Data Communication & Networking in Manufacturing SystemNanang Ali SutisnaMaster Eng. in Computer Integrated ManufactureSenior PLM Consultant, IBM Indonesia (Retired)Senior Manager, Product DevelopmentMultistrada Arah Sarana

Chapter 2Digital ManufacturingData Communication & Networking in Manufacturing System

Todays Business Requirements Drive Change & Determine Real-time Enterprise NeedsGlobalizationRapid Product InnovationProcess InnovationCollaborationSynchronization LeanContinuous ImprovementComplianceRisk ManagementPerformanceFlexibilityPull-based ProductionEtc.

Evolution of the Design/Build Process90s80s20002006..3DDigital MockupDigital ManufacturingKnowledgeCapture2DTechnological Advance

Digital Manufacturing represents an integrated suite of PLM tools that supports manufacturing process design, tool design, plant layout, and visualization through powerful virtual simulation tools that allow the manufacturing engineer to validate and optimize the manufacturing processes. What is Digital Manufacturing?

R&DDesign EngrProcess PlanningWork Flow, Mfg Processes Materials & Product ResearchProduct DesignMfg EngrIndustrial EngrDesign, Produce Tools, Jigs, Fixtures, & Automated SystemsControls/Tool EngrObtain, Operate, Control, & Maintain Equipment & Automated Systems to Manufacture ProductsFactory Operations/ Production Systems

Collaborative PDM CAM/NCProduct DomainProduction DomainSchedulingResource MgmtMfg IntelligenceQ/AVisibility Supply ChainSpecs, E-BOM, M-BOMAutomated AssemblyProcessesOrgFunction (Systems)EngineeringOperationsProduct Lifecycle: Design/Build/Automate/MaintainPLM Solutions: Interoperability & CollaborationWhere Does Digital Manufacturing Fit?

Manufacturing PlanningDefine High-Level Manufacturing ProcessesProcess Planning (Assembly & Installation) Define Work Instructions & Work Flow

Detailed Process Design & AnalysisDetailed Resource Modeling & SimulationProcess Definition and Validation3-D Factory Layout Equipment, Tool & Fixture SimulationErgonomic Simulation

Validation & Virtual CommissioningControl Logic ValidationKinematic (Robotic) ValidationQuality Assurance/Process Improvement ValidationSensor/Metrology Placement ValidationVirtual Commissioning/Validation of Automation SystemsKnowing that the Production System Works Prior to Launch: Priceless.

What Does Digital Manufacturing Do?

Digital Manufacturing Redefines Concurrent Engineering Product Authoring (CAD) tools are employed to define What" is to be built.Manufacturing Process Design tools are used to define How" it is to be built.Integration of Product & Process Design directly supports the concept of Concurrent EngineeringDigital Manufacturing facilitates the Holistic view of Product and Process Design as integral components of the overall product life cycle

PLM/Digital Manufacturing are Process-Centric Managing the Manufacturing ProcessIntegration of Product Design with Mfg Processes allows Production Management & Execution Applications to be Integrated with the PLM Solution SetManufacturing Process Design coupled with Digital Mfg Simulation Integrates the Definitions of the Product, Processes, Factory, and Resources into a Comprehensive and Consistent Manufacturing SolutionManufacturing Process Mgmt (MPM), as a Component of the PLM Solution Set Generates traditional Operations Management Functions such as Process Planning, Work Instructions, and Operations & Quality Assurance Records Scheduling, Workflow, Resource Mgmt, WIP, and Visibility

Global Manufacturing Operations= Manufacturing Node= Design Node

Operations Management Definition:Operations Management is the management of the people, business processes, technology and capital assets involved in: Procuring and receiving raw materials and componentsEspecially as it relates to obtaining, storing, and moving necessary materials/components in a timely manner and of suitable quality to support efficient productionImplementing product designs, specifications, formulations, or recipes by manufacturing productsIncluding manufacturing process planning and validationDistributing these products to customersEspecially as it relates to sequencing and in-house logisticsAnd for some products, supporting them through their End-of-LifeLet Business Requirements Drive Technology Solutions

Todays Dynamic, Demanding Environment Places a Premium on Information and Synchronization

IndustryClassic MESNew RequirementsSemiconductorComplex Routing, Resource Allocation, Quality, WIP Tracking, etc.Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, KPIs, Performance, Change Mgmt, Security, Electronic Manufacturing History etc. PharmaceuticalCompliance, Quality (Direct and Enforce Production), Electronic Batch Records, Electronic Signature, etc.Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History etcContinuous ProcessCollection of Apps: Optimization, Historian, Advanced Process Control, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etcA&D (Complex Discrete)CAPP, Quality, Resource Allocation (Operators, Workstations, Tooling, etc.) WIP Tracking, Traceability, Work Instructions, NCR Resolution, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Supplier Quality Mgmt, Change Management, Security, Electronic Manufacturing History, etcAutomotive SupplierQuality, Resource Allocation (Operators, Workstations, Tooling, etc.) Work Instructions, Just-in Sequence Manufacturing/ Packing/ Shipping, Error-proof Packout and Labeling, etc.Visibility, Analytics/Decision Support, Orchestrate Inventory Replenishment by Operation, Traceability and Recall Management, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etcAutomotive OEMVisual Alarms, Stack Lights, and Marquees, Line Control & Broadcasting, Supplier Component Sequencing, etc. Visibility, Outsourced Manufacturing, Global Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, Traceability and Genealogy, etc

BusinessCustomersEquipment & AutomationSuppliersProductionDesignOperations InfrastructureEnterprise InfrastructureSupport(Standalone, Industry-Specific Application)(Collection of Applications)CMM Applications Map Lets Get on the Same Page re: MES and OM

Production Mgmt Systems are Extension of PLM Manufacturing ProcessesDigital Manufacturing Solutions + MESAs Built RecordsEngineering DesignValidate

PLM Integrated with Shop Floor ExecutionPLM E-BOM M-BOM Bill of Process Product Config.ERP

Digital Mfg + Shop Floor Execution = Validation of As-Built to As-Designed

Merging Virtual Simulation and Automation Simulation to Control: Making the Final Step from Virtual to RealDigital Validation Produces Real Control Execution Collaborative Environment for Control Design & Digital ValidationReal OperationsVirtual SimulationProduction SystemProcess Design

Interoperable Virtual to Real-World Environment for Manufacturing and Control Engineering

3D Mechanical DesignControl Engineering (Design)Line Building & InstallationProduction StartupCurrent workflow.Workflowwith Virtual Automation3D Mechanical DesignControlEngineeringLineBuilding Control Eng.Production StartupValidation & Virtual CommissioningMerging Virtual Design and Automation Shortens Time to LaunchControl Engineering (Commissioning)

Effective & Efficient Use of Digital Mfg (DM) Tools: Guidelines for Users

Integrate Use of DM Tools into the Manufacturing Design Process Set and Implement guidelines for application of DM technology Provide DM training for Mfg Engineering Discipline & ResourcesEmphasize Re-use Re-use dependent on a strategy common process design Common components is a key enabler Establish a library of virtual production devices & equipment A modular approach is key for efficiently building virtual models Start with basic virtual devices building blocks Build virtual production systems by combining virtual devices Integrate DM Tools into the Information & Control ArchitectureVirtual models can be developed & maintained by multiple engineering disciplines (Manufacturing, Tooling, Controls) Use latest Production Process data for Virtual Simulations

Digital Manufacturing LandscapeManufacturers are focusing on Optimization of Production ProcessesReducing Time to Product Launch and Cost of Commissioning Production Systems Todays PLM Suppliers now offer robust Digital Manufacturing SolutionsLarge Manufacturers Are Adopting End-to-End PLM Strategies, including Digital Manufacturing A&D: Boeing, Lockheed-Martin, Northup-GrummanAutomotive: GM, Chrysler, Ford, Toyota, Nissan, BMW, Mercedes BenzHeavy Equipment: Caterpillar, John Deere, CumminsCompanies are Transforming how they Define their Manufacturing Processes

Key Benefits of Digital ManufacturingIntegration of Product Design and Manufacturing ProcessesReduce Cost and Development Time for Process DesignShorten Time-to-Launch for New Product Introduction with Faster Ramp-up for Production SystemsProvide Manufacturability by Simulating Manufacturing Operations before the Start of ProductionIncrease Quality by Validating Production Process DesignReduce and/or eliminate Prototypes and Physical Mockups with Virtual SimulationsImprove Collaboration with Suppliers by Providing Early Access to Design, Production Process, and Resource informationImprove Concurrent Design Methods by Linking Product Design to Manufacturing & Controls EngineeringValidate Manufacturing Processes, Production Systems, and operational resources through Virtual Commissioning prior to physical implementation

*So just what is Digital Mfg? ARC defines Digital Mfg as: (read definition)

Here a robotic welding cell is defined virtually and then can be placed within the virtually defined production line. Production systems like this can be components of an entire virtual factory layout. *Lets look at the product lifecycle across the design/build process of the manufacturing enterprise, with the emphasis on the lifecycle processes. We see the product and production domains and can follow the lifecycle through the processes of concept & design, process planning, manufacturing operations, and so on. At the top there are organizations that support the processes, and at the bottom are functional systems that support the processes. Digital Mfg represents a set of solutions that supports production process design, virtual simulation, and automation, and is integrated fully with the product design. *As I stated in the previous slide, manufacturing must be process-centric. Digital Mfg enables this: Go through bullets*Merging virtual simulation of the production processes with automation represents the final step from virtual world to real operations and physical production systems. Controls engineers are now able to design and validate control systems as a component of the digital simulation of the machines, work cells, and production lines, and generate real executable control code to drive these systems. *Ill go through a typical scenario of real controls implementation through virtual design and validation:

First the controls/manufacturing engineer designs and models the actual production processes, work steps, etc. Next the controls design is created based on the work processes and controls standards such as IEC 6-1131-3 ladder logic, function block, and so on. This control design is then validated by running it in a virtual simulation of the work cell or production system.After the control design is validated generic control logic is generated and targeted to specific PLCs or automation platforms. A post-processed machine code is produced based on signal mapping specific to the controller platform. Additionally, HMI and operator interface information can be created and interfaced through industry standards like OPC client/server technology. *This simple sequence chart illustrates on a time line basis just how merging virtual design of production systems with controls design and validation significantly speeds up process of product launch. Validating the controls prior to the actually production line build saves substantial time and cost. *Here is a summary of some of the key benefits of Digital Mfg, and that I have been covering to this point.