presentation date: 2018 10 30 presenter name: …...© 2018 baker hughes, a ge company, llc - all...

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


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


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


October 27, 2018 5


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


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


October 27, 2018 8


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)


October 27, 2018 9


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)


October 27, 2018 10


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)


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


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


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


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


Electronic Work Instructions(demo)


Model Based Definition (demo)


Lessons Learned &Next Steps


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


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

http://www.plm-europe.org/

http://www.siemens.com/plm