presentation date: 2018 10 30 presenter name: …...© 2018 baker hughes, a ge company, llc - all...
TRANSCRIPT
Presentation date: 2018 10 30
Presenter name: Nicola Campo; Massimo Matteini
Room name: Estrel Hall C1
Presentation title: Electronic Work Instructions implementation in
BHGE Turbomachinery & Process Solutions
© 2018 Baker Hughes, a GE company, LLC - All rights reserved. Nicola Campo; Massimo Matteini Baker Hughes, a GE company
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Electronic Work Instructions implementation in BHGE TPS
Nicola Campo; Massimo Matteini
October 30th 2018
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
BHGE: We are fullstream
October 27, 2018 3
Fullstream projects leverage the breadth of the BHGE portfolio, combined with new commercial models,
to drive successful outcomes for our customers.
UPSTREAM
• Evaluation
• Drilling
• Completion and production
• Subsea
MIDSTREAM
• LNG
• Pipeline
• Storage
DOWNSTREAM
• Refining
• Petrochemical and fertilizer
• Processing
INDUSTRIAL
• Power and renewables
• Control and sensing
Sharing risk
and reward.
Reducing costs.
Increasing
productivity.
Early engagement to maximize the end-to-end value chain
Horizontal approach with connection at all levels within
the customer’s organization
Partnership and support during all phases of the project
Fullstream commercial models that deliver changes in project
economics by lowering the cost of production and increasing industrial yield
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 4
Turbomachinery & Process Solutions (TPS)
• 10,000+ employees
• Operating across 120 countries
in 7 Regions: Europe, Russia &
CIS, Africa, Middle East & India,
Asia Pacific & China, North
America and Latin America
• 30 manufacturing facilities
• 10 service facilities
• 1,000 Field Service Engineers
• Solutions tailored to industry
segment needs
Structured to serve our customers
Refinery & petrochemical Industrial
Onshore & offshore
production
Liquefied natural gasPipeline & gas processing
Portfolio
• Aeroderivative and heavy-duty
gas turbines
• Small- to medium-sized steam
turbines
• Centrifugal and axial
compressors
• Reciprocating compressors
• Process, control and safety
valves
• Integrated power, compression
and LNG modular systems
• Service solutions
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 5
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 6
Digital Thread & Model Based Enterprise
Digitizing within and connecting across all systems and functions
• Create a Digital Thread to improve efficiency,
productivity and quality … remove hidden
waste in data manipulation across functions.
• Annotated 3D Models as the Master of
Product Definition… database for downstream
re-use
• ... foundation for the creation of a new
Industrial Environment: Digital Twin of assets
to predict, measure & optimize performance PROJECT
MANAGEMENT
SUPPLY
CHAIN
MANUFACTURING
SERVICES
COMMERCIAL
ENGINEERING
CostQuality
Cycle
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 7
Our Journey towards a Model Based Enterprise
The Roadmap
Rules definition for Model Based Definition (MBD)
Material Data Base
Technical Data Package (TDP)
Routing integration in PLM Bill of Process (BoP)
Simulation for assembly operation
Electronic Work Instruction (including offline)
Automations (TDP, EWI, CAD, CAM, Suppliers)
Digital Twin
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 8
Our Journey towards a Model Based Enterprise
Three Pillars
MBD
EWI
TDP
Digital dossier with fully integrated
routing management.
Work Instruction with:
• Assembly & Machining simulation
• Standard Work Sheet for Setup &
Operations
• Annotated 3D model with PMI (MBD)
Electronic Work Instructions (EWI)
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 9
Our Journey towards a Model Based Enterprise
Three Pillars
MBD
EWI
TDP
Single Source of Product Definition with
Product & Manufacturing Information
(PMI):
• Geometrical Dimensioning &
Tolerancing (GD&T)
• Sub-Assembly according to process
• A fully digital communication
protocol
• Pillar for TDP approach
Model Based Definition (MBD)
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 10
Our Journey towards a Model Based Enterprise
Three Pillars
MBD
EWI
TDP
Technical Data Package as the single
object that collects all the information
needed for downstream processes
(extended Supply Chain, Services):
• Annotated 3D model
• Material properties
• Annotations & Specifications
• Fully aligned to the Bill of Material
(BoM)
Technical Data Package (TDP)
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Author 3D CADRelease
TDP in TC
Link TDP to planning
BoM
Author routing in
MES
Clone & enhance
BoP in TCM
Visualize Work
Instructions
Visualize 3D CAD
Media
Overview of applications Vs process
October 27, 2018 11
CAM
Workshop
Operator
Workshop
Operator
Design
Engineer
Manufacturing
Engineer
Manufacturing
Engineer
Design
Engineer
Design
Engineer
Materials SimulationSpecs MBD Fixture
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 12
TC interfaces and integrations
• Current TC version 11.2.1.1
• Active Workspace Client (AWC)
available at version 3.2 including
EWI3.2
• TC PLM is interfaced mostly with
outbound integrations with Enterprise
Resource Planning (ERP)
• Interfaces are normally scheduled
using WebMethods solution
TC interface and integrations
PLMTC 11.2
Rule
stream
CADENAS
NX CAD
GRANTA MI
EDM
(web)Other CAD
systems
MES
P6 Planning
Oracle
report
ERP
Oracle eBS
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
October 27, 2018 13
TC interfaces and integrations
MES-to-TC sequence diagram
• Manufacturing Execution System (MES) is
fed by ERP with BoM
• Manufacturing Engineer creates routings,
starting from templates
• MES-to-TC interface extracts routing
changes
• Routing changes are moved to interface
table
• TC custom SW read interface tables and
creates/updates MBE collaboration
context structure
MES-to-TC MFG Process Planner
Trigger on
tables load
data
Records
moved
every 1hrRuns .exe to
import TC
structure
Updates records
w/ feedback
Updates records
w/ feedback
Manufacturing
Engineer
modifies data
MES
Volume: About 100 routings per days, about
1000 operations per day
Source
systemMiddleware
Target
system
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Manufacturing Process planner in TC
October 27, 2018 14
October 27, 2018
Routing composition in TC
- Part (finished product “MEtarget”)
- General consumed documents/ parts (technical
dossier)
- Multiple Operations… composed by
- Part program (if needed)
- Resources (Fixtures)
- Consumed (Specific Parts / Documents)
- Work Area (Location in workshop)
Data is imported
under a specific
routing (in this
case “279043”)
Data from MES
are assembled in
TCM using typical
MPP data
structure
Routing heeder content
Information created in
MFG process planner
available in TC (including
models and documents)
MPP information
can be easily
accessed via EWI
and EWI off-line
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Electronic Work Instructions(demo)
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Model Based Definition (demo)
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Lessons Learned &Next Steps
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Lessons Learned
October 27, 2018 18
Manufacturing operations relying on TC availability... introducing a risk to be mitigated
Account / policy management for workshop operators... adding complexity to daily operations
EWI off-line solution developed on our requirements… it is a resource demanding solution
Dependencies with Google Chrome version... Tight monitoring of EWI package generation module is required
3D CAD Quality impacting reliability of NX-to-JT conversion... Additional rigor is required in product definition
© 2018 Baker Hughes, a GE company, LLC - All rights reserved.
Next Steps
October 27, 2018 19
Improve EWI off-line
Enhance JT creation process
Extend Process to multiple sites
Upgrade to NX12 to de-customize solution
www.plm-europe.orgwww.siemens.com/plm
October 2018
© 2018 Baker Hughes, a GE company, LLC - All rights reserved. Nicola Campo; Massimo Matteini Baker Hughes, a GE company