디지털공정계획솔루션 - dbguide.net · 2009-02-26 · v5 dpm-assembly v5 delmia human...

© 2009 IBM Corporation

®

디지털 공정 계획 솔루션

PLM Solution RoadShow 2009

IBM Software Group – Product Lifecycle Management

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목 차

What is Digital Manufacturing?What is Digital Manufacturing?III

Design-to-Build Process with DELMIA Design-to-Build Process with DELMIA IIIIII

Process Engineer IntroductionProcess Engineer IntroductionIIIIIIIII

DELMIA Process Engineer Key BenefitsDELMIA Process Engineer Key BenefitsIVIVIV


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What is Digital Manufacturing?

Process planning

Factory Modeling

Visualization and Collaboration

Simulation of operations

Ergonomic and human factor analysis

“the Keyhole to the Future”

Digital Manufacturing is…


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INTELLECTUAL PROPERTYINTELLECTUAL PROPERTYINTELLECTUAL PROPERTY

VIRTUALTangible Assets

REAL OPERATIONSREAL OPERATIONSREAL OPERATIONS

Non Tangible Assets

PHYSICAL

Product & Process Knowledge Production

Courtesy Dassault Aviation- Falcon 7X

Bringing the two together


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Product Development

Process PlanningManufacturing Concept

Layout planning Standard Time Measurement

A Seamless End-to-End Workflow

RobotSimulation

Manufacturing SimulationQuality Control

Material FlowSimulationProduction

Planning

3D WorkInstructions

ControlEngineering

Process Planning

WorkstationLayout

Ergonomics

HUMAN

Resource Modeling

and Simulation

Process Planning

Production

Flow

Simulation

Process Detailing

And

Validation

Automation

Manufacturing

ExecutionProcess Detailing

And

Validation


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ProcessPlanning

Process Detailing & Validation

Resource Modeling & Simulation

Product EvaluationProcess & Resource PlanningTime MeasurementLayout PlanningLine BalancingCost Analysis

3D geometry based detailing Assembly SequencesFastener ManagementMachining OperationsFactory/Cell Layouts

Factory Flow SimulationsRobotic Work cell Setup and OLPNC MachiningVirtual Reality ScenariosErgonomic AnalysisControl Engineering

Three Distinct Domains for Digital Manufacturing


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OUT Tail Number MBOM & Tooling/Equipment/ Manpower Definition, Part/Equipment Ordering,

Work Scheduling, Textual Planning

ERP

INTa

il N

umbe

r EB

OM

D

efin

ition

•40%+ Higher Re-planning Cost•25%+ Higher Assembly Cost•25%+ More Assembly Errors & Rework

• Risks meeting commitments• Competition will make this model unsustainable• Limits future growth through hampering innovation

• Longer Time to Production / Market• Longer Cycle Times in Production

• Production Knowledge Undocumented• Intellectual Property Left Untapped

OUT Model-Based Definition: Features, Annotations, Tooling Definition

IND

esig

n R

equi

rem

ents

DESIGN

Design Engineers

Model Views

Textual Work Instructions

PRODUCTION

OUT Build Aircraft, Document As-Built Record

INB

uild

Pla

ns &

Wor

k In

stru

ctio

ns

MRP/MES

Manufacturing Engineers

Workers

MRP/MES

MBD Explosion(Model Views)

EBOM-MBOM Reconciliation

Design-to-Build Process in non-DELMIA Digital Manufacturing


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PRODUCTION

OUT Build Aircraft, Document As-Built Record

INB

uild

Pla

ns &

Wor

k In

stru

ctio

ns

MRP/MES

ERP

INTa

il N

umbe

r MB

OM

D

efin

ition

OUT Part / Equipment Ordering, Work Scheduling

Workers

Design Data Integration:Product Structure / Metadata / Configuration / Effectivity (ENOVIA)Intellectual Property (CATIA)

Shop Floor Integration: Assign Daily Work OrdersPart / Equipment / Worker Status

Shop Floor Integration:Model-Based Instructions per Work Order

ERP Integration:

Tail Number M

BOM

(including Standard

Parts re

ferenced in

CATIA design)

Routings

Tools & Equipment

OUT Model-Based Definition: Features, Annotations, Tooling Definition

IND

esig

n R

equi

rem

ents

DESIGN

Design Engineers Production Engineers

MANUFACTURING ENGINEERS

OU

TM

odel

-Bas

ed P

lann

ing

IN Model-Based Definition: As-Designed Requirements

ME Planners

Design-to-Build Process with DELMIA Digital Manufacturing


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PRODUCTEngineering HubEngineering Hub

((Product))

Manufacturing HubManufacturing Hub((Product, Process, , Resource))

Process EngineerProcess Engineer

Process Engineer Position in PLM

PRODUCT

RESOURCES

V5 DPMV5 DPM--AssemblyAssembly

V5 DELMIA HumanV5 DELMIA Human

QUESTQUEST

PROCESS


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Process Engineer에 의한 Digital Process Planning

=> 생산기술 전체 영역의 디지털 공정 및 생산계획 Solution => 가상생산의 PPR Hub

M-BOM 및 Option 관리

Process Planning

Resource Planning

Digital 환경에서 제품의 조립체계에 의한 공정계획 및 공수산정, 최종 생산설비 Layout 계획을 수행할 수 있는Digital Manufacturing Solution

Process Engineer®

생산 전제조건 정의 (Target, Shift Model, 투자비, 부자재, 생산계획조건 등…)

Process Engineer의 주 역할

자재계획 정의, 생산 Concept 및 3D Layout

M-BOM 정의 및 OPTION, 이력관리 인간공학적 작업자 계획 및 작업자 분석

작업 표준공수 산정 Cost 분석

공정계획, Work Plan, Process Flow 정의 제품, 공정, 자원 DB 관리

1

2

3

4

6

7

8

9

Line Balancing (Work Load 및 Automatic ) 공정도, 작업표준 및 문서 출력5 10


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Process Engineer Process Planning &

Resource management Product Data Management

P D M

3D CAD

설계 DMU CAE

2D CAD

제품설계지원 Solution 생산기술지원 Solution

자재 Layout 조립 DPA 검증

HUMAN

공장 물류흐름

Robot OLP, MCP, MCS 공정계획, 표준작업시간, 조립공법서, 작업편성표

선행제품검토, Concept Manufacturing에서 최종 Layout 설계에 이르기 까지관련 제품, 공정, 자원을 고려하여 쉽고, 빠르고, 정확하게, 경제성을 고려한 최적의 Process

Plan 을 수립할 수 있는 시스템 지원 필요합니다.

Why we need Process Engineer?


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Process

Resource

Product

BOM 관리

조립프로세스

Layout

자원

제품

필요한 모든 Data와 시스템이상호 유기적으로 Link 되어 있지 않다.

시간, 노력, Data 손실

현재 생산기술과 제조에서 필요한 기술검토와 문서(공법서, 작업지시서)들은 매번 Engineer의 경험과수작업에 의해 Excel로 만들어지고 있습니다.!!

AS IS TO BE

PDM

SAP, Manual (Excel)..

AutoCAD /EXCEL..

CATIA..

CATIA..

Integrated Environment for Digital Process Planning

All in one


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Non-Integrated Environment for Process Planning

Project Premises Process Definition

Concept Layout

Line Balancing

Simulation

Ergonomics

Product Evaluation

Layout

Time Analyses

Product Viewer

123


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Project Premises Process Definition

Concept Layout

Line Balancing

Simulation

Ergonomics

Product Evaluation

Layout

Time Analyses

Product Viewer

123

Integrated Environment for Process Planning


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IntegratedDatabase

Project Premises

Process Definition

Manufacturing Concept

Line BalancingTime Analyses

Simulation

Layout

Ergonomics

Product Evaluation

Systematic Process Planning


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Premises

Manufacturing Hub

Line Balancing

Product analyses

Process definition Process graph

Time analyses

EvaluationManufacturingConcept

LayoutErgonomicsSimulation

Quick access to up to date data

Quick documentationQuick analyses

DELMIA

Digital Process Planning in Process Engineer


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Engineering Engineering -- BOMBOM Manufacturing Manufacturing -- BOMBOMPProductroduct

Process PlanProcess Plan

PProcessrocess

RResourceesource3D 3D –– Layout PlanLayout Plan

Production PlanProduction Plan

2D 2D –– Manufacturing ConceptManufacturing Concept

Preliminary PlanPreliminary Plan

Concept M-BOM

Final M-BOM

Process Engineer의 전체 Work Flow


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Listviewlists up all objects which belong to selected parent object

Property dialogfor a selected object

Easily access/edit/view

– List views

– Object properties

– Process Graphs

– Time Analyses

– Product geometry (from PDM)

– Layout

– Line Balancing

Process Engineer User-Interface


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Planning Premises ( 전제조건 )새로운 Project 시작 시, 생산계획을 위한 경계조건(Boundary Condition) 정의

제품 생산계획 곡선

전제 조건의 속성 Data

– 생산일정별 생산계획

– 생산공장 Site 정보

– 교대조건(Shift Model)

– Cost 목표

– Cost 비율(Cost Rates)

– 혼류생산 비율

– Target Volume

– Target Cycle Time

– ...


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Product Evaluation ( 제품 검토 )

외부 시스템이나 소스로부터 E-BOM Import/Update

– E.g : From VPM or PDM or Excel File

M-BOM 생성

Product variants 관리

– By use of variant codes and mathematically logical expressions


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Process Tree 구조에서 Process 생성 및관리 (관련 부품과 Link)

다중의 상세 Level 단계를 가진 Process 계층 구조 정의

Process Graph에서 Process의 우선순위조건과 Process 순서 정의

Process에 제품과 설비의 쉬운 Link (Drag & Drop 사용)

Drag&drop parts directly on process

Model precedence constraints for processes

Process Definition ( 프로세스 정의 )


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Same DataManufacturing Hub is the

common data source(one common data model)

DELMIA V5 Interaction


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Time Analysis

빠르고 효과적인 표준시간 분석값 생성

– 사용 가능한 국제표준 시간분석방법 :

– MTM-I, MTM-II, Standard Data, UAS, MEK, WF, Office tasks, Visual Inspection,…

표준시간 Data Card를 사용한 신속하고 효과적인시간분석

사용자 정의 Data Card 생성

Process 시간을 계산하기 위한 사용자 정의함수(Formulas) 생성

정확성을 위한 Rules Check

유연한 검색 기능(Filtering)


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Line Balancing

PROCESS ENGINEER에서 2가지의 line balancing module을 제공합니다.

– Work Load Balancing module

• 일반적 Line Balancing • 신속한 Process의 Balancing• Station/작업자 편성율(가동율) 최적화

– Automatic Line Balancing module

• 다양한 제약 구속조건 고려

• 혼류생산과 자재면적 Balancing


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기간별 생산계획조건에 따른 생산 능력 검증

3D layout 생성

Simulate material flow

다른 시나리오 조건의Manufacturing Concept과 비교

사용자 작업표준서, 공정계획서 출력

목표 Cost 추적

From the Manufacturing Concept...

Traffic light evaluation of Occupancy levels


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Manufacturing Concept

Manufacturing Concept에 의한 직접적, 대략적 상세 3D Layout 생성

Line Balancing된 Resource Tree 구조와 Link

BOR(Bill of Resources) 자동 생성

공구, 지그, 설비들에 대한 공용 System Library 활용 다중 Layout에서 재사용

Library

Layout

Line Balancingresource structure


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3D 작업장에서의 정적 작업자에 의한 작업환경평가

– human models of different nationalities and size (5th, 5th,95th percentil)

– View reach ranges, field of vision

Assess workplace by using common check sheets and analysis methods

– NIOSH, REFA, DIN, EN, etc.

– Analysis & check sheets are stored with each workplace and can be accessed anytime

Ergonomic Evaluation


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Reporting in Process EngineerProcess Engineer는 내장된 template editor를 이용하여 각 회사에서요구되어지는 문서 표준에 맞추어 프린트 기능을 제공

Work plans,Cost sheets,Station resource lists,…

– Combine any geometry and meta data from product, process and resource on a single template

– Print documents, or output to

• MS Office,• html, xml, pdf, etc.


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TargetCosting

ProcessGraph

Work Plan

Assembly SimulationPre-Planning

Bill of Resources

Integrated Process Modeling(Common Data Model)

MBOM

Task sequencing

Reconcile EBOM-MBOM, & Process Plans

Status reports

Cost Tracking

Capture and Reuse Best Practices

StandardTimes

Operations Balancing

Output Result

Summary Process Planning


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목 차






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DELMIA Process Engineer Key Benefits

체계적 방법론에 의한 생산준비 계획업무의 Structure화

Planning Process안에 모든 기술요소의 통합화

선행단계에서 Process의 위험 및 Error요소의 검출

검증된 공정과 자원의 재 사용

다양하게 분산된 공정지식의 통합 사용

시나리오를 기반한 선행단계에서의 대안평가

체계적인 Cost Input 평가에 의한 최적 Solution의 실현

합리적이고 이해하기 쉬운 의사결정과 변경

중복업무의 감소

계획의 질과 신뢰성 증진

계획시간의 단축 (생산준비시간의 단축)

Process Planning, Detailing and Validating에 대한 연속되고 통합된 3D 환경 제공

Product Process Resource 정보를 공유하고 활용하는 Collaborative Workspace 제공


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감사합니다.

디지털공정계획솔루션 - dbguide.net · 2009-02-26 · v5 dpm-assembly v5 delmia human...

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