Introduction

IPC Digital Manufacturing Platform

For Industry 4.0

Edward Acheson, IPC-2581 Consortium Chair, Sr. Principle Product Engineer at Cadence Design Systems, Inc.

Major Contributors: Michael Ford, Aegis Software, Hemant Shah Cadence Design Systems

1. What is Industry 4.0?

2. IPC CFX IIoT Communication

3. The IPC-1782 Digital Build Record

4. The IPC-2581 Digital Product Model

5. IPC Industry 4.0 Digital Manufacturing

DesignSolution

EngineeringSolution

MESSolution

TraceabilitySolution

DFMSolution

Legacy Design Through Manufacturing

The Legacy Manufacturing Engine• Inconsistent data without provenance or value• Needless delays, costs and lost opportunity• Mistakes affecting quality & reliability• Impossible to support Industry 4.0

DigitalDesign

Solution

DigitalEngineering

Solution

DigitalMES

Solution

DigitalTraceability

Solution

DigitalDFM

Solution

IPC Digital Manufacturing Engine

Digital Engine Components:• IPC standards form digital best practices• Design - Manufacturing - Design• Enables inter-operable solutions• Comprehensive, sustainable Industry 4.0

People making decisions, take time:• Discovery / discussion / uncertainty• Delays impact business flexibility

Decisions Will Be Enhanced By Digitalization:• Visibility of every aspect of the operation• Decision support including value and consequence

Decisions Will Be Made By Digitalization:• Increasing use of “AI” to make decision• Simple at first, will grow in complexity

Industry 4.0: Automation of Automation

Is your data good enough to trust?

Business Case:• Manufacture close to the market• Minimize distribution chain costs (logistics, depreciation)• Protection against taxes and tariffs

Business Challenges:• How to “Build to Order” with “Mass Production

Efficiency”?• How to make many disparate systems work together?• What to do with humans in the digital factory?

Industry 4.0 Is About Business

What Is Connected Factory Exchange (CFX)?

Triggered By 30 Years of Frustration:• Difficulties to acquire live accurate manufacturing data• The need for actionable data for Industry 4.0

The IPC CFX Standard: • Hundreds of vendors & solution providers working together• Genuine IIoT “plug & play” standard for Industry 4.0• Eliminate waste & enable digital value creation• Available free to companies of all sizes in all sectors• Working with IPC-2581 digital product & process modelling

CFX Components For True Plug And Play

Communication Protocol

Defined Language Content

Data is Encodedusing• Secure (like ATM)

• Encrypted option• Send and forget (host)• Point to point (direct)

• Structured topics and messages across all manufacturing elements

• “Build” a model for any type of automation

CFX Content Blocks

Driving CFX Adoption

Publication expected September / October 2018

• Open-source SDK available free of charge from IPC• No fees, licenses, bespoke hardware or middleware• Almost 50 native machines trials already implemented• “Drop-in” SDK supports bespoke machines & systems• Very old unsupported machines require conversion

Traceability Business Case:• Reduce cost of manufacturing issues• Reduce scope of re-work• Supports “do it right the first time”• Find unique reasons behind defects• Immediate shipping confidence• Anti-counterfeit tool• The use of CFX makes traceability “free” to manufacturing

Insurance•

Assurance QualityDigital Product Model Values

Digital Build Record: IPC-1782 Traceability

Digital Components of Traceability:

• Product model (design)• Process model (configuration/programs)• Materials and tools etc. used & source information• Process flow events & faults, operator actions• Test and inspection measurements• Potential to benchmark performance of design features

Contents Of IPC-1782

IPC-2581: Intelligent Design DataDigital Best Practice Design To Manufacturing

IPC-2581 Digital Product Model:• The complete digital PCB product model• As simple as a single file• Design and local BOM data & variants• Ready for direct process engineering tasks

Legacy “Design Through Manufacturing” Flow

Experience:• Hands-on• Inconsistent• Incomplete• Erroneous• Many emails!

Consequences:• A lot of work• Excessive lead-time• Inevitable mistakes

Experience:• Single click• Reliable• Dependable• Accurate

Consequence:• Almost zero work• Very short lead-time• No mistakes

Digital Best Practice Design Through Manufacturing

Digital Design (since 1980s):• So, why not Digital Engineering?

Traditional Model:• Digital-ish, manual, days• Time for one configuration

IPC-2581 Digital Flow:• Digital end to end flow, minutes• Single digital product model, re-used• Time for many configuration options• Critical to Industry 4.0

IPC-2581 Digital Flow Velocity

DigitalEngineering

DigitalDesign

Happening TODAY With IPC-CFXEnabling Industry 4.0

IntelligentHand-off

Adoption of IPC-2581 Is Becoming Dominant

Case Study:• 2018 target over 60% jobs• Typical example from:

Conclusion:• Digital engineering support for

Industry 4.0 is ready to go!% Of Manufacturing Jobs Using IPC-2581

IPC-2581 Consortium: 98 Corporate Members

OEMs:Cisco, EMC, Ericsson, MSFT, FLIR, Fujitsu Network Communication, Huawei, Harris, LMCO, QCOM, Qlogic, NVIDIA, Orbital, ZTE

ECAD:Altium, Cadence, Zuken, SiSoft, Mentor Graphics, Ansoft, Intercept …

DFM/CAM Software Companies:Frontline, AEGIS, Downstream, ADIVA, Wise, Numerical, Polywog, Quadcept, Vayo….

MCAD/PLM Companies:PTC, ARAS, Siemens

EMS/FAB Companies:Axiom, Sanmina, TTM Technologies, Multek, Sierra Circuits, …

Support Matrix: As Posted On IPC-2581.com

Support Enhanced DFX:• “Closing the loop” with data accumulation• Augment IPC-2581 with engineering, quality, materials, production attributes• IPC-2581 enhanced by CFX and IPC-1782

IPC-2581 Digital DFX Manufacturing

QualityFlows Quality & Yield

AnalysisQuality & Yield

Analysis

EngineeringAnalysis

EngineeringAnalysis

FeatureAttributes

ProcessAttributes

From Design

ManufacturingFlows

Back To Design

EngineeringFlows

MaterialAttributes

AugmentAugment

Enterprise Business SystemsERP / MRP / PLM

EnterpriseAttributes

Manufacturing SystemsNPI / MES / MOM

Configurable

MechanicalAttributes

ECAD & MCAD ECAD & MCAD

IPC Digital Best Practices

Engine Components:• IPC standards: A complete digital flow• Design - Manufacturing - Design• Enables inter-operable solutions• Comprehensive, sustainable Industry 4.0

QualityBest Practice

Digital Product Model

ManufacturingBest Practice

EngineeringBest Practice

Digital Process Model

Digital Thread

Complete Digital Twin

Satisfaction of business goals:• Flexible factory, automation of automation• Increased Industry 4.0 accessibility• Solution inter-operability, without waste• Human opportunities within the digital factory• Clear actionable data, from design to design

The Future of Digital Manufacturing

IPC Digital Manufacturing Platform

Q&A:• How does your business plan to move to Industry 4.0?• How “digital” is your operation?• What business goals do you need to achieve?• How can IPC digital standards help you?

http://www.ipc-cfx.org/

http://www.ipc2581.com/