openMOS · Project

Plug-and-Produce Operating System That Lets Factories Swap Equipment Without Reprogramming

manufacturingPilotedTRL 7

Imagine if adding a new machine to your factory floor was as easy as plugging in a USB stick — the system recognizes it, configures itself, and starts working. Right now, every time a manufacturer changes a product line or swaps a robot, engineers spend days or weeks reprogramming everything. openMOS built a shared "operating system" for factory equipment so that machines, robots, and sensors can talk to each other and self-configure automatically. They proved it works at TRL7 in real production lines at Ford, Electrolux, and SenseAir.

By the numbers

consortium partners across the value chain

countries represented in consortium

industrial pilot validations at TRL7 (automotive, white goods, electronics)

SMEs in the consortium, reflecting the SME-first design approach

63%

industry partners in consortium (12 of 19)

total project deliverables produced

The business problem

What needed solving

Every time a manufacturer needs to change a product, introduce a new variant, or swap a piece of equipment on the production line, the entire system needs expensive and time-consuming reprogramming. This sensitivity to change is a direct bottleneck for companies trying to reduce lot sizes and respond faster to market demands. For SME equipment makers and system integrators — who make up the vast majority of the automation supply chain — the integration cost of making their components work together is especially painful.

The solution

What was built

The project built an open manufacturing operating system (MOS) — a software platform that lets automation components (robots, machines, sensors) recognize each other and self-configure when connected. This was validated at TRL7 across 3 industrial pilots: a Ford engine assembly line, an Electrolux injection moulding system, and a SenseAir sensor assembly line, plus a TRL6 large-scale hardware-in-the-loop simulation. The project produced 28 deliverables including the embedded plug-and-produce middleware, vertical connectivity tools, and changeover management strategies.

Audience

Who needs this

Automotive assembly plants running multiple product variants on shared linesWhite goods and appliance manufacturers with frequent mould or tool changeoversSME system integrators building modular production cellsElectronics manufacturers with high-mix low-volume sensor or component assemblyFactory automation OEMs developing smart, self-configuring equipment modules

Business applications

Who can put this to work

Automotive manufacturing

enterprise

Target: Car and engine assembly plants running mixed-model production lines

If you are an automotive manufacturer dealing with costly downtime every time you retool an assembly line for a new engine variant — this project developed a plug-and-produce platform validated at TRL7 on a Ford engine assembly line that lets you swap and reconfigure equipment modules without full-line reprogramming. The system was tested by production managers and signed off by engineers from the end-user partners.

Consumer electronics and white goods

enterprise

Target: Appliance and electronics manufacturers with injection moulding or assembly operations

If you are a white goods manufacturer struggling with long changeover times on injection moulding systems — this project built and validated at TRL7 an open manufacturing operating system on Electrolux moulding lines that enables rapid changeover through intelligent self-configuring equipment. The platform was tested across 3 industrial sectors with 19 consortium partners.

System integration and automation

SME

Target: SME system integrators building automated production cells

If you are an automation integrator spending weeks on custom programming every time you deploy a new production cell — this project created an open, standards-based plug-and-produce platform specifically designed for SME requirements. With 7 SMEs among the 19 partners, the technology was built by and for smaller integrators who need to deliver faster installations with less engineering overhead.

Frequently asked

Quick answers

What would it cost to implement this plug-and-produce system?

The project data does not include specific licensing or implementation costs. The platform was designed as an open, accessible system specifically to lower costs for SME equipment manufacturers and system integrators. Contact the coordinator for current licensing terms and deployment pricing.

Has this been tested at industrial scale?

Yes — the system reached TRL7 validation in 3 real industrial pilot environments: a SenseAir sensor assembly line, a Ford engine assembly line, and an Electrolux injection moulding system. A separate TRL6 verification was also completed using a large hardware-in-the-loop simulated system covering scenarios from all 3 end users.

What is the IP situation — is the platform open or proprietary?

The project name itself signals the intent: 'open' Manufacturing Operating System. It was designed as a common, openly accessible plug-and-produce platform so that all players in the automation value chain can jointly develop and use solutions. Specific IP terms should be confirmed with the consortium coordinator INTROSYS.

Which industrial sectors does this cover?

The platform was validated across 3 key sectors: white goods (Electrolux), automotive (Ford), and electronics (SenseAir). The underlying technology is sector-agnostic — it works with any modular automation equipment that needs plug-and-produce capability.

How does this connect to existing factory IT systems?

openMOS was specifically designed for both vertical and horizontal connectivity — linking shop-floor automation components to higher-level control and business systems like MES and ERP. The platform uses industrial middleware and embedded control technology compatible with standard automation architectures.

How long has this technology been in development?

The project ran from October 2015 to January 2019, a period of over 3 years. It built on many years of prior plug-and-produce research and integrated these concepts into industrial-grade technology platforms. The consortium included 19 partners across 6 countries.

Is there ongoing support or further development?

The project closed in January 2019. The coordinator INTROSYS (a Portuguese SME specializing in robotic systems integration) and the 12 industry partners may offer commercial implementations. Based on available project data, the project website at openmos.eu may have further information on exploitation activities.

Consortium

Who built it

This is a strong, industry-heavy consortium with 12 out of 19 partners (63%) coming from industry, including major end users Ford and Electrolux alongside sensor manufacturer SenseAir. The coordinator INTROSYS is a Portuguese SME specializing in robotic systems integration, which signals practical, implementation-focused leadership rather than academic-driven research. With 7 SMEs in the mix across 6 countries (Switzerland, Germany, Italy, Portugal, Sweden, UK), the project was designed to produce technology that smaller automation companies can actually use and sell. The 3 university and 4 research organization partners provided scientific backing without dominating the direction. For a business looking to adopt this technology, the consortium composition means there are multiple potential implementation partners already experienced with the platform.

INTROSYS-INTEGRATION FOR ROBOTIC SYSTEMS-INTEGRACAO DE SISTEMAS ROBOTICOS SACoordinator · PT
LINKOPINGS UNIVERSITETparticipant · SE
KUNGLIGA TEKNISKA HOEGSKOLANparticipant · SE
AFAG AUTOMATION AGparticipant · CH
HSSMI LIMITEDparticipant · UK
KITE SRLthirdparty · IT
FORTISS GMBHparticipant · DE
UNINOVA-INSTITUTO DE DESENVOLVIMENTO DE NOVAS TECNOLOGIAS-ASSOCIACAOparticipant · PT
SENSEAIR ABparticipant · SE
WE PLUS SPAparticipant · IT
ELECTROLUX ITALIA SPAparticipant · IT
MASMEC SPAparticipant · IT
LOUGHBOROUGH UNIVERSITYparticipant · UK

How to reach the team

INTROSYS (Portugal) — SME specializing in robotic systems integration. They led the consortium of 19 partners and have direct experience deploying the platform in industrial settings.

Order a report on this consortium See INTROSYS-INTEGRATION FOR ROBOTIC SYSTEMS-INTEGRACAO DE SISTEMAS ROBOTICOS SA profile →

Next steps

Talk to the team behind this work.

Want to know if openMOS plug-and-produce technology fits your production line? SciTransfer can connect you with the right consortium partner for your sector and use case.

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