product development is crucial for the prosperity of the automotive
industry, in 2012 and beyond. But the links between innovation and mobility
have been at the heart of our economic progress for a while…
We are living in a world characterised by connection. A world in which
transport, technology and communications link us to each other, to the world
around us and to information at unprecedented rates.
The automotive vehicle is one breakthrough that has put the shift to
connectedness in fifth gear. And while today the sector is under pressure to
stay ahead of the curve, revolutionary development has always played an
important role in keeping the industry moving….
1900
The era of small-scale
‘mass production’ begins.
1901-1910
Petrol engines make steampower
automobiles obsolete.
The internal combustion engine
kickstarts aviation history.
THE FUTURE’S ELECTRIC
Environmental concerns are at the forefront of all our minds
– whether you’re a customer or a manufacturer.
Ford
Plan to market three new electric vehicles: Focus
Electric, C-MAX Energy and C-Max Hybrid.
1910-1920
The assembly line
developed by the
Ford Motor Company
revolutionises large-scale
production processes.
1950s
Cars spread across the world
with innovations in engine
power, speed and design.
Renault
Intend to launch four electric vehicles by the end
of the 2012, including a saloon car, a compact
hatchback and a two-seater.
BMW
Are set to launch three electric vehicles under
their ‘Megacity’ brand. The first is being readied
for launch in 2013.
1960s
The rise of the computer
confirms the inextricable links
between electronics and mobility
innovation. As a result, man is
able to land on the moon.
1970s
First electronic 4-wheel
multi-channel ABS
developed by Chrysler.
1980s
First automotive
navigation systems
developed.
1990s
Lean production,
system integration and
concentration.
2000s
Innovation and revival of
mass interest in electric
vehicles. Focus turns to
sustainability.

A world in constant
EVOLUTION
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Innovating global solutions for
automotive logistics
The automotive industry is truly global. Markets are evolving, environmental
pressures are growing, resources are in shorter supply and globalization
is presenting its own geographical challenges. All this opens up new
opportunities for logistics companies like DHL. The question is: how do
we meet these myriad challenges efficiently and sustainably? The answer?
Excellence in innovation….
KEY TRENDS AND CHALLENGES
Resource shortages
Rising energy prices mean higher transport costs.
OEMs are increasingly unwilling to pay them. What’s
more, fossil fuel are expensive and limited resources.
The need to switch to alternative energy has never
been more urgent.
Solutions: Near-sourcing, component consolidation,
multi-modal approaches using road, rail and river
connections.
Environmental sustainability
‘Going green’ is more than a concern – it’s a global
necessity. For companies like DHL, providing
sustainable logistics solutions and greener supply
chains is a must.
Solutions: DHL now offers carbon footprint reporting,
carbon reduction programme consulting, reusable
& returnable packaging and a host of cutting-edge
visibility tools (e.g. RFID, real-time track and trace
tools).
Growing globalization
Automotive demand is growing in emerging markets
like India, and looks set to surge in the coming years.
In developed markets, the focus is on replacement
vehicles, though this is rapidly spreading to emerging
markets too.
Solutions: Strategic planning around networks and
geographical coverage in key markets.
Market evolution
Markets are constantly changing. And people are more
demanding in some countries and cities than others.
Solutions: Multi-tiered dealer city distribution models,
local distribution centers (LDCs) to help deals react
more quickly to customer demands.
DHL works closely with Renault, managing
the transportation, distribution and collection
of reusable car batteries to minimise their
environmental impact.
RESOURCE
SHORTAGES
ENVIRONMENTAL
SUSTAINABILITY
Solutions:
EXCELLENCE IN
INNOVATION
GROWING
GLOBALIZATION
MARKET
EVOLUTION

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Tackling change and winning
THE ROLE OF… ORIGINAL EQUIPMENT
MANUFACTURERS (OEMS)
FUTURE-PROOFING GLOBAL
LOGISTICS AT DHL
At Volvo, the future is already here…
Volvo Group Trucks Technology ATR (Advanced
Technology and Research) brings visionary new
technical services to life. It covers everything from
long-term research to delivering solutions and services
to market. It’s where a host of groundbreaking hybrid
technologies and safety functions were born. And it
ensures Volvo Group stays ahead of the pack when it
comes to revolutionary technology.
Key innovations
Electrical & embedded systems: optimising
electrical and embedded software, in combination
with sensors, actuators, cable harnesses, and
connectors, brings excellence in functionality,
dependability, robustness and energy efficiency.
Propulsion: working closely with everyone from
universities and research institutes to the European
commission and various national public agencies,
Volvo strives to develop vehicles with the best
possible performance in exhaust emissions.
Soft products: focusing on trailblazing new soft
products to meet customers’ changing needs, Volvo
seeks to deliver higher efficiency, lower operating
costs, better environmental performance and
enhanced delivery.
In a rapidly changing world, the automotive industry
is constantly facing new challenges. Supply bases
are becoming more globalized, emerging markets are
expanding and the era of mega cities is finally here.
But with big changes come big opportunities for
logistics companies like DHL. In fact, globalization
is continuing to push logistics to the fore. As the
demands for efficient transportation become greater
and more complex, the pressure is on to provide
logistics solutions that guarantee connectivity – fast,
straightforward shipping services that continue to
provide reliability and predictability.
Key challenges for logistics companies
As supply chains become more complex, the risk
of disruption becomes ever greater. Solutions are
required that provide stability now and well into the
future. But our responses have to be attentive to the
wider implications of finite natural resources and
issues of environmental sustainability. Vehicles must
run optimally with absolutely minimal CO 2 emissions.
One example is just-in-case vehicle maintenance,
where manufacturers replace parts after a certain
mileage, no longer meets our aims. With recycling and
optimal usage more important then ever, future-proofed
logistics solutions must switch to a ‘just-in-time’
approach to maximise each component’s lifespan.
Such future-thinking solutions require connected
thinking. That’s why DHL are taking a proactive
lead, collaborating with companies who share our
commitment to tackling the biggest challenges of
the next fifty years – from congestion and pollution to
market competitiveness.
“Innovation is at the heart of our strategy. We work closely with different partners
to develop energy-efficient solutions, including MoDe. Putting partners and
players from different industries together will bring brilliant global solutions. By
providing sustainable, reliable and innovative global logistics solutions we can
help prepare our customers for some of the future trends in automotive”
Fathi Tlati, DHL Global Sector Automotive President,
Customer Solutions & Innovations

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Collective challenges in the automotive industry
THE ROLE OF GOVERNMENTS AND THE EU
The challenges faced by the automotive industry –
from dealing with resource scarcity to fighting climate
change – calls for a wide-ranging approach. An
approach that delivers inventiveness in future mobility,
manufacturing and integrated safety. An approach on
which competitive and sustainable vehicles depend.
And for which public funding across EU members
states is crucial and the governments and the EU
have a big role to play...
Cooperation: is necessary between funding bodies
at the national and European level, along with an
integrated exchange of information and ideas.
Learning from each other will help the EU lead the
world in automotive innovation.
Research should build: on the work that has gone
before, and be widely disseminated. This avoids
stagnation and duplication. It requires an immersion in
other research projects, past and present.
Users should be involved: in defining the needs
of freight delivery and different business models
addressed by national- and EU-funded research.
Involving transport and logistics operators as advisors
helps make sure a project effectively helps meet the
needs of supply chain operations.
Easy-to-deploy solutions: are needed to ease supply
chain operations in the short-term. Funding should
be directed at these kinds of projects, where potential
in practice is shown and there’s a potential for fast
market take-up to the benefit of everyday business
operations.
Cross industry perspectives
AEROSPACE AND THE AUTOMOTIVE INDUSTRY
Meeting the ever-shifting challenges faced by the
automotive industry cannot happen in isolation.
It depends on ongoing and close cross-industry
collaboration. Integrating breakthrough, precisionengineered
technologies is one vital way in which the
industry is meeting the challenges of the 21st-century
head on…
Harnessing aerospace findings helps us to…
• Apply new technologically advanced materials with
superior properties for true automotive innovation
• Develop more streamlined vehicles for people and
businesses
• Work out new ways to protect the environment and
preserve resources
• Improve vehicle safety and security
• Ensure cost-effectiveness
Applications of aerospace
Durable and adaptable multi-material lightweight
design
Sophisticated aerospace designs are helping the
automotive industry move away from costly metal
components, to lightweight, high-performance fibrereinforced
plastic materials.
Future-thinking advantages include:
• Reduced assembly costs
• Less driving resistance
• Minimised fuel consumption
• Better sustainability
• Reduced life cycle costs
Structural health monitoring (SHM)
Remarkable aerospace techniques like SHM capture
data, allowing an ongoing inspection of vehicle
components – so repairs can be made at just the right
time. Benefits include:
• Enhanced vehicle reliability
• Improved performance and maintenance
procedures
• Associated cost savings
Anti-vibration technology
Cutting-edge aeronautical research has made
possible multi-functional components. This has driven
forward innovations in vibration control – in the active
damping of plate vibration in car roof structures, for
example. Benefits include:
• Reduced noise
• Better driving experiences
• Increased efficiency

MoDe
The future of
automotive is
just around
the corner…
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In a fast-changing world full of challenges
and opportunities, creativity and the spirit of
collaboration are needed to prepare us for
the world of tomorrow…
“MoDe aims to strengthen the scientific
and technological bases of the
community…with a view to assuring
a high level of competitiveness,
and improving the quality of life for
European citizens”
Maintenance on Demand (MoDe) is a
groundbreaking global project that sets out to do
just that.
MoDe brings together 11 leading companies
and academic institutions from around the world.
Together they have pooled their technical knowhow,
market knowledge, insight and future thinking
to tackle issues of central importance for industry,
the economy and the environment.
THE MoDe CHALLENGE
Whatever the future holds, manufacturers will be
under increasing pressure to reduce, or eliminate
completely, the possibility of vehicle downtime.
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The question is: how can you maximise reliability,
avoid unplanned maintenance and keep a vehicle
on the road with minimal disruption? It all depends
on having a constant, clear and precise picture of
a vehicle’s health at any given time.
Developing the technology to give us this picture is
at the heart of the MoDe project.
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In a world without MoDe…
• Wear and tear goes undetected for long periods
• Eventual damage is more unpredictable,
extensive and costly
• Breakdowns and accidents are more likely to
occur
• Time waiting for assistance, sourcing parts and
dealing with emergencies expands
• Vehicle downtime grows
• Customer dissatisfaction increases

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Project MoDe
Automotive advancement
and innovation
The main focus of the project is on developing a
commercially viable truck that can identify where
and when maintenance is required. It should also be
able to provide alerts on the maintenance needed.
In short, MoDe aims to:
• Maximise vehicle uptime
• Minimize vehicle downtime
THE RESEARCH
The MoDe collaboration has produced extensive
research into vehicle condition monitoring and the
prediction of remaining lifetime.
A more complete understanding of the remaining
useful life of a vehicle component means
maintenance and repairs can be made at just the
right time.
Improper use can also be identified, cutting down
the risk of breakdown, damage or environmental
pollution.
HOW DOES IT WORK?
Energy-efficient wireless sensors pick up signals of
damage or deterioration to vehicle parts.
A wireless network effectively and reliably connects
station units positioned around the engine to a central
network.
An ongoing process of condition monitoring checks
for signs of damage or wear. Signals are sent to a
central maintenance platform.
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Information is analysed based on vehicle information
and parts data. A maintenance decision is then taken.
The innovative technologies researched and
developed by MoDe, such as intelligent services
planning, which helps group together maintenance
operations and therefore reduces vehicle
downtime, ensure a more competitive offering for
manufacturers and users alike.
suspension strut
mount sensor
wheel hub
sensor

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Towards the automotive technologies
of tomorrow
DEFINING USER REQUIREMENTS
Understanding what the people who
will eventually use MoDe want from the
system is vital for tailoring it to the needs of
everyday users.
DHL drew on its experience of operating a
fleet of 80,000 trucks and vans. It defined
exactly what drivers, dispatchers and fleet
engineers might really need from MoDe
technology. DHL has also worked on
revising Volvo’s supply chain by drawing
on MoDe insights.
REPAIR PROCESSES
How do we make the repair process
more efficient? That’s one of the key
questions asked by MoDe. Mobile
workshops, where trucks are met at an
agreed repair spot, are one significant
innovation…
Mobisoft designed, and is currently
implementing, a tool to identify the
perfect location for maintenance to take
place once a truck has been diagnosed
as unable to reach its destination.
UPTIME
Volvo developed a smart service
planning tool. The tool means
maintenance can be perfectly tailored
to the vehicle’s needs depending on
incoming information.
INTEGRATED MAINTENANCE
PLATFORM
For the system to work effectively, everyone
from drivers and owners to dealers and
manufacturers needs to be constantly
kept in the loop with accurate and relevant
information. What’s more, changes in the
condition of the vehicle, its usage, or even
environment, need to be responded to quickly.
An Integrated Maintenance Platform is
necessary for processing and providing
such information, and for proposing effective
responses so a maintenance plan of action
can be put together immediately.
SENSOR TECHNOLOGY
The latest in sensor technology
has been developed to identify
damage or material degradation – a
breakthrough that allows advanced
status monitoring.
Continental provided sensor
technology for the damper system.
Fraunhofer IIS developed a
streamlined and energy-efficient
wireless communication system with
improved reliability using their s-net®
protocol stack.
LMS focused on evaluating the
effectiveness of in-vehicle sensors for
condition monitoring.
Wireless communication experts
Avonwood are responsible for the
design, development and integration
of Radio Frequency Identification
Technology.
STRUCTURAL HEALTH
MONITORING (SHM)
SHM makes condition monitoring – the first
step towards effective uptime maximization
– possible. The system provides
crucial data on wear and condition,
allowing durability and life expectancy
to be calculated. Timely and informed
maintenance decisions can then be made.
University of Technology of Troyes tested
lifetime models for vehicle components,
focusing on how such models can be
used to estimate a component’s remaining
useful lifetime. They also looked at ways
to optimize decisions about maintenance,
drawing on dynamic online data about
component health.
VTT worked on methods to estimate the
remaining lifetime of a damper, as well
as the reliability of the Sensors Network
Monitoring system.

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MoDe comes into its own
THE FUTURE WITH MoDe
Scenario 1 – Maintenance on Demand
Now…
The vehicle maintenance contracts sold with a vehicle
rely on ‘static’ information provided at the time of a
sale.
The MoDe vision…
Services are tailored to a vehicle’s exact configuration,
mission, and the dynamic feedback of information.
Reducing periods of vehicle unavailability means that
businesses can better achieve their objectives.
In practice…
Dealers and their clients agree what is required
by the business up front. Uptime needs, the exact
configuration of the vehicle, and service needs are
then considered within the sales process. This level
of tailoring makes it easier to precisely plan vehicle
stops, and makes service provision far more dynamic.
“Maintenance on demand represents a
major leap forward for fleet management.
And for trade and transport in general. This
collaborative innovation project is already
changing our perspective of logistics. The
ripple of effects will be far-reaching…”
Keeping the wheels in motion
Dynamic maintenance planning: plans for
maintenance are changed based on information
from the Maintenance on Demand suite.
Your vehicle stops earlier than planned but
can continue its journey with less threat of
disruption.
Maintenance on-the-fly: data shows immediate
service is required. Your vehicle drives to
a conveniently located repairspot, before
continuing its journey.
Repair on-the-fly: A component breaks down
or is close to breakdown. With MoDe, the
problem is immediately detected so you can
wait for a service engineer.
Scenario 2 – Repair on-the-fly
Now…
Drivers are warned of problems by an on-board
system. They then report issue to a call centre. But the
location of the vehicle and the nature of the problem
aren’t always obvious, making it difficult to get the right
parts delivered to the right place at the right time.
The MoDe vision…
Roadside repairs are made more efficient. Condition
monitoring and estimates of remaining lifetime
help detect failures in advance. Key information is
communicated to a central system, which calculates
the nearest and most suitable workshop for the repairs.
In practice…
Where it’s not possible to reach a workshop, the MoDe
system will advise drivers of the ‘best location to stop’.
Details will be sent to mobile workshops, equipped with
the resources needed to make roadside repairs, and
the vehicle will be met at an agreed ‘meeting point’. An
efficient spare parts management system will be set up
to support this process.
Summary of the key benefits
Safer travel
Chances of breakdowns and accidents are radically
reduced by early fault detection. Associated congestion
is avoided.
More economical
With fewer and shorter breakdowns and unplanned
stops, vehicle uptime is boosted by 30%. More accurate
and timely feedback means more efficient repairs. And
less risk of human error.
Complete control
The system’s centralized synchronization makes possible
remote monitoring, vehicle reconfiguration and ongoing
analysis, for better decision-making.
Environmental gains
By making sure vehicles are serviced at exactly the right
time, sub-optimal performance is reduced. Unnecessary
part replacements are avoided and driving time to
maintenance locations cut down. Fuel consumption is
optimized and CO2 emissions cut.

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TOMORROW’S
WORLD
with MoDe

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Coming soon…
MoDe is leading the automoive industry’s march towards the future with groundbreaking
research and technological advancement. This collaborative project has already produced
startling developments that are already being incorporated in exciting new product offerings…
ZONESAFE COMPACT
LOCAL DISTRIBUTIONS CENTRES
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A proximity-based warning system, Avonwood’s
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Zonesafe Compact system helps reduce the risk of
dangerous collisions between vehicles and personnel,
for better health and safety site management.
How does it work? By creating a 360° detection zone
around the vehicles (e.g. compact machines, fork lift
trucks) it’s fitted to.
Personnel wear safety transponders that are picked
up by the system. Then when staff enter the zone,
a warning alert is triggered and sent to vehicle
operatives.
The system’s responses to tag identification can also
be configured, for complete control.
S-NET® TECHNOLOGY
Local Distribution Centres (LDCs) store parts in small
warehouses located close to dealers for ultra fast
delivery.
These LDCs are fairly common in the passenger
vehicles sector. But they haven’t yet been used to
streamline the delivery of spare parts in commercial
vehicle sector.
Until now. On June 1st 2012, DHL opened its very first
LDC exclusively dedicated to serving the needs of
commercial vehicle dealers. Dealers can now order
spare parts for super-fast delivery several times a day.
What’s more it means parts will arrive within only a few
short hours.
Key benefits? Dealers can now reduce their inventory,
whilst accessing a bigger-than-ever range of parts.
Better ‘fixed right, first time’ performance brings a real
competitive edge for manufacturers and dealers alike.
The s-net® technology developed by Fraunhofer IIS
provides optimal communication protocols for the
creation of energy-saving wireless networks.
Sensor networks are made up of a series of sensor
nodes, interacting with each other by radio.
As part of the MoDe project, these networks are being
used to acquire, process and forward digitalized
information about the ‘health’ status of vehicles
components, so maintenance and repair can happen
just in time.
Fraunhofer IIS’ s-net® technology can be tailored to
customers’ needs and uses exceptionally low levels of
power for longer operating times.
SCADAS MOBILE TECHNOLOGY
Extreme conditions can make accurate data
acquisition a difficult challenge to overcome.
Thankfully, the robust and rugged LMS SCADAS
Durability, makes data capture possible even in the
most testing real-life situations. Built on LMS SCADAS
Mobile technology, it’s a piece of equipment that can
handle water, dust, dirt, jolts, shocks and vibrations.
No need for a PC, LMS SCADAS Durability cuts down
on the equipment needed for data acquisition, cutting
operation costs down in the process.
Data is instantly recorded and validated for quality with
LMS SCADAS Smart Control. High quality information
is guaranteed, reducing the need for test campaign
reruns and removing risks to the design cycle.

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utt
université de technologie
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RFID Solutions to Identify & Manage
RFID Solutions to Identify & Manage