Upload
jade-nunez
View
53
Download
1
Embed Size (px)
DESCRIPTION
Unapređenje upravljanja proizvodnim procesom sa Windchill MPMLink -om. Agenda. Šta predstavlja upravljanje proizvodnim procesom ? Opseg , definicija i izazovi PTC Windchill MPMLink Deo PTC rešenja za proizvodnju Istorija Ključne mogućnosti Summary. Realnost proizvodnih preduzeća. - PowerPoint PPT Presentation
Citation preview
Unapređenje upravljanja proizvodnim procesom sa Windchill MPMLink-om
© 2009 PTC
Agenda
Šta predstavlja upravljanje proizvodnim procesom?
Opseg, definicija i izazovi
PTC Windchill MPMLink
Deo PTC rešenja za proizvodnju
Istorija
Ključne mogućnosti
Summary
© 2009 PTC
Realnost proizvodnih preduzeća
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Upravljanjem povećanom varijabilnosti i kompleksnosti proizvoda
Upravljanjem i poslovanjem u globalizovanom lancu snabdevanja
Poboljšanjem operativne efikasnosti i preimućstvom
Meet cost targets Postizanjem pravog kvaliteta
iz prvog pokušaja sa razumnim troškovima
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Upravljanjem povećanom varijabilnosti i kompleksnosti proizvoda
Upravljanjem i poslovanjem u globalizovanom lancu snabdevanja
Poboljšanjem operativne efikasnosti i preimućstvom
Meet cost targets Postizanjem pravog kvaliteta
iz prvog pokušaja sa razumnim troškovima
Brži izlazak na tržište... Ako ne i prvi
Nema više “univerzalnih” proizvoda …
varijabilan i kompleksan Sve veće odgovaranje na
potrebe klijenata … fleksibilan
Dobavljači i i partneri širom sveta
Visok kvalitet… Ali ne po svaku cenu
Brži izlazak na tržište... Ako ne i prvi
Nema više “univerzalnih” proizvoda …
varijabilan i kompleksan Sve veće odgovaranje na
potrebe klijenata … fleksibilan
Dobavljači i i partneri širom sveta
Visok kvalitet… Ali ne po svaku cenu
Stvara se potreba za…Stvara se potreba za…Današnja realnostDanašnja realnost
© 2009 PTC
Realnost proizvodnih preduzeća
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Upravljanjem povećanom varijabilnosti i kompleksnosti proizvoda
Upravljanjem i poslovanjem u globalizovanom lancu snabdevanja
Poboljšanjem operativne efikasnosti i preimućstvom
Meet cost targets Postizanjem pravog kvaliteta
iz prvog pokušaja sa razumnim troškovima
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Upravljanjem povećanom varijabilnosti i kompleksnosti proizvoda
Upravljanjem i poslovanjem u globalizovanom lancu snabdevanja
Poboljšanjem operativne efikasnosti i preimućstvom
Meet cost targets Postizanjem pravog kvaliteta
iz prvog pokušaja sa razumnim troškovima
PressuresPritisci tržištaPritisci tržišta
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Translates into the need to…Translates into the need to…
© 2009 PTC
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
PressuresMarket PressuresMarket Pressures
Realnost proizvodnih preduzeća
Kako preduzeća da se izbore sa ovim izazovima…Pogledajte MPM i njegovu ulogu u procesu razvoja proizvoda (PDP)
Nepovezanost inženjerskih, proizvodnih i produkcionih timove
Poteškoće sa pronalaženjem i upotrebom proverenih proizvodnih procesa i resursa
Poteškoće sa obezbeđivanjem tačnih informacija iz proizvodnje u produkciju na vreme
Procesi na papiru i u manuelnim alatima (Word, Excel, ..)
Disconnected legacy systems
Nepovezanost inženjerskih, proizvodnih i produkcionih timove
Poteškoće sa pronalaženjem i upotrebom proverenih proizvodnih procesa i resursa
Poteškoće sa obezbeđivanjem tačnih informacija iz proizvodnje u produkciju na vreme
Procesi na papiru i u manuelnim alatima (Word, Excel, ..)
Disconnected legacy systems
Problematične tačke/ IzazoviProblematične tačke/ Izazovi
Rezultuje ….NeefikasnostVeći troškoviPomeranje rokovaGreške
© 2009 PTC
Jaz– od vizualnog do virtualnogKako
… da preoizvedemo u skladu sa vremenom, budžetom i zahtevima
kvaliteta
Proizvodni inženjering
Prema učešću na tržištu Prema profitabilnosti
Inženjering Izrada
Functional System PerspectiveManufacturing Perspective
Str
uc
ture
Pro
pu
lsio
n
Ele
ctr
ica
l
Hy
dra
uli
cs
Co
ntr
ol
Sy
ste
ms
…
Plants
Assembly Stations / Lines
Sub-Assemblies
Details Parts / Raw Materials
…
Šta--- da li moramo da proizvedemo?
Gde i kada… da proizvedemo zahtevanu
količinu?
?
© 2009 PTC
?
The Gap – From Virtual to Physical
MPMIzrada
Inženjering
How … to produce meeting time, cost
budgets and quality requirements
Upravljanje proizvodnim procesom– Prevazilaženje jaza
Male izmene u Inženjeringu imaju veliki uticaj na Proizvdonju i Izradu
© 2009 PTC
Radne instrukcije
Tooling requests
eBOM /As-Designed
Procena vremena & troškovaZahtevi za izmenom
Des
ign
Procesni plan dela & sklopa
INPUTI AUTPUTI
3D CAD Modeli
2010 30
NC/CMM programi
Resursi & Standardi proizvodnje
Interno i u lancu snabdevanja
Milling Machines
Drilling Machines
Skills
Work Centers
Tools
Work Centers
Skills
Tools
Proces definisanje i upravljanje proizvodnim procesima koji se koriste za izradu delova, za sklapanje finalnih proizvoda i izvršavanje inspekcije ,
mBOM / As-Planned
Upravljanje proizvodnim procesom– Prevazilaženje jaza
Inženjer projektuje proizvodProizvodni inženjer projektuje proizvodne procese
UpravljanjeProizvodnim
procesom
© 2009 PTC
Agenda
What is Manufacturing Process Management?
Scope, definition and challenges
PTC’s Windchill MPMLink
Part of PTC’s Manufacturing Solution
History
Key capabilities
Summary
© 2009 PTC
PTC strategija proizvodnje
PTC-eva misija je da pomogne klijentima da uvide vrednos u poboljšanju proces razvoja proizvoda
Razvoj proizvoda uključuje razvoj proizvodnih procesa i alata neophodnih za izradu proizvoda
Za optimalne rezultate, proizvodni poslovni procesi treba da se izvršavaju istovremeno sa projektantskim procesima
Zahteva vizualne, asocijativne, digitalne sposobnosti proizvodnje kao integralne komponente PDS-a
“…(MPM / Digitalna proizvodnja) … je najefektivnija kada predstavlja INTEGRALNU komponentu cele PLM strategije preduzeća.”
[CIMdata: “Digital Mfg: Moving the Design into Production”, 2006]
© 2009 PTC
Tipični MPM
proces
Istovremeni razvoj procesa i proizvoda
Razvoj koncepta
Sistemsko projektovanje
Detaljno projektovanje
Smanjenje trajanja ciklusaLimited
opportunity for Manufacturing to influence design and reduce cost
Istovremeni MPM proces
Potpuna proizvodnjaProductionRamp-up
Upravljanje proizvodnim
procesomSmanjenje troškova
usled izmene
Smanjenje troškova proizvodnje
“[Manufacturing companies] identified that the need to reduce manufacturing costs was driving their need to improve their manufacturing planning process at practically the same rate as compressed development schedules.”
Aberdeen Group, Digital Manufacturing Planning – Concurrent Development of Product and Process, 11/2007
© 2009 PTC
Windchill MPMLink
Pro/PLASTIC Advisor
Expert Moldbase eXtension
Pro/TOOLMAKER
Tool Design Option
Projektovanje kompletnog kalupa
ComputerAided
Verification
NC SheetmetalProgressive
Die eXtension
CAM Lite
Prismatic MillingProduction MachiningComplete Machining
PTC’s rešenje za proizvodnjuPortfolio proizvoda
PTC sistem za razvoj proizvoda
© 2009 PTC
PTC Acquired Polyplan for MPM
•Osnovana 1999 u Montrealu, Kanada
Windchill Technical Committees
• CAB has now been incorporated into the Windchill Technical Committees
Windchill MPMLink first point release
• Enhancing core functionality and streamlining common tasks
First LIVE Customer !
• First customer in production with Windchill MPMLink
xv
Windchill MPM Customer Advisory Board formed
• Orient Windchill MPMLink roadmap with customers’ requirements and priorities and therefore maximize customer and PTC benefits from use of Windchill MPMLink
•Worked closely with Windchill MPMLink product management team during initial development
•Objectives
• Allow PTC to gather real-world use cases from world-class customers
• Joint prioritization of future capabilities and use cases
•Various Industries represented
• Aerospace & Defense, Industrial Equipment & Hi-Tech Electronics
Windchill MPMLink - Istorija
2005
Windchill “10”Windchill “10”
2006 2007 2009
Windchill MPMLink RELEASED!
• The industry’s first integral solution for Manufacturing Process Management
• Part of Windchill release streams
• Transformed Polyplan capabilities into an Integral Windchill module called MPMLink
• Control of critical manufacturing information and associated development processes
• Collaborative process development through the sharing of knowledge, product information, concepts and ideas
• Complete model supporting product, process and resource definition
9.1 F0009.1 F000
2010x
xv
x
2008x
9.0 F0009.0 F000
xv
Windchill MPMLink X-20
• Focusing on functionality, productivity improvements and serviceability
xv
xv
© 2009 PTC
Windchill MPMLink key capabilities …….. enabling Concurrent Product and Process Development
An integral part of the Product Development
System
Associative eBOM to mBOM management
Digital definition and management of process
plans
Digital definition and management of manufacturing
resources and standards
Dynamically generated visual work Instructions
Integral change and configuration management
Streamline release to Manufacturing
© 2009 PTC
An Integral part of the Product Development System
ProposalsCustomer Requirements
Part DesignsBoMsChanges
CustomConfigurationsField Notices
RequirementsDesign Feedback
ModelsDrawingsSimulations
ConceptsRequirements
Market RequirementsBrochures, Data Sheets
Preferred PartsApproved Vendors
Customer ConcernsFailure ReportsUser, Service ManualsTraining guidesParts catalogs
CustomersCustomers
SupplierSupplier
ServiceService
ProcurementProcurement
EngineeringEngineering
MarketingMarketing SalesSales
SupplierSupplier
SupplierSupplier
Captive ODCCaptive ODC
Local Design PartnerLocal Design Partner
Offshore Design Partner
Offshore Design Partner
CustomersCustomers
Regulatory AuthoritiesRegulatory Authorities
Distributed MfgDistributed Mfg
ManufacturingManufacturing
Distributed MfgDistributed MfgDistributed MfgDistributed Mfg
Windchill
Workflow Change & Configuration ManagementAccess Control Document Management
PDMLink• Product Requirements• Products• As Designed (eBOM)• CAD Files• Documents
ESI (Enterprise System Integration)
MPMLink• As Planned (mBOM)• Process Plan / WI• Time & Cost Estimates• Mfg Standards Library• Resources Library
Enable the management of manufacturing data and deliverables as true enterprise data
By providing a common central repository for engineering product and manufacturing process planning data
Complete model supporting product, process and resource definition
Leveraging PLM and facilitating the …
Control of critical manufacturing information and associated development processes
Collaborative manufacturing deliverables development through the sharing of knowledge, product information, concepts and ideas
Feasibility FeedbackTooling DesignsWork InstructionsNC Programs
© 2009 PTC
Associative eBOM and mBOM Management
Ensure that mBOMs are conform and reflect the ever-changing engineering designs
By providing powerful capabilities to easily transform BOMs while maintaining associativity using traceability links
Flexible mBOM definition and restructuring
– Use engineering parts as-is or create manufacturing parts
– Derive multiple mBOMs from a single eBOM
– Maintain multiple Alternate BOMs describing the different manufacturing variations that can produce the same part
Leverage 3D designs using embedded 3D environment provided by ProductView technology
– Visualize engineering designs, eBOMs and mBOMs
– Create mBOM by selecting parts from the 3D environment
– Automatically generate 3D manufacturing mockup
Reduce difficult and time consuming task of ensuring BOM conformities
– Maintain associativity between eBOM and mBOM parts
– Visual indicators showing part reconciliation errors
– BOM Compare report quickly identifying quantity discrepancies between associated BOMs
New 9.1
New 9.1
© 2009 PTC
Digitally Define and Manage Process Plans
By providing powerful capabilities that support the digital authoring and definition of manufacturing plans
Define process plans in terms of sequences and operations to describe how a part is manufactured, assembled or inspected
– Define plant-specific process plans including part and resources allocations, standard procedures, documents, time breakdowns
– Define alternate process plans for the same part
– Reuse standard process plans from a standards library
Leverage 3D designs
– Allocate parts and resources directly from 3D
– Automatically generate 3D manufacturing mockup of the process plan and view the in-process state of an assembly
Ensure process plan completeness
– Visual indicators showing parts remaining to be allocated
– Part allocation report listing parts with allocation issues and parts that remain to be allocated
– Review and analyze process plan definitions in an easy-to-use, interactive Gantt chart, with resource loading and usage
Enable the concurrent development of product and manufacturing processes
New 9.1
© 2009 PTC
Digitally Define and Manage Manufacturing Resources and Standards
By providing powerful capabilities that support the digital definition and management of manufacturing resources and standards
Define and share a common libraries of both physical manufacturing resources and human skills
Define and share a common libraries of standardized and normalized processes
– Define a standard set of operations that can be used and/or references within multiple process plans
– Define manufacturing capabilities indicating how the process can be executed in terms of resources, documentation and standards
Define technical compatibilities and enforce manufacturability
– Indicate how resources and/or manufacturing capabilities must, can, or cannot be combined together
Manage the relationship between a resource and its CAD design
– facilitates the creation of visual aids that include both parts and resources
...
work center
skillsprocess material
...
...
optional
plant A
Supplier 1
tool 1 tool 2
work center 2
work center 1
work area
tooling
work cell
mandatory
Re-use proven manufacturing plans, standards and knowledge and systematically drive manufacturability
© 2009 PTC
Op025
Op035
Op025
Op 020
Op 010
Op 030
Sequence Main
Sequence 2 (Alternate)
Sequence 1 (Parallel)
Op025
Op035
Op025
Op 020
Op 010
Op 030
Sequence Main
Sequence 2 (Alternate)
Sequence 1 (Parallel)
Dynamically Generated Visual Work Instructions
Process Planand Operation Headers
Allocated Parts
Time Breakdown and DescriptionWork Center
Visual Annotation
Change and Configuration Information and History
Allocates Resources and Documents
Navigate to Windchill detail object pages from work instructions via hyperlinks
Embedded 3D information
– Directly interact with embedded ProductView 3D visualization
– Set any image as illustration within the Work Instruction
Improve production ramp-up, reduce scrap and rework and improve quality
By providing powerful capabilities that dynamically generate rich shop floor instructions
Accurate Work Instructions, on demand, according to the process plan configuration
Eliminate discrepancies between the process definition and the work instruction used on the shop floor
Can be accessed from the shop floor via a web browser
New 9.1
© 2009 PTC
Integral Change and Configuration Management
By providing robust data control services such as change and configuration management as well as enabling end-to-end process automation
Manage manufacturing changes and configurations with full traceability and history of changes
– Configure part numbering and versioning schemes
– Track configuration by baseline, lot, serial effectivity and date
– Problem reporting, deviation/waiver requests, change requests, change notices and change activities
Standardize, automate the change with robust workflow engine
– Repeatable, consistent and predictable processes including automatic change routing and task notification
– Streamline and continuous change process between engineering and manufacturing
Facilitate change impact
– Visibility to engineering changes and related product information ensure accuracy and speed of changes
– Change Visual indicators, Reports and Navigate relations
• Easy to use “Related Manufacturing Item” Action
Reduce change cycle time, cost of change and fully manage manufacturing configurations
New 9.1
© 2009 PTC
Windchill MPMLink 9.1 - Integration to Production Systems
Efficiently communicate and ensure accurate and on-time availability manufacturing planning data to the enterprise
By automating exchange and sharing of manufacturing deliverables using secure and reliable enterprise system integration technology
Publish MPMLink objects via Windchill ESI or Windchill ERP Connector
Production Systems(ERP/MES)•Parts
•eBOM•mBOM•Change•Process Plans•Documents URL (Work instructions)
•Tooling•Skills•Process Material
WindchillW
indchill ESI(or) ERP Connector
– MBOMs
– Process Plan, Sequence and Operations
– Tools, Skills, Process Materials
OOTB Integration to SAP and Oracle Manufacturing
Flexible and open framework for integration to other systems
New 9.1
© 2009 PTC
Agenda
What is Manufacturing Process Management?
Scope, definition and challenges
PTC’s Windchill MPMLink
Part of PTC’s Manufacturing Solution
History
Key capabilities
Summary
© 2009 PTC
Windchill MPMLink key capabilities …….. enabling Concurrent Product and Process Development
Builds
Time Breakdown
Textual Description
Op025
Op 030
Op 010
Op040
Op 020
Process Plan
ConsumedOperated on
Tooling
Performed
with
Work Center
...Lines
Skills Process Material
Resource List
Part List
ResourcesPlants
Equivalent
Part 1
Part 2
Support
Sub-Assy
Vehicle mBOM
Part 8
Part 9
mBOM
Part 1
Part 2
Rear Frame
Support
Vehicle eBOM
Frame Assy
Part 3
Part 4
eBOM
Windchill PDMLink & MPMLink
IllustrationsNEWREVISION
NEWREVISION
An integral part of the Product Development
System
Associative eBOM to mBOM management
Digital definition and management of process
plans
Digital definition and management of manufacturing
resources and standards
Streamline release to Manufacturing
Dynamically generated visual work Instructions
Integral change and configuration management
Pro
du
ction
System
s (M
ES
/ER
P)
Windchill ESI
(or) ERP Connector
© 2009 PTC
Disconnected engineering, manufacturing & production teams
Difficulty to find and re-use proven manufacturing processes and resources
Struggling to provide accurate manufacturing information to production on-time
Paper based processes and manual tools (Word, Excel, ..)
Disconnected legacy systems
Disconnected engineering, manufacturing & production teams
Difficulty to find and re-use proven manufacturing processes and resources
Struggling to provide accurate manufacturing information to production on-time
Paper based processes and manual tools (Word, Excel, ..)
Disconnected legacy systems
ChallengesChallenges
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence Meet cost targets Achieve first time quality at reasonable cost
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence Meet cost targets Achieve first time quality at reasonable cost
The need to…The need to…
Remember the pain points?
Remember the market pressures?
Windchill MPMLink key capabilities … …. driving value and addressing manufacturing pain points
Manufacturing InitiativesManufacturing Initiatives PTC’s PLM-Enabled Manufacturing Capabilities
PTC’s PLM-Enabled Manufacturing Capabilities
Addressed by…
Enabled by… Driving…
BenefitsBenefits
© 2009 PTC
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Manufacturing data and deliverables managed as true enterprise master data
Upravljanje i ponovna upotreba proizvodnih planova, standarda i znanja
Istovremeni razvoj proizvoda i procesa proizvodnje
Leverage 3D digital design Enable end-to-end change
process automation and control services
Efficiently communicate manufacturing planning data to the enterprise
Systematically drive manufacturability
Enable Collaboration and securely exchange information with suppliers
Enforce product and process compliance and traceability
Embrace a manufacturing philosophy
Manufacturing data and deliverables managed as true enterprise master data
Upravljanje i ponovna upotreba proizvodnih planova, standarda i znanja
Istovremeni razvoj proizvoda i procesa proizvodnje
Leverage 3D digital design Enable end-to-end change
process automation and control services
Efficiently communicate manufacturing planning data to the enterprise
Systematically drive manufacturability
Enable Collaboration and securely exchange information with suppliers
Enforce product and process compliance and traceability
Embrace a manufacturing philosophy
An integral part of the product development system
Associative eBOMs and mBOMs Digitally define and manage
process plans Digitally define and manage
manufacturing resources and standards
Dynamically generated visual work instructions
Integral change and configuration management
An integral part of the product development system
Associative eBOMs and mBOMs Digitally define and manage
process plans Digitally define and manage
manufacturing resources and standards
Dynamically generated visual work instructions
Integral change and configuration management
Manufacturing InitiativesManufacturing InitiativesWindchill MPMLink ključne
karakteristikeWindchill MPMLink ključne
karakteristike
Pro/ENGINEER Production MachiningPro/ENGINEER Production Machining
Pro/TOOLMAKERPro/TOOLMAKER
Complete Mold DesignComplete Mold Design
……
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
Reach faster ramp-up, shorter development cycles and quicker time-to-market
Manage increased product variability and complexity
Manage and operate in a globalized supply chain
Improve operational efficiency and excellence
Meet cost targets Achieve first time quality at
reasonable cost
PrednostiPrednosti
Windchill MPMLink ključne karakteristike… …. driving value and addressing manufacturing pain points
© 2006 PTC
Founded in 1991, Grand River Group (GRG) is China’s top motorcycle manufacturer. GRG develops, manufactures and sells motorcycles, engines, and parts to both foreignand domestic markets. They are the largest motorcycle manufacturer in China with a production capacity of 3 million engines and 3 million motorcycles per year. GRG is the largest partner and export base of Suzuki Motor Corp. in China. Based in Jiangmen City, GRG has over 9,000 employees.
Grand River Group wanted to shorten their time to market by improving their manufacturing engineering process in order to accelerate the engineering to manufacturing change process, improve reliability of manufacturing data and standardize process plans and work instructions
PTC Global Services implemented Windchill PDMLink, Windchill MPMLink and Arbortext® software solutions to streamline the creation of standardized manufacturing engineering deliverables and to implement a closed loop process
Processes improved: Manufacturing Process Management; New Product Introduction
Capabilities implemented: Manufacturing Process Planning; Enterprise Content and Process Management; Dynamic Publishing
Increased production and manufacturing engineering efficiency
Improved product quality and consistency of manufacturing data
Dramatically reduced the time to propagate a new product derivative to manufacturing
“Our PTC Windchill MPMLink solution is just the thing we need to help us improve our entire manufacturing process.”
Dai JunXiang, Grand River Group
BUSINESS INITIATIVE
Grand River Group Improves Manufacturing Process Management with a Windchill® MPMLink™ Software Solution from PTC
SOLUTION
RESULT
AutomotiveAutomotive
Hvala