rapid product innovation
TRANSCRIPT
Rapid Product Innovation: Improving Processes for Production System
Design Implementation and Operations
Rapid Product Innovation: Improving Processes for Production System
Design Implementation and OperationsDesign, Implementation, and Operations Design, Implementation, and Operations
Digital Manufacturing andCollaborative Digital AutomationCollaborative Digital Automation
February 8, 2010
Greg GorbachVice President
ARC Advisory [email protected]
Today’s Business EnvironmentMakes Innovation and Responsiveness A NecessityToday’s Business EnvironmentMakes Innovation and Responsiveness A Necessity
A Turbulent Marketplace:Global Competition
Impact on Production:• Re-tool for new productsGlobal Competition
Customers have many alternativesPrice pressureMore products and variations needed
p• Rapid Introduction of New
Production Processes• More Automation• More Plant Software• Re tool to Reduce Energy &More product info: Traceability,
Pedigree, Carbon footprint, etc.Consistently high quality is criticalFast turnaround
• Re-tool to Reduce Energy & Emissions
• Re-Tool for Green Packaging• Re-tool for more flexibility
Complex delivery terms and scheduleGreen
Increasing CostsEnergyEnergyNatural resources
Regulatory PressureGrowing Climate Change Pressure
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Other Environmental/Safety
Today’s Product/Process Innovation BottleneckToday’s Product/Process Innovation Bottleneck
Product Lifecycle
For certain manufacturing segments (especially discrete and portions
DESIGN BUILD OPERATE
Physical Production System
For certain manufacturing segments (especially discrete and portions of hybrid), introducing new products or improving the manufacturing process usually requires creating or modifying production systemsMany production system problems are not discovered until late in the d i /i l t ti hi h i t d d l d tdesign/implementation process, which introduces delays and costOnce in operation, virtual reference models, if available, could aid in performance monitoring, process optimization, problem diagnosis, operator training, and continuous improvement
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Limitations in Today’s Digital Manufacturing and Automation Tools Limitations in Today’s Digital Manufacturing and Automation Tools
Physics-Based Component
Models
Product Mechanical
Design
Component 3D Solid Models
Design Modeling/Simulation
Typically, many different design and modeling environments are
ModelsDesign Models
Physics-Based Equipment
Models
Mfg Systems Process Design
Queuing/Network Models
Mfg Systems Mechanical
Design
Equipment3D Solid Models
gused. They often don’t integrate well. Limited tools have been available for designing and
Chemical Process Model
Product Electrical Design
Product Electrical
Simulation
Design Models
Energy & Emissions
Model
available for designing and simulating the implementation of control systems and devices, and the behaviors of the control systems as they interact with
Mfg Systems Electrical Design
EquipmentElectrical Models
es g S u at o
Inspection & Test Systems
Design
Inspection & Test Systems
Models
systems as they interact with the electromechanical systemsControl Engineers need to be able to collaborate and interact with other manufacturing
Mfg Systems Controls,
Logic Design
Controls & Logic
Models
Mfg Systems Software Design
HMI & MES Software Models
I/O Emulation
with other manufacturing engineers and their models and systems
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Models/Simulations Can ImproveDesign, Build, and Operate Phases
Digital ManufacturingDigital Manufacturing
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Developing Production Systems Requires Parallel Engineering ActivitiesDeveloping Production Systems Requires Parallel Engineering Activities
PRODUCTION PROCESSES• Equipment Layout• Queuing/Throughput
Industrial Engineering • Queuing/Throughput
Models• Human Factors Models• etc.
El t i lMechanical
Engineering
GEOMETRY AUTOMATION SYSTEMSProduction
System
Electrical & Controls
Mechanical Design
• Mfg Equipment Design• Mfg Equipment 3D Model(s)
• Electrical & Wiring Design• Electrical & Wiring Models• Controllers & Control Devices• Controller & Control Device
Models• Control Code
t
y
Virtual, Science- • etc. BEHAVIORS• Core Manufacturing Process
Models• Equipment Modeling• Kinematics• Simulated Work Environments
Virtual, ScienceBased Modeling &
Simulation
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Simulated Work Environments• etc.
Digital Manufacturing: Modeling and Simulating Geometry, Processes, Behavior, and AutomationDigital Manufacturing: Modeling and Simulating Geometry, Processes, Behavior, and Automation
Digital Manufacturing & ProductionPRODUCTION PROCESSES• Equipment Layout• Queuing/Throughput
Models• Human Factors Models• etc.
Industrial Engineering
Mechanical Design
Electrical & Controls
Digital
Digital PROCESS Models
Collaborative
GEOMETRY• Mfg Equipment Design• Mfg Equipment 3D Model(s)
AUTOMATION SYSTEMS• Electrical & Wiring Design• Electrical & Wiring Models• Controllers & Control Devices
C ll & C l i
Production System
GEOMETRY (3D)
Digital BEHAVIOR
Models
Digital Automation
• Controller & Control Device Models
• Control Code• etc.
BEHAVIORS• Core Manufacturing Process
Models
Virtual, Science-Based Modeling &
Simulation
Models
Management & Integration• Project Management• Data Management• Portfolio Management• Connectivity
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Models• Equipment Modeling• Kinematics• Simulated Work Environments• etc.
• etc.
Digital Manufacturing: Model-Based Development of Production SystemsDigital Manufacturing: Model-Based Development of Production Systems
Product Lifecycle
DESIGN BUILD OPERATEPhysical Production System
Concept & Design Validation and
Validation and Problem-SolvingValidation and
OptimizationProblem-Solving through Start-up
System Design Models & Simulation Production System
DigitalMfg
RobotConveyor
CAD, etc
RobotConveyor
Simulation Environment
RobotConveyor
Mfg
USE & REFINEVirtual Models
DEVELOP & USEVirtual Models
Environment
Physical Production Cell
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Typical DM Scope
Manufacturers Need Better Tools for Digital Manufacturing and CDAManufacturers Need Better Tools for Digital Manufacturing and CDA
Production Systems
• Assembly LinesC• Conveyors
• Work Cells• Safety Systems• Packaging Lines• Batch Vessels• Power Plants
Collaborative Digital
Automation• etc.• All with Mechatronics:
• Electrical Systems & Wiring• Controllers, Sensors &
Control Devices• Plant Software, etc.
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Collaborative Digital Manufacturing (CDA)Collaborative Digital Manufacturing (CDA)
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What is Collaborative Digital Automation?What is Collaborative Digital Automation?
The application of digital tools, simulation, and virtualization to the process of developing,
CDAp p g,
implementing, and operating production systemsEspecially involving the interaction of control devices and systems with the electromechanical components a d sys e s e e ec o ec a ca co po e sthat constitute the production system
Design Virtual Simulation Physical System
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Design Virtual Simulation Physical System
Collaborative Digital Automation (CDA) in the Design – Build Phases Collaborative Digital Automation (CDA) in the Design – Build Phases
DESIGN
Software Design
IMPLEMENT
Software System
Manufacturing Process, System, & Components
Build, Test, & Deploy Physical System
VALIDATE
Software System
Process, Interference, Kinematics, Controls, etc.
n
Execution
Visibility
Controls Interface
Control Logic
MESEMI
Execution
Visibility
HMIControls Interface
ControllerControl Logic
MESEMI
Execution
Visibility
HMIControls Interface
Virtual ControllerControl Logicig
n
cal In
stal
lation
CDA
I/O BlockSensor Drive
Electrical Design
I/O BlockSensor Drive
Electrical System
I/O BlockSensor Drive
Electrical ModelO
ptim
ize
Des
i
alid
ate
Phys
icCDA
Safety MCCHOA
Mechanical Design
Safety MCCHOA
Mechanical System
Safety MCCHOA
Mechanical &Environmental Model
Val
idat
e &
O
mis
sionin
g:
Va
RobotConveyor RobotConveyor
CAD,
RobotConveyor
Environmental Model
Simulation Virtu
al C
om
m
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Production Cell Design Physical Production Cell
CAD, etc
Virtual Production Cell
Simulation Environment
V
Collaborative Digital Automation (CDA)is an immature but rapidly developing spaceCollaborative Digital Automation (CDA)is an immature but rapidly developing space
Collaborative Digital
A i
Processes
Geometry
Software & Human Interfaces
Live Production Systems
Collaborative Digital
A t ti
Electrical & Wiring Model Execution Logic
Automation
Virtual Simulation
SystemsAutomation
Other Systems
Electrical & Wiring ModelControl Devices ModelsI/O EmulationControl System Design
Execution LogicMES/CPM ConfigurationVirtual CommissioningConnectivity to:Control System Design
Control LogicController CodeC ll l i
Connectivity to:• Process Models• Geometry Models• Simulations
Controller EmulationHMI Configuration
• Mgmt & Integration
etc.
Standards Libraries Tools
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Standards, Libraries, Tools, Interoperability, etc. Are Needed
Virtual Production SystemsVirtual Production Systems
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Virtual Production SystemExtend Digital Mfg to OperationsVirtual Production SystemExtend Digital Mfg to Operations
Physical Production
Virtual Production
Design System
Production System
Execution & Visibility S/W
Interface
Systems
Interface
• Performance Deviations• Optimization• Diagnose Problems• Operator Training• Maintenance Activity Modeling• etc
• Process Improvements• Problem Resolution• Alternate Designs• etc
MetrologyQualityInspectionSignoffs
Product Data
FaultsThroughputShift DataCAPA
Process Data
MetrologyQualityInspectionSignoffs
Product Data
FaultsThroughputShift DataCAPA
Process Data
SignoffsEtc.
CAPAEtc.
MaintenanceCycle CountEtc.
Asset Data
Supplier QualityInventory LevelsRejectionsNCR
Material Data
SignoffsEtc.
CAPAEtc.
MaintenanceCycle CountEtc.
Asset Data
Supplier QualityInventory LevelsRejectionsNCR
Material Data
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NCREtc.
Actual Manufacturing Results & As-Built
NCREtc.
Virtual Results (As-Designed & Simulated)
DM, CDA, and VPSModel-Based Development & Operation of Production SystemsDM, CDA, and VPSModel-Based Development & Operation of Production Systems
Product Lifecycle
Production System Simulation Enables
DESIGN BUILD OPERATEPhysical Production System
Concept & Design Validation and
Validation and Problem-Solving
Continuous Improvement
Virtual Production
Validation and Optimization
Problem-Solving through Start-up
USE & EXTEND
Production System
DigitalManufacturing(DM)
USE & REFINEDEVELOP & USE USE & EXTENDVirtual Models
• Steady State DesignD i Si l ti
• Virtual CommissioningDi P bl
• Performance DeviationsO ti i ti
Virtual ModelsVirtual Models
Collaborative DigitalAutomation (CDA)
Digital Manufacturing and CDA
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• Dynamic Simulation• Design Optimization• etc
• Diagnose Problems• Process/System Validation• Operator Training• etc
• Optimization• Diagnose Problems• Operator Training• Maintenance Activity Modeling• etc
Issues Faced by UsersIssues Faced by Users
There are lots of different pieces involved, it’s hard to know how to proceedpHow do I get to the point where I can re-use things -such as models and control code – for equipment that I use frequently?use eque yWhat will we encounter when we start down this road? What don’t we know?Integration and InteroperabilityIntegration and InteroperabilityWhat are the costs? What are the benefits?Etc.
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Issues Faced by SuppliersIssues Faced by Suppliers
How to persuade manufacturers to try CDA apps• Seems complicated risky and costly• Seems complicated, risky, and costly• Who drives buying decision?
How do I justify creating device models and solution t ?components?
• Is the market ready? • Can I afford NOT to participate at this stage - will that
effectively cede the market to others and negatively impact my automation business?
Etc.
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Summary: Key PointsSummary: Key Points
Digital Manufacturing is becoming more important in creating competitive advantageg p gARC advocates extending Digital Manufacturing to the Operating phase (Virtual Production System)Collaborative Digital Automation (CDA) unlocks theCollaborative Digital Automation (CDA) unlocks the true potential of Digital Manufacturing
Digital Manufacturing & Production
Digital PROCESS Models
& Production Digital GEOMETRY
(3D)
Digital BEHAVIOR
Collaborative Digital
Automation
CDA
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BEHAVIORModels
Digital Manufacturing With CDA Helps Create Competitive AdvantageDigital Manufacturing With CDA Helps Create Competitive Advantage
Enterprise
Products
Enterprise
ProductsEquipmentProcesses
Engineering Operations
Digital
Digital Mfg
Automation
Collaborative Solutions for Digital
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Collaborative Solutions for Digital Automation are Beginning to Emerge
Thank YouThank You
For more information, contact the author at [email protected] or visit our web pages at
www arcweb com
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www.arcweb.com