new trends in manufacturing
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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
3Zurich, November 2007
Key Industrial Market Trends
Globalization (production, suppliers, R&D, …)
New leaner technologies
Product / Process competitiveness
Outsourcing (logistics, engineering, production, …)
Customer satisfaction and retention concerns
4Zurich, November 2007
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
5Zurich, November 2007
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 shop- floor 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
7Zurich, November 2007
Why Digital Manufacturing?
8Zurich, November 2007
Digital Manufacturing solutions: a seamless end-to-end workflow
9Zurich, November 2007
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
10Zurich, November 2007
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
11Zurich, November 2007
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
12Zurich, November 2007
EU Platforms: ManuFuture
13Zurich, November 2007
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
14Zurich, November 2007
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
15Zurich, November 2007
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
16Zurich, November 2007
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
17Zurich, November 2007
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
18Zurich, November 2007
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
19Zurich, November 2007
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
20Zurich, November 2007
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
21Zurich, November 2007
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
22Zurich, November 2007
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
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