2. plm tools speed developments

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PLMTools: i l : : :' lLatest ollaborativeools help compressanufacturingtime-to-marketwithglobalvirtualdesigns

Using3-D echnology, Dassault'sDelmiaV6simulationshelp usersimprovemanufacturingprocesses.

, :;;:,,, ollaborativeproductdevelopment hroughproduct

' ',., the criticalstagewheremanufacturersmust use vir-

time-to-marketand qualitydemands.Newvirtualdesignanddevelopmentools now allow fast andprecisemodelingofproduct developmentprocesses,ncludingthe latest systemsofferingaccurate irtual commissioning fplant layouts andautomationgearon the factory floor.

Patrick WaurzyniakSenior ditor

PLMsoftware oolsand serv-

iceshavegainedractionas man-ufacturersn aerospace, utomo-tive,and otherindustrieshaverealized he value ofPLM, andits subsetdigital manufacturingtools, n effectivelymanagingar-f lungglobal productdes ign ,development,nd manufacturingefforts .As outsourcingandglobalf.actoryoperationshave

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becomemore common,manufactur-ers are embracingPLM technologiesas a way to speedproductdevelop-mentprocesses.

Worldwide demandfor PLM soft-ware and servicesgrew at a L3.5o/ogrowth ra te to reach an es t imated524.3 billion in 2007, according to

market esearcher IMdataInc.(AnnArbor, MI), exceedinghe company'searlier orecasts.Manufacturers reinvesting eavi ly nPLMas manage-mentrecognizeshe valueof PLM forc o mp a n i e s f a l l s i z e s , o t e sEdMiller,CIMdatapresident.

"Executive-levelecognitionof thesignificant usiness alue ofPLM isdrivingincreasedmplementationofthe approach,"Miller says.Manyofthese ar-reaching ystems xtendbeyondengineeringesigno a broadrangeof activities-from early-stageproductstrategydevelopment ndplanning,o productengineering ndmanufacturingengineering ,andthrough oproductmaintenance ndsupport."PLMinvestments illcon-tinue to climb, as CIMdataforecastsPLM increas ing t a compounda n n u a l g ro w t h ra te (CAGR)ofapproximately9.8oA, expanding hemarketo nearly$40billion bv201.2.

"Theuseron the loorcan eplay that

simulationoverand over."

"One of theprimarytrends hatwe'reseeing ow,that's beena part ofthe Dassault ision or alongtime, sthe conceptof tru e virtualproductdevelopment-theabilityin the com-puterto be able o design,manufac-ture, test, and evenservice roductsvirtuall beforeyou reallystart anyphysicaldesignor too ling construc-

t ion ," notesBob Brincheck,PLMdirector,DassaultSystmes merica(Woodland ills,CA, and Paris).

"Ten yearsago, there was morebest-in-classypeof approach,whereyoucould usea reallygoodCAD tool,a different,oodproductdatamanage-ment tool, and a differentand goodmanufacturingimulation ool, and aslongas you hada coupleof threads

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betweenhose ools,youcouldmake twork and seea lo t of benefi ts ,"Brincheckadds."Butthe wholebest-in-classhilosophwhile t mightgiveyou some useful nitialbenefits, tcauses lotof long-term ssues."

Virtualplant-floorcommissioningof assemblyinesand factory ayoutscan be a boon to manufacturersry-ingto compressroductdevelopmentcycles.n aerospace,utomotive, ndothertransportationroducts, hemeldingof mechanical,lectronic,and softwaresystemss becomingcommon,notes Brincheck.The sep-arationbetween hysicalCAD,PDM,andmanufacturing eallycauses omeproblems,"he adds . "One of therecentDelmiatechnologiess DelmiaAutomation's irtual comrrissioning.Fora long ime,we'vehad robotsim-ulation. canprograma robot an dsimulate ow thatrobotdoes ts taska n d a c t u a l l yc re a t e o d e o r th erobot. But therobot oftentimeshassomesimpler automationhat'smorePLC-based r moreactuator-based,and the robot hassystemshat startit, stopit, and provide t with the

electricityor hydraulicsor whatever'sdrivingt so t can run."Problemsaround commissioning

have ypically been hatyou'll getarobot inplace,and the robotwillrunthroughthe routine that it needsorun through.Buttheautomation,ool-ing, or the machineshat I'm using ofeed he robot parts-the conveyorline, or other components f automa-tion-don't necessarily ork asa sys-tem. Sowhen argeassemblyinesarecommissioned, anufacturers ftenspendmanyweeksust gettingall thestuff owork."

To help solve hatpuzzle,Dassaultteamedup withRockwell Automa-tion (Milwaukee)n December 007to jointlydevelopan integrated igi-tal factory andplant-operationsolu-tion.Under the agreement,RockwellSoftware 's SLogix5000 contro l

programmingand configurationsoft-ware would be in tegratedwithDassault'sDelmia Automation PLMsoftware."' 7hatthe Delmia Auto-mation solutiondoes s that we'vepartneredwith somemajorautoma-tion suppliersike Rockwelland wecan actuallysimulatehowtheirprod-uct works-qrs 's able to developcode or that productfrom thesimu-lation," Brinchecknotes. "'S7e utthat simulation nthe context of therobotsand the controlpanels-downto the solenoids,ctuators, ndwhat-ever else s on that assemblyine-and then I can iterallyvirtually com-mission hat product.Before set tup at the plant,I can run that assem-bly linevirtually.I can debug all ofthosesystems, ndmake sure hat mymanufacturinginewillwork,so thatwhen I come n to install it, it'sactu-allygoing o run correctly."

Focusingon 3-D technology,Dassaultast year alsoaddedmorecore3-D capabilities ith theacquisi-tion ofSeemagenc., a developer f3-D product-documentat ionoft -ware. Alongwith its earlier 3Dlive

software echnology,Dassault e-brandedSeemage'sackage s 3DViaComposer,which complementshe 3-D focusof Dassault'satestV6 PLM2.0 applicationsuite hat includesCATIA,Enovia ,and Smarteam.Brinchecksays hat with the 3DViaComposer echnologyuserscan use3-D designnd engineeringata con-tent, along with the structuredbill-of-materials nformation forquicklyandeasilygenerating2-D and 3-Dpubli-cations, ncludingshop-floornstruc-tions and inspection heetsor techni-calpublications.Brinchecknotes hatDassault's ifferent approachoffersavery 3-D-focusednvironmentapa-ble of eliminating ny confusion hatcan result fromthe relianceon text-based ommon anguagesnd erms.

"Oneof the challengese'vehadover thelast numberof years s that

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In Siemens PLMSoftware's NX CAM,3-D model

annotating with industrystandard product man-ufacturing informationenables evaluation ofmachining methods.

we do the 3-D design,we share hat information:: 'Delmia,we do a lot of the3-D simulation, utpublish::that informationhas alwaysbeena.gap, o a cerr. i , -extent.Or we'vedone hat,but it's not inthe bigger t.:text," Brinchecksays. It's not done as effectively' scouldbe.Andwith the 3DViaComposerroduct,harhi''eratesa lot of the 3-D information fromengineering-frommanufacturingngineeringnd enablest to be d:'tributedto the shop loor,to our viewersor to otherpt,-ple,much moreefficientlyand effectively.

"Thevalueof workingwithDelmiaand heease f u*of a tool like3Dliveis that you can do a simulation':howto change ut amachineool ora die n a pressn rhemostefficientwa" headds. 'Sith3Dlive,the useronthe floor canreplay hat simulationroma PC, aptop.ora terminal, andplaythat simulationover andover,anJuse t as a real-lifeexample f how they cando their ob .That'ssomething urcustomers assaultAviation aniToyotahavedone whenusing heDelmiasimulationsn training context. Someof thefeedbackwe got early on

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with the Falcon7X a couple yearsago was that when the workersstarted o put it together,hey got averyin teres t ingcase of dj vu,becauseheyhad beenworkingwiththis visionin a virtualenvironmenrfor so longthat putringactual physi-c a l p a r t st o g e t h e rw a s s t r a n g e l yfamiliar.The first t ime they evertouchedphysicalproduct,heyknewexactlywhat to do with it, becausetheyhad workedwith it virtuallysomany imesbefore."

Developingighterlinksbetweenproductdevelopmentesigners,ngi-neering,and manufacturingengineerson the factoryflooralsohas beena

key focalpoint for Siemens LMSoftware Plano,TX) sinceSiemensAG acquiredUGSPLM Softwareearlylast year.With its Archimedesproductdevelopmentffortunderwayto forgesrrongeries betweendigital

nizingthat in thefuturethemanufac-turingprocesses re goingto evolve.We seemorebuild-to-ordernow thanwe everhavebefore,and n thefuturethat 's goingto evenevolvemorebecause f consumers'equirementsfor person lizationn their products.

"Allthe automakers re real lystartingo engagen an open nnova-tion activitSwhere heyare sponsor-ing contestsor they'regoingto theirsuppliers,ndaskinghem o takeona broader ole in the peopledevelop-mentprocess,"Carrellistates. ,Over-all the vehiclemodel,on a globalbasis,s movingmuchmore o a col-laborativemodel,whereautomakersare open o ideasand innovationhataremorecloselyalignedwiththe spe-cificmarketplaceshat they'reserv-ing,and that'sreallyimportantwhenyoutry to creare globalvehicle.Theautomotiveworld 'smovetoward

"Becausehey had been workingin avirtualenvironmentfor so rong, prttingactualphysicalartstogetherwasstrangelyamiliar."

manufacturingools and factoryautomation,Siemens LMhas ever-aged ts expertisen manufacturingexecutionysremsMES)and factoryautomationalongwith the additionof UGSPLMsoftware.Siemens'LMsuite ncludeshe TecnomatixsuiteofdigitalmanufacturingoolsacquiredearlierwhenUGSbought he IsraelicompanyTecnomatixsee EntertheVirtual' lorld"in the October2007issue f ManufacturingEngineering).

"Oneof thebigtrendsn themar-ketplacehat is nor so differentthanwhat has beenaroundfor years s,'how do companies et to marketfaster,"'notesBillCarrelli,SiemensPLMSoftwarevice president.,Thecaveat s the fact that not only docompanies ant to get to marketfaster, ut companies rereallyrecog-

globalengineeringeallyreflectsheunderstandinghatcompetitivenessnthe futureis goingto be governedbycompanieshat can respondmorequicklyo marketdemands. nd tharreallybuilds owardcomingup withthe flexibilityto have heirmanufac-turingprocesses eet he moreper-sonalizedequirementshat are com-ing out of the designand develop-ment organizations."

Collaborativeevelopmentoolsare enablingPLM to developighterbondsberween esigners,ngineeringand the factoryfloor."'We'vecreatedan internalcodenameprojectwithinSiemensalledArchimedes,nd it's across-organizationrojectnvolvingPLM,automationsystems, nd mo-tion-controlpeoplewithinSiemens,',Carrellisays. The idea s to lookat

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common ways of linking thevirtualdesign ools andthe manufacturingtools,simulation ools, manufacturingand processes, nd tying thatall the

way to theactualphysicalesourcesnthe actoryso hat as designs re beingconceived,hat a t the same ime,they'redesigningwith the knowledge

and contextof the manufacturingprocessesnd resourceshat are avail-able o them oday."

Digital manufacturingools withfactory-floorvirtual commissioningspeeds ime- to -marke t . Th i s i sabsolutelye and with the virtualcommissioningf factories,he wholeideaof mechatronics ecomes venabiggerssue,"notesCarrelli."'Whatvirtualcommissioningeally meanssthe ability to validatea manufacturingfacilitor process, rior to actuallymaking he investment. utomakerstodaywillbuildup segments f theirfactoryautomation; hey'l l buildacompleteine in a differentacilitthen test t, and once t works, theytear t all down, thenset t up in theiractual manufacturingproductionsite.It's a hugelyexpensive,ime-consum-ing process.hat we want to doisgivemanufacturershe ability to buildthat line n theproductionsitewithouttheexpense f validatingt physically.

"Vhat we're doingnow is we'retrying to si mulatemuch more accu-ratelythe whole interactionof what'shappeningon the shop floor-the

mechanicalropertiesf the factor aswellas the electronics-thedrives, hemotors, he controllers,nd the soft-warethat runsthe PLCs,"Carrell isays. Whenyouthinkabout doing anaccurate imulation,ou really need obe able o take into considerationhemechanical,he electrical, nd hesofr-ware sidesof the factoryitself andthose esources-that'swhat mecha-tronicss all about. You need o inte-grate hePLCswith thecontrollers,he

sensors, nd the motors.The

electricalnetwork sa verycomplexenviron-ment in its own right, and integratingit with themechanical ide s reallywhat's equired f you're goingo getmoreaccurateommissioning.

Anotherkey aspect o Siemens'efforts s the control-level ntegrationof its NX CAMsoftwarewith ma -chine ool controls onthe shopfloor.

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As part of theArchimedes evelop-ment, the effortsnclude a focus onwhat Siemensalls Hi-Fi Machining,with tighterlinks betweenCAM andthe physical ontrollers.Carrelli saysthe companywill introduce hefirstsuchproductsater hisyear.

"Thisideaof CAM and CNCma-chiningntegration s wherewe'rereallyintegratingmore closely hevirtualCAMmodelswith the actualmachinecodes hat are drivinghe machine oolsthemselves,"arrelli explains.'Vlhat

A second evelopmentiemens illshow soon s the firstproductionrelease alledAutomationDesigner,which Carrelli describess an integra-tion between heTecnomatixTeam-centerandAutomationDesignerrod-ucts,which will createa betterenviron-ment forvirtual commissioning. WithArchimedes, otonlyare we focusingon greater ntegration of the designenvironmentwith themanufacturingenvironment ll theway to the shopfloor,butwe'realso ocused eryheav-

Highly realistic simulationsin Da ssault's new V6PLMapplicationsoffer life-like viewsfor manufacturing engneers and designers.

we'redoing theres we're creatingamuch higher evel ofin tegrat ionbetween he code hat's being usedndesigning hetoolpath and theactualmachinecharacteristicshemselves,othere'sa lot lesscorrection hathas tobe done by themanufacturer n theshopfloor. Themodels hat are devel-opedtake into account he capabilitiesand characterist icsf the precisemachine.The softwares goingto beused o actuallyeneratehe machiningoperation.ntegrationof the CAM andthe CNCis something hat'sgoingtobe delivered s part of ourstandardproductofferingsby the end of theyear,and we think that'llgo a longway towardgreateroptimizationof theequipmentn the shop loor, and evengreaterquality inthe products hat arebeingmanufactured."

ilyon managing hat data and closingthe oop. As thereal-timemanufactur-ing is occurring,we're able o monitorthe factorydata and compare)on areal-timebasis, hat datato the as-designed ata in the virtualmodel,"Carrelliadds, and do real-time orrec-tions, optimizations,o see ssues hatmay be occurring hathave o befixedon the shop loor that can be read-justed n the product. But the wholeideaof closing heoop betweenhe as-designednd the as-builtworldis keyto maintaininghe highestqualiryandalsomakingsure hatwe are ookingattheway wecanoptimizehowproductsarebeingmanufactured.

Siemens LM Softwarealsoha saddeda new elementcalledsynchro-nous.technologyhat will beincludedsometimehis summern Siemens'NX

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2. plm tools speed developments

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