Reconfigurable Pilot Line

The project

The Reconfigurable Pilot Line (RPL) concept aims to provide an accessible, flexible and modular alternative to a traditional fixed pilot line.

The project aims to design, develop and validate a reconfigurable, modular and scalable production system. To deliver this, the project has been defined with two phases: single-cell and multi-cell or line development.

Single-cell

  • The design and development of the concept of the Reconfigurable Production Cell (RPC) into a working product, i.e. a proof-of-concept RPC
  • The installation of manufacturing capability, integration of all associated robotics and successful delivery of manufacturing trials on the proof-of-concept RPC

Multi-cell/line

  • The assembly of multiple additional RPCs to form an RPL
  • Digital integration of all RPCs, demonstrating communication, flow of data and remote monitoring/operation
  • Finally, the manufacture of a product on the RPL, demonstrating full line capability

What is a pilot line?

Pilot lines are small-scale production lines used to develop and de-risk the manufacturing process as products are moved up the technology readiness level (TRL) and manufacturing readiness level (MRL) scales.

These lines are equivalent to a preliminary, reduced version of a given product's final and full-scale production line.

The establishment of a pilot line marks the transition of a product or process from the laboratory scale towards industrialisation.

Collection of images of a pilot line production line and workers

As in the full-scale production process, the purpose of the line is to convert raw material into a finished part. To achieve this, pilot lines comprise a series of pilot production cells, each with distinct capabilities, which sequentially perform operations on the material to progress it towards the form of the finished product.

Pilot lines are generally very static in nature, with production cells fixed in place and set capabilities. They tend to be highly bespoke, permanent installations to function as essentially what is a miniaturised factory.

 This results in the requirement for a very high capital cost system and complexity for any business with a need to de-risk their production process. For small and medium enterprises (SMEs), these factors represent significant barriers to innovation and could adversely affect cash flow and risk.

Alex Cochrane, Research and Development Engineer, Lightweight Manufacturing Centre

At the Lightweight Manufacturing Centre, we plan to also support small and medium sized businesses in scaling up manual composites manufacturing processes and facilitate their entry into automation, allowing for crucial cost and time savings.

Low risk and accessible

The RPL concept is intended to benefit manufacturers of all sizes and has been designed to be scalable for deployment in various settings.

However, some of the most significant risks in product development are shouldered by smaller businesses and this project aims to provide an accessible and low risk and accessible environment in which these businesses can innovate.