New trends in manufacturing

Zurich, November 2007

Manufacturing: new trends in production systems design and operation

Fulvio RUSINA (Comau), Yves COZE (Dassault Systemes)

2Zurich, November 2007

Table of Contents

Industrial key trends and main drivers

The actual design and manufacturing environment

Currents RTD efforts

Future trends in Digital Manufacturing


Key Industrial Market Trends

Globalization (production, suppliers, R&D, …)

New leaner technologies

Product / Process competitiveness

Outsourcing (logistics, engineering, production, …)

Customer satisfaction and retention concerns


100% flexibility

Minimum duration 2 generation of vehicles

Optimized cost for investment

Zero loss launch

Optimized cost per piece

Production rate scalability

Product improvement

Requirements for the Body Shop of Tomorrow


PWT - Machining

PWT - Machining

Design and Production Network

Excellence CentersNetwork

COMAUNETWORKED PROCESS

Program Management

Simultaneous Engineering & Quality Management

Make or Buy Policies & Strategies

Workload balance

Sub-Suppliers Management

Innovation and Standardization Management

PWT - Assem

bly

PWT - Assem

blyBWA - Welding

BWA - Welding

BWA - Tooling

BWA - Tooling

BWA - TransportBWA - Transport Maintenance SvcsMaintenance Svcs

ENG - Process

ENG - Process

ROB – Std Product

ROB – Std Product

ROB –Applic

ations

ROB –Applic

ations

ENG - Product

ENG - Product

Zurich, November 2007

Production SystemSupplierimpact

• Flexible/Agile Systems

• Re- programmable

• Convertible solutions

• More “robotized” systems (< infrastructure)

• Intelligent and rational use of automation vs. operators

• Design for safety and ergonomics

• Innovative process (new joining technologies, MQL machining, …)

• Dismantling

• Integration of shopfloor automation at plant level

• Intuitive HMI & field data collection and analysis

• Virtual engineering & Digital Manufacturing (modeling & simulation)

• Higher reliability

• R&M approach

• Local sensors for process monitoring

• Remote diagnostics

• Tele-service (WEB network)

Manufacturing Systems - Evolution Drivers

DRIVERS

• Standard & lean

• Low cost solutions

• Modular and re-usable

(“agile”)

• Plug & Play modules

• Wireless applicationsin manufacturing

• New process (e.g. remote laser welding

Factory Cost Flexibility Optimized ShopFloor Mgmt

Maintainability Environment & Safety


Why Digital Manufacturing?


Digital Manufacturing solutions: a seamless end-to-end workflow


DIES

S.O.P.

Body Quality Program

PRODUCT ENGINEERING

BODY SHOPBODY QUALITY

PROGRAM

BODY QUALITY&

PRODUCTIONTARGETS

SIMULTANEOUS ENGINEERING PHASE

PROCESS ENGINEERING & BODY GEOMETRY SET UP


Static (Torsional Stiffness)

PRODUCT ANALYSIS:• Static• Fatigue• Vibration and noise• Crashworthiness• Bio-mechanics• Optimisations/robust design• Multibody

Stocastic spotwelds analysis (Optimisation/RD)

Product / Process Analysis

PROCESS ANALYSIS:Process macro-cycle is a preliminary hypothesis on• needed plant room, • time cycle, • panels to be loaded


COMAU Standardization Process

Knowledge Integration Tools

Digital Manufacturing

Business Processes

TechnicalJob Management

Business ProcessProcedures (Quality)

MaterialManagement

(PBS, WBS, …)Design Book

WEB sites

Design Book as “Easy” Catalog

Proposal Engineer Design Engineer

The standardization process


EU Platforms: ManuFuture


RI-MACS is the acronym for Radically Innovative Mechatronics and Advanced Control Systems.

The main objectives of the RI-MACS R&D program are the definition of a radically innovative manufacturing control open architecture based on state-of-the-art ICT technologies (in particular wireless technology) and modular mechatronics.

All the technology being investigated will conform to open architecture standards. Interfaces must allow for easy integration with the other process units. Other factors considered include

increasing factory safety andreducing the environmental impact.

RI-MACS R&D Program*

*) EU Contract Number NMP2-CT-2005-016938


Future

Current

PlantServer

LinePC

CellPLC

Eth

Eth

Field Bus

Sensors/Actuators

PlantServer

Line/CellPC

Sensors/Actuators

Eth

Web based services

System Integration & Control Architecture Evolution

http://www.ibm.com/developerworks/wireless/library/wi-global/


Make open approaches and the multi-agent paradigm more robust and demonstrate their feasibility (web services/agent-based mechatronics control technology with embedded intelligence);Exploit wireless technology in networking and in novel architectures;Develop flows to support the design and operation of the manufacturing plant of the future with particular attention to the simulation of service oriented services (SoA) and automatic code generation for control;Develop industrial strength test beds.

RI-MACS - Main Project Objectives


Embedded Controls and Wireless Manufacturing

control room

WLANbluetooth

processes

inpu

t

power

logistics

WLANMultihopZigBee

manufacturing

outputWiFiBluetoot

h

maintenance

UMTS

busines s

models

new control

paradigm

device models

WLAN

collaborative communication

models

Location -based services

Production- based services

embedded wireless physical

layer (hardware)

abstract communication

layer (middleware)

collaborative control

layer

production planning

layer (software)

Multihop

Communication -based services

Communication -based services


Devices with complex cinematics

Electropneumaticdevices

Pure logicdevices

Cinematics

Geometry

Internal Logic

Logical I/Os

Control Logic

PLC program

Comunication

Objects libraries

Virtual cell

All the objects could be stored in libraries

RI-MACS – Digital Manufacturing Environment


3D Model creation

SW Automatic generation

SW Completation

- Mechanical description - 3D Mechanism- Internal Logic (IL)

High level simulation

Control Logic creation

- Normal cycle diagram - Control Logic (CL)

Normal Machine CycleVALIDATED

- Special cycle diagram- I/O Mapping

- Target PLC SW

Low level simulation

SW PLCVALIDATED

- Diagnostic alarm list- HMI Specification

- PLC SW completed

Integrate Control Engineering Flow

Mechanical modification

INPUT OUTPUT

INSIDEDelmia

AUTOMATION

OUTSIDEDelmia

AUTOMATION

- OPC Connection

RI-MACS – Digital Manufacturing Environment


Digital Manufacturing: knowledge-based engineering roadmap

Digital Manufacturing Engineering

Integrated/Networked Engineering Environment

Multi-scaleSimulation

3D CAD IntegrationEngineering ToolsDigital Prototyping

Factory Data Management

Digital Factory

Adaptation to RealityIntegration (MES)

and Smart (wireless) Factory

Digital Product Engineering

Ergonomics andProcess Standards

Life Cycle Data Management Config. Management

Rapid PrototypingDigital Prototyping

Integrated Project and Knowledge Management

…and Support ofKnowledge-basedFactory and Services

Towards the Digital Manufacturing…

Standards

Models ofManufacturing


Digital Manufacturing: IT Environment requirements

Creates a COLLABORATIVE standards-based manufacturing environment

Provide VISIBILITY throughout the organization and with suppliers, partners and customers

Enables FLEXIBILITY to manage operations remotely and react quickly

Ensure SECURITY for all business communications

Lower TOTAL COST OF OWNERSHIP


Digital Manufacturing: “Openness/Friendliness ” requirements

OPEN design, simulation and validation framework INTEROPERABLE with market leader Digital Manufacturing software products

INTEGRATED Digital Manufacturing environment based on common data models

Easy CUSTOMIZATION to include specific customer’s needs and solutions

Simple reference METHODS and friendly and easy to use SOFTWARE TOOLS to support all stage of the design and development

Elementary EDUCATION AND TRAINING ENVIRONMENTS to test and practice new Digital Manufacturing solutions


ADHERENCE between the real and the virtual environments

EASY DATA AND INFORMATION TRANSFER between the real and the virtual worlds and vice versa

Effectiveness in MANAGING DIVERSIFIED SOURCE OF INFORMATION: economics, product, process, mechanical, control, piping and wiring, hydraulic, pneumatic, etc.

Capability of MANAGEMENT CUSTOMERS NEEDS from process planning, to production operation, to system maintenance and re-tooling

Digital Manufacturing: “Real vs. Virtual” requirements

Education

New trends in manufacturing