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Vibrant and Innovative Economy

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A*STAR’s Future of Manufacturing (FoM) Initiative

Vibrant and Innovative Economy
A STAR PIPS Signing Ceremony as ITAP 2018

A*STAR’s Future of Manufacturing (FoM) Initiative aims to help Singaporean enterprises adopt the latest Industry 4.0 technologies, so as to remain relevant and ahead of the pack in their respective industries. The key thrusts of the FoM Initiative – Tech Depot, Tech Access, and Model Factory @ A*STAR – are public-private partnership platforms that drive technology innovation and knowledge-transfer across different enterprise types, especially Small and Medium-sized Enterprises (SMEs) in Singapore. 

Model Factory @ A*STAR 

The Model Factory @ A*STAR enables the ecosystem of research performers, end users, technology providers, and system integrators to jointly innovate and testbed Industry 4.0 technologies. It is co-located at two of A*STAR’s research institutes – the Singapore Institute of Manufacturing Technology (SIMTech) and the Advanced Remanufacturing Technology Centre (ARTC). 

With the Model Factory, companies at different stages of their tech adoption journeys can learn about the latest manufacturing technologies, and collaborate with stakeholders to experiment with, and jointly develop, technology solutions. The end goal is for companies to adopt, in part or whole, the Model Factory platform on their own factory floors.

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Racer Technology is a Singaporean MedTech manufacturing company that chose to adopt advanced manufacturing technologies from the Model Factory @ SIMTech, so as to increase its overall efficiency and agility in responding to customer demands. Between 2017 and 2018, Racer adopted four Model Factory @ SIMTech solutions – the Overall Equipment Effectiveness Monitoring System (OEEMS), the Manufacturing Operations Management (MOM) System, the Inventory Tracking System (ITS), and Workflow Mobile (wfMobile). These solutions allow Racer to have real-time visibility of its production schedules so that it can quickly identify and address key problems in its manufacturing processes. Since adopting the technologies, Racer has increased the efficiency of its factory floor by up to 70 percent, and also enjoyed cost savings of up to 70 percent.

Another Singaporean company, Abrasive Engineering (AE), is working with the Model Factory @ ARTC to co-innovate digital solutions for improved productivity. AE manufactures machines for, and provides services in, shot peening – a manufacturing process that strengthens metal components so that they last longer. AE serves mainly the aerospace, automotive, medical, oil and gas and electronics industries. Some of the solutions co-innovated with the Model Factory @ ARTC include the addition of sensors and the Industrial Internet of Things (IIoT) connectivity to AE’s shot peening machines, which allow for data analytics that track its activity for optimal performance. This will help to optimise machine maintenance cycles, reduce machine downtime, and in turn, minimise disruptions on the factory floor. Advanced image analytics and an online quality check system are also tapped on for quality control of the shot-peened metal components. This provides quality assurance as well as manpower savings. The digitalisation of the entire process also allows for data to be visualised and organised in a manufacturing intelligence control room, so that the end-user can make quick decisions to ensure productivity is kept at an optimal level. 

Tech Access

Tech Access supports SMEs’ innovation efforts by providing them with access to A*STAR’s installed base of equipment and facilities, user training, as well as consultancy to optimise equipment effectiveness. The primary aim is the eventual deployment of advanced technologies in local companies. 

With Tech Access, SMEs avoid unnecessary risks and capital expenditure by experimenting and prototyping with A*STAR technologies first, before making the decision to scale up and acquire similar equipment if they wish to do so. A*STAR’s suite of research equipment and facilities offered are in the areas of 3D Additive Manufacturing and Robotics, among others.

Tech Depot

This one-stop platform on the SME Portal offers SMEs a suite of easily adoptable, Ready-To-Go (RTG) technology solutions that can help them to plug technology gaps, digitalise and automate workflow, and improve overall productivity. Launched in April 2017, the various solutions listed on Tech Depot have been developed and pre-qualified by A*STAR, Enterprise Singapore, and the Info-communications Media Development Authority of Singapore (IMDA). Tech Depot also comprises technology solutions supported under the Productivity Solutions Grant. 

A*STAR’s Programmes for SMEs

In addition to A*STAR’s Future of Manufacturing Initiative, the organisation offers a wide range of assistance to help SMEs address challenges in technology development, deployment and adoption, and is committed to helping them maintain their competitiveness through R&D. A*STAR’s programmes for SMEs include: 

Operation and Technology Roadmapping (OTR) Programme

Through the OTR programme, A*STAR partners SMEs to help them develop long-term technology roadmaps aligned to their business goals. The process enables companies to grow their businesses by exploiting the right market trends, products, services and technologies. Since the launch of the OTR programme in 2002, A*STAR has helped companies establish long-term growth strategies driven by innovation, and remain competitive.

Building on the success of the Operation and Technology Roadmapping (OTR) programme which targets individual companies, A*STAR launched its Consortium OTR (COTR) programme in 2018, and is working with local Trade Associations and Chambers (TACs) to develop technology roadmaps for groups of local companies within the same sub-sector. As of January 2019, COTRs in various sectors, including Food Manufacturing and Lasers & Optics, have been completed.

Technology for Enterprise Capability Upgrading (T-Up) Programme

To help local companies build in-house R&D capabilities and enhance their competitiveness, A*STAR seconds its research scientists and engineers (RSEs) to the industry under the T-Up programme. 

For example, between 2011 and 2016, A*STAR seconded three researchers under the T-Up programme to Admaterials Technologies, a materials testing firm specialising in construction of materials, to help the company build new technological capabilities in environmental and microbiological testing. These two areas of services are increasingly demanded by various industries, from construction, building maintenance, to food manufacturing. Besides helping Admaterials to set up brand new environmental and microbiological testing labs, the A*STAR researchers also trained AdMaterials’ staff to run the two laboratories. Admaterials has since hired 20 chemists for both laboratories, contributing to a 20 percent increase in staff strength.

In another example of a T-Up secondment, Mr. Wong Kim Sing, a senior research engineer at A*STAR’s Institute for Infocomm Research (I2R), was seconded to a Singaporean pest management solutions provider, Pestech Holdings, from July 2017 to June 2018. During his secondment, Mr. Wong helped to develop RodentEye – an automated, cost-effective rodent surveillance system that integrates the use of sensors, data analytics, and Internet of Things (IoT). The system allows for real-time, 24/7 monitoring of rodent activities in commercial premises, and has the potential to reduce manpower costs by an estimated 50 per cent for the average pest control company. Pestech has deployed RodentEye to more than 50 sites to date, including shopping malls and restaurants, and projects that total deployment will reach 200 sites over the next two years. Over 70 pest technicians and sales representatives have been trained to use RodentEye. The company has also successfully broken into regional markets (India, Philippines, Hong Kong and Thailand) with the product.

A*STAR Collaborative Commerce Marketplace (ACCM)

A joint effort with the Economic Development Board (EDB) and Enterprise Singapore, the A*STAR Collaborative Commerce Marketplace (ACCM) was launched in 2016 as a one-stop collaborative platform to facilitate business matching, partnerships and research collaborations amongst platform members, especially SMEs. Many TACs have signed up for ACCM to date, and are actively promoting the platform to their members through internal collaterals and announcements. 

Theme 4: Global-Asia Node of Technology, Innovation and Enterprise

Pharma Innovation Programme Singapore (PIPS) 

The Pharma Innovation Programme Singapore (PIPS) is a partnership between A*STAR, the National University of Singapore (NUS), the Nanyang Technological University (NTU), the Singapore Institute of Technology (SIT), and pharma companies GlaxoSmithKline (GSK), MSD International GmbH (Singapore branch), and Pfizer Asia Pacific. The S$34 million consortium agreement was inked in October 2018, and aims to drive the transformation of the local pharmaceutical manufacturing industry and help it gear up for the future economy.

With the local pharma sector facing global pressures on drug pricing and increased competition, the PIPS consortium will focus on increasing productivity and operational efficiency through technology and data analytics. Industry 4.0 initiatives such as process automation, smart manufacturing and digitalisation through the Industrial Internet of Things will be test-bedded through PIPS projects. More specifically, PIPS will zoom in on areas such as continuous manufacturing, bio-catalysis, advanced process control and process analytical technology, digitalisation, and enhanced pharmaceutical operations. This will raise the bar for pharma manufacturing, resulting in more sustainable processes and quicker production of active pharmaceutical ingredients that would allow drugs to reach patients faster. 

National Supercomputing Centre Singapore (NSCC)

Established in 2015, the National Supercomputing Centre (NSCC) manages Singapore’s first national petascale facility with high performance computing (HPC) resources available to support science and engineering computing needs for Singapore’s academic, research and industry communities. Its vision is to democratise access to supercomputing, support national R&D initiatives, attract industrial research collaborations and enhance Singapore’s research capabilities. NSCC’s stakeholders include A*STAR, Nanyang Technological University (NTU), National University of Singapore (NUS), and Singapore University of Technology and Design (SUTD).

The Technology Centre for Offshore and Marine Singapore (TCOMS) 

The Technology Centre for Offshore and Marine Singapore (TCOMS) is Singapore’s first research and development (R&D) centre for the industry. Jointly opened by A*STAR and the National University of Singapore (NUS) in 2016, TCOMS enables the local marine and offshore engineering industry to undertake higher-value activities through various global partnerships. The centre has signed MOUs with various industry players – including Singapore's Keppel Offshore & Marine and Sembcorp Marine – to explore research collaborations in marine and offshore engineering technologies. 

TCOMS’ anchor research facility will be the next-generation Deepwater Ocean Basin (DOB), an ocean basin facility equipped with the state-of-the-art wave and current generation systems that can simulate harsh ocean environments – including those in ultra-deep waters. The facility, slated to be completed in 2019, will facilitate the development of innovative concepts including intelligent floating platforms and ships, autonomous systems, marine robotics, and subsea systems. Research at the facility will be aided by petascale supercomputing capabilities. This allows researchers to access leading technologies such as smart sensing, physical modelling, numerical simulation, and real-time data analytics to better understand non-linear fluid-structure interactions in complex sea states.

A Global City and Home for All

New Catalytic System by A*STAR’s ICES and Japanese Company IHI 

A*STAR’s Institute of Chemical and Engineering Sciences (ICES) and Japanese engineering firm IHI Corporation have developed a new catalytic system that can help companies to cut emissions by efficiently converting unwanted carbon dioxide into fuel. The reactor system, which uses a specially-developed catalyst, allows for efficient conversion of carbon dioxide and hydrogen to methane. Methane is the main component of liquefied natural gas, used for most of Singapore’s electricity generation. Now, instead of storing the captured carbon dioxide to keep it from harming the environment, firms can convert it to fuel. This makes environmental and economic sense for energy-intensive industries, and power utilities companies, which generate large amounts of carbon dioxide. More broadly, an effective catalyst increases yields, cuts waste and reduces energy needs.

A demonstration unit was launched on Singapore’s Jurong Island in May 2019 to show the process to potential customers. IHI is now scaling up the technology, which might hit the market as soon as 2020. IHI is in talks with potential customers in Singapore and Japan, with a larger demonstration unit to be set up in Japan. 

A*STAR’s Collaborations with SMEs in Sustainable Food Waste Management 

A*STAR collaborates with various SMEs in the area of sustainable food waste management. One such SME is Westcom Solutions, a company that specialises in food waste reduction and recycling services. When founder Mr. David Tan set up Westcom Solutions in 2016, he imported food waste processing machines and microbes from Japan. However, these microbes were not effective or efficient in breaking down local food waste, due to differences in food consumption habits and environmental conditions between Singapore and Japan.

Realising the need to develop a customised solution for the Singapore market, Mr. Tan contacted A*STAR’s SME Office, which linked Westcom to A*STAR’s Institute of Chemical and Engineering Sciences (ICES) for its microbial biotechnology expertise. ICES began collaborating with Westcom in 2017, and initial R&D activities were conducted at ICES’ industrial biotechnology lab on Jurong Island. 

A*STAR helped Westcom to develop a now-patented microbial solution customised for local food waste – it can break down bones, dough, tofu and sugar cane, among other things, quickly and effectively, in a safe, pathogen-free manner. A*STAR also assisted Westcom with amplifying the potential of these microbes to break down large amounts of food waste – Westcom’s largest machine can process up to 10 tons of food per day – and advised Westcom on a simple, inexpensive storage and stabilization solution for the microbes, in the form of sawdust.

With these new capabilities, and no longer having to import microbes to operate its food waste processing machines, Westcom has been able to reduce its operating costs by up to 30 percent.

The patented microbial solution is also a cutting-edge one that has helped the company rake in millions in revenue last year:

It reduces the volume of food waste by up to 90 percent. The remaining 10 percent is converted into odourless organic fertilizer, which can be used immediately without further processing. No wastewater is discharged throughout the treatment either.

It breaks down food waste within 24 hours; most other solutions available in the market take 7 days or more.

It allows for the food waste processing machine to be operated at a lower temperature; at 40 degrees Celsius instead of the usual market standard of 80 to 120 degrees Celsius. This leads to energy savings of up to 50% for Westcom’s clients.

Westcom primarily packages the fertilizer by-product for its clients to use, or sells it to landscaping companies. Westcom’s machine at JTC’s Pandan Loop Industrial Estate produces about a ton of fertilizer every month.

 A*STAR also helped to train and upskill Westcom’s R&D staff. A*STAR researchers were seconded to Westcom from 2017, under A*STAR’s Technology for Enterprise Capability Upgrading (T-Up) scheme. The A*STAR researchers helped Westcom set up its own 1,000 sq. ft R&D laboratory, and trained Westcom’s newly hired laboratory engineer, to facilitate the SME’s independent large-scale in-house production of a proprietary microbes mixture for food waste processing. Westcom currently has the capacity to produce two tons of microbes a month. Westcom has since hired additional R&D staff, bringing the total R&D headcount to five, a quarter of the company’s total headcount. Westcom’s laboratory engineer still frequently returns to A*STAR for training sessions.

 To date, Westcom has spent a few million on R&D, researching and test-bedding new technologies for sustainable waste management. The company now has six patent registrations under its belt.

 This year, Westcom also launched its subsidiary Westcom Technologies to better market the company’s products and solutions to potential clients. Westcom has also expanded its business internationally; entering the Taiwan and China markets, and currently boasts a client portfolio of about 30 companies, both local and international, including JTC, DBS, SIT, and Khoo Teck Puat Hospital.

 Westcom and A*STAR are currently exploring further collaborations in sustainable food waste management. These include solutions to break down bio-degradable plastic waste that may be commonly disposed alongside food waste (e.g. plastic cutlery, straws, and cups, etc), and large animal bones, from butcheries or abattoirs.

About the Agency for Science, Technology and Research (A*STAR)

The Agency for Science, Technology and Research (A*STAR) is Singapore's lead public sector agency that spearheads economic oriented research to advance scientific discovery and develop innovative technology. Through open innovation, we collaborate with our partners in both the public and private sectors to benefit society.

As a Science and Technology Organisation, A*STAR bridges the gap between academia and industry. Our research creates economic growth and jobs for Singapore and enhances lives by contributing to societal benefits such as improving outcomes in healthcare, urban living, and sustainability.

Vibrant and Innovative Economy
A STAR Model Factory @ARTC

We play a key role in nurturing and developing a diversity of talent and leaders in our Agency and research entities, the wider research community, and industry. A*STAR’s R&D activities span biomedical sciences and physical sciences and engineering, with research entities primarily located in Biopolis and Fusionopolis.

For ongoing news, visit www.a-star.edu.sg. 

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