Sirris manufacturingday2011 digital-factory

het collectief centrum van de Belgische technologische industrie

Manufacturing Day 2011Digital Factory introduces a new era for product development

marc.bollen@sirris.be

10-04-2023© Sirris | www.sirris.be | info@sirris.be | 2

Product Development

The GoalBring the products that your customers want to market at the

right time and the lowest cost.

By The Way• on a limited budget• with limited resources• with limited time• and changing priorities• on a daily basis

#1Start now and create your strategic Digital

Factory plan !

Rule #1: Start Now!

What are the strategic options?

2012 2013 2014 2015 2016 2017

Do Nothing

BreakthroughInnovation

Incremental improvements

Room for improvements

Additional room for improvements

1.1 Set Strategic Goals

• Time To Market • First Time Through Rate• Customer Satisfaction• Product Performance• Efficiency • Flexibility• Cost Reduction• Margin• …

1.2 Analyse Current Processes

'When we understand this slide, we'll have won the war.'General Stanley McChrystal,

US and NATO force commander

ActiveVOS, Adeptia, Altova, Appian Corporation, Avolution, Axway, Bizagi, BOC AG Borland, Cordys, Corel, Embarcadero Technologies, HandySoft Corporation, IDS Scheer, ILOG, Interfacing Technologies, MEGA International, Microsoft, No Magic, Omni Group, Orbus software, Pegasystems, SAP AG, Software AG, Sun Microsystems, Sybase, Tibco Software, Troux Technologies, Visual Paradigm, yWorks, …

1.2 Analyse Current Processes

1.3 Define Actions Issue

ImprovementAction

Impact

1.4 Prioritise actions

Impact

Size = investment

1.5 Action-types

• Eliminate steps • Increase efficiency• Minimise iteration-effects

#2Think Digital !

2.1 Digitise your processes

CAADCADCADDCAECAMCAPPCAQCARCASCASECFDCIMEDAFEAKBEMPMMPPPDMPLM

Technologies

2.1 Technologies

A photorealistic rendered picture created with POV-Ray 3.6. Glasses and ashtray are modelled with Rhinoceros 3D. Dice with Cinema 4D

2.2 Quy Orthopedic Milling Services (1)

Original Process

Assess Patient-geometry

Create Plaster-negative

Adjust Plaster-negative

Copymilling

• Long Lead Time • Average Quality • High Cost• Labour Intensive

2.2 Quy Orthopedic Milling Services (2)

• Digitised Process

Asess Patient-geometry

Create Plaster-negative

Adjust plaster-negative

Create

Copymilling

MillingCapture 3D data

X XAdjust in CAD

2.3 Simulation of rain penetration (1)

• Original Process

Design Data

OK?Physical

PrototypeTesting

Certification

• New Process

Design Data

SimulationOK?

TestingCertification

• No straight forward model to apply all the physics(rain droplets, wind driven motion in fluid domain, droplet accumulation and motion over the wall boundaries)

• DPM (Discrete Particle Model) lacks modeling droplet-accumulation. Therefore, trial tests were done with Eularian Mixing Model which is capable of modeling water accumulation and motion on the louver walls

• Initial results were in poor agreement with the experimental study. Changing the droplet size improved accuracy. 30 days of simulation time were required to do droplet size optimization. Initial results indicate that modeling with 150micron droplet size is in better agreement with the experimental results.

• In 2008 simulation was more expensive than physical testing. Now (2011) it is cheaper

• Increase your knowledge and prepare for setbacks

#3Topmanagement

has to support the improvement

process !

10-04-2023© Sirris | www.sirris.be | info@sirris.be | 23Room filled with people who care.

3.1 Manage the project

• Allocate resources (PM)• Plan learning (and setback) curve• Monitor KPI • Adjust implementationspeed• Feedback results to stakeholders • Plan second improvement project• Take 1 step at a time

#4Modularise, Configure, Automate !

CustomerOfferte

Archive

Workpreparation

BOM and routing

DelayOrderconfirmation

Modified Offer

3.1 Typical Sales Proces: Order (3)

Source: Sofon

3.2 Manuals (1)

Provide CAD-linkages.

3.3 Modularity, standardisation

k100 klantenspecificaties, 1 1 1k200 klantenspecificaties, 2 2 219Touch screen 21 1 2101generator 3 1 1 3 1 1 1 1 1 1 1 1 1 102deoxo-dryer 4 1 1 1 4 1 1 1 1 1 1 103H2-dryer 5 1 1 5 1 1 1 1 104Fritz sparger H2 6 1 1 1 1 605oxy 7 1 1 706dehydro 8 1 1 8 1 1 1 1 1 1 107O2-dryer 9 1 1 1 9 1 1 1 1 108Fritz sparger O2 10 1 1 1 1 1009storage 11 1 1 11 1 1 1 110Electrische voeding 12 1 1 1 1 1 1 1 12 1 1 1 1 111Proceswater 13 1 1 1 1312Cooling water (chiller / closed loop / dry cooler)14 1 1 1 1 1 14 1 1 113Nitrogen 15 1 1 1 1 1 1 1 15 1 1 1 114Instrument air 16 1 1 1 1 1 1 1 16 1 115Enclosure 17 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 17 1 1 1 1 1 1 116Online purity o2 18 1 1 1 1 1 1817Online purity H2 19 1 1 1 1 1 1920Hydrogen compressor 22 1 1 1 2221Oxygen compressor 23 1 1 1 2323Mass flow meter 25 1 1 1 2524Control panel 26 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 26 1 126Interconnections 28 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 28 1 127Power distribution 29 1 1 1 1 1 1 1 1 29 128Power rack 30 1 1 1 1 3018Visualisatie 20 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 20 125Software 27 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2722On site erection 24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24

Actions• Productportfolio (5)• Conceptual Design (8)• Systemdesign ( 20)• Detaildesign (100)

Leadtime decreases 50%

#5Collaborate !

5.1 Internal Collaboration (1)

Documentserver

PDMCMS

Content Management System

IntranetCommunities

Collaboration Platform

Atos Origin sets out its ambition to be a zero email company within three years (07/02/2011)

• By 2013, more than half of all new content will be the result of updates of existing information

• Online social networking is now more popular than email and search • Middle managers spend more than 25% of their time searching for

information • 2010 : Corporate users receive 200 mails per day, 18% of which is

Why search when you can ask your network?

My smmr hols wr CWOT. B4, we usd 2 go 2 NY 2C my bro, his GF & thr 3 :-@ kds FTF.

2003, nn, 12 years old.

Now 20 years and starting in your company!

5.2 External Collaboration (1)

SuppliersRaw

Material

Supplier

Distributors

ComponentSuppliers

ContractManufacturers

Factories

ConsumersManufacturer Channels

PlantWarehouses

HQ Retailers

Resellers

Direct

Individual

Businesses

ServiceDesign / R&D

Source: Microsoft

5.2 External collaboration (2)

• Data exchange : JT, STEP, 3DPDF, …• SME’s will be pressured to collaborate with Large

Enterprises• LE provides portals for offering and collaborative design• Larger companies (Vestas, Airbus) centralise all engineers

on a project base.

5.3 Benchmark (1)

Source: CIMData 2011

Proces Deelproces BeginnerMidden-

mootGevorderd

Engineering Change Management l lProduct Data Vaulting and Management l l lBill of Material Management l lItem Management and Classification lDesign and Project Collaboration -

Visualization, Markup and Translation -

CAD Design Integration l l lEnterprise/ERP Integration

Product Cost Estimation - -

Portfolio Management - - -Project Management - -

Stage Gate Process, Workflow - -

Ideation - -

Requirements Management -

Production Process Planning - -

Production Process Design and Validation -

Production Modeling and Simulation -

Ergonomic Evaluation and Simulation - -

Product Identification l lProduct As-Built Configuration - lProduct As-Is Configuration -

Product Service History and Parts -

Design for Compliance - Management of Hazardous and Controlled Substances - -

Regulatory and Compliance Documentation l lManaging Recyclables and Controlled Waste - -

75-100 l50-75 25-50 0-25 -

Maturiteit

Engineering and Collaboration

% bedrijvendie dit gebruiken

Legende

Portfolio & Project Mgt

Manufacturing Proces

Management

Service

Regulatory & Compliance

Idea & Requirement Mgt

5.3 Benchmark (2)

5.4. Audit

Audit Digital Factory

Hierarchy Criterion 0 1 2 3 4 Comment1 Discrete Industries1,1 Engineering Change Management1.1.1 Engineering Change Definition1.1.2 Managed Change Process1.1.3 Engineering Change Effectivity

1.1.4Engineering Change Cost/Impact Analysis

1.1.5Engineering Change Execution/Communication

1.1.6 Managing Engineering Changes

1,2Product Data Vaulting and Management

1.2.1 Product Data Vaulting1.2.2 Product Data Organization1.2.3 Product Data Search and Retrieval1,3 Bill of Material Management1.3.1 Product Structures1.3.2 BOM Definition1.3.3 BOM Structure1.3.4 BOM Content1.3.5 Managing BOM's1.3.6 BOM Validation

1,4Item Management and Classification

1.4.1 Item Classes/Attributes1.4.2 Item Definition

1,5Routing, Approval, and Lifecycle Process

Conclusions (1): 5 Golden Rules

#1Start now and make a

plan !#2Think Digital !

#3Manage !

#4Think Modular !

#5Collaborate !

Conclusions (2): So what?

% improvement20 40 60 80

Savings tool design

Communication and collaboration

Reduction Design Changes

Timesavings production planning

Time to Market

Project efficiency

Questions

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