Manufacturing: new trends in production systems design and operation

Fulvio RUSINA (Comau), Yves COZE (Dassault Systemes)

Zurich, November 2007

Table of Contents

Industrial key trends and main drivers The actual design and manufacturing environment Currents RTD efforts Future trends in Digital Manufacturing

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Key Industrial Market Trends

Globalization (production, suppliers, R&D, ) New leaner technologies Product / Process competitiveness Outsourcing (logistics, engineering, production, ) Customer satisfaction and retention concerns

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Requirements for the Body Shop of Tomorrow

100% flexibility Minimum duration 2 generation of vehicles Optimized cost for investment Zero loss launch Optimized cost per piece Production rate scalability Product improvement

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Design and Production Network

Excellence Centers Network

BW BW A A - To o Too lin lingg

y bl ly m b e m ss se - AAs T T PWW P

COMAU NETWORKED PROCESS

Program Management Simultaneous Engineering & Quality Management Make or Buy Policies & Strategies

BWA - - Transport BWA Transport

t duc rooduct P Std Pr B Std s RO B RO on ns i at io ic cat l i pp pl A p A B O B R O R

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ng g di n el l d i e - WW A A BWW B

g inin g chhinin a - M ac WTT - M P W P

Maintenance Svcs Maintenance Svcs

Workload balance
E ENNG G - Pro Pro duc duc t t

E ENNG G - PPr r o oc ce es ss s

Sub-Suppliers Management Innovation and Standardization Management

Manufacturing Systems - Evolution Drivers

DRIVERS

Factory Cost

Flexibility

Optimized Shop Floor Mgmt

Maintainability

Environment & Safety

Standard & lean

Flexible/Agile Systems

Low cost solutions Modular and re-usable (agile)

Plug & Play modules

Reprogrammable Convertible solutions

More robotized systems (< infrastructure)

Integration of shopfloor automation at plant level

Higher reliability R&M approach Local sensors for process monitoring

Design for safety and ergonomics Innovative process (new joining technologies, MQL machining, )
Dismantling

Production System Supplier impact

Intuitive HMI & field data collection and analysis Virtual engineering & Digital Manufacturing (modeling & simulation)

Remote diagnostics Tele-service (WEB network)

Wireless applications in manufacturing

New process (e.g. remote laser welding

Intelligent and rational use of automation vs. operators

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Why Digital Manufacturing?

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Digital Manufacturing solutions: a seamless end-to-end workflow

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Body Quality Program

S.O.P.

PRODUCT ENGINEERING
SIMULTANEOUS ENGINEERING PHASE

PROCESS ENGINEERING & BODY GEOMETRY SET UP

BODY QUALITY PROGRAM

BODY SHOP DIES

BODY QUALITY & PRODUCTION TARGETS

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Product / Process Analysis

PRODUCT ANALYSIS: Static Fatigue Vibration and noise Crashworthiness Bio-mechanics Optimisations/robust design Multibody
Static (Torsional Stiffness)

PROCESS ANALYSIS: Process macro-cycle is a preliminary hypothesis on needed plant room, time cycle, panels to be loaded

Stocastic spotwelds analysis (Optimisation/RD)

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The standardization process

COMAU Standardization Process

Knowledge Integration Tools Business Processes
Technical Job Management

Digital Manufacturing

Business Process Procedures (Quality)

Design Book Design Book as Easy Catalog

Material Management (PBS, WBS, )

WEB sites

Proposal Engineer Zurich, November 2007

Design Engineer 11

EU Platforms: ManuFuture

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RI-MACS R&D Program*

RI-MACS is the acronym for Radically Innovative Mechatronics and Advanced Control Systems. The main objectives of the RI-MACS R&D program are the definition of a radically innovative manufacturing control open architecture based on state-of-the-art ICT technologies (in particular wireless technology) and modular mechatronics. All the technology being investigated will conform to open architecture standards. Interfaces must allow for easy integration with the other process units. Other factors considered include increasing factory safety and reducing the environmental impact.
*) EU Contract Number NMP2-CT-2005-016938

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System Integration & Control Architecture Evolution

Current
Plant Server

Future
Eth

Web based services

Line PC Eth Cell PLC

Plant Server Eth

Field Bus

Line/Cell PC Sensors/Actuators

Sensors/Actuators

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RI-MACS - Main Project Objectives

Make open approaches and the multi-agent paradigm more robust and demonstrate their feasibility (web services/agent-based mechatronics control technology with embedded intelligence); Exploit wireless technology in networking and in novel architectures; Develop flows to support the design and operation of the manufacturing plant of the future with particular attention to the simulation of service oriented services (SoA) and automatic code generation for control; Develop industrial strength test beds.

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Embedded Controls and Wireless Manufacturing

Productionbased services

WLAN

busines s models new control paradigm collaborative communication models

production planning layer (software)

Communication -based services

bluetooth

WLAN

collaborative control layer

control room Communication -based services

abstract communication layer

(middleware)

Multihop ZigBee Location -based services

ut in p

Multihop

WiFi Bluetoot h

WLAN

power

UMTS

logistics processes maintenance

device models
ou ut tp

manufacturing

embedded wireless physical layer (hardware)

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RI-MACS Digital Manufacturing Environment

Cinematics Geometry
Logical I/Os

Internal Logic
Comunication

Control Logic

PLC program

Pure Electropneumatic logicdevices devices

Devices with complex cinematics

Virtual cell

All the objects could be stored in libraries

Objects libraries

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RI-MACS Digital Manufacturing Environment

Integrate Control Engineering Flow

INPUT
- Mechanical description

OUTPUT
- 3D Mechanism - Internal Logic (IL) - Control Logic (CL)

3D Model creation

- Normal cycle diagram

Control Logic creation

High level simulation

Mechanical modification

Normal Machine Cycle VALIDATED

- Special cycle diagram - I/O Mapping - Diagnostic alarm list - HMI Specification

SW Automatic generation

- Target PLC SW

SW Completation

- PLC SW completed

- OPC Connection

Low level simulation

INSIDE Delmia AUTOMATION

SW PLC VALIDATED

OUTSIDE Delmia AUTOMATION

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Digital Manufacturing: knowledge-based engineering roadmap

Towards the Digital Manufacturing
Integrated Project and Knowledge Management Multi-scale Simulation

l ita Dig

ct du Pro

ng eri e gin En

Integrated/Networked Engineering Environment

Models of Manufacturing
ng eri e gin En

Life Cycle Data Management Config. Management 3D CAD Integration Engineering Tools Digital Prototyping

Standards
ng uri t fac nu Ma l

Ergonomics and Process Standards

ta igi D

Adaptation to Reality Integration (MES) and Smart (wireless) Factory

Factory Data Management Digital Factory Rapid Prototyping Digital Prototyping

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and Support of Knowledge-based Factory and Services

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Digital Manufacturing: IT Environment requirements

Creates a COLLABORATIVE standards-based manufacturing environment Provide VISIBILITY throughout the organization and with suppliers, partners and customers Enables FLEXIBILITY to manage operations remotely and react quickly Ensure SECURITY for all business communications Lower TOTAL COST OF OWNERSHIP

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Digital Manufacturing: Openness/Friendliness requirements

OPEN design, simulation and validation framework INTEROPERABLE with market leader Digital Manufacturing software products INTEGRATED Digital Manufacturing environment based on common data models Easy CUSTOMIZATION to include specific customers needs and solutions Simple reference METHODS and friendly and easy to use SOFTWARE TOOLS to support all stage of the design and development Elementary EDUCATION AND TRAINING ENVIRONMENTS to test and practice new Digital Manufacturing solutions

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Digital Manufacturing: Real vs. Virtual requirements

ADHERENCE between the real and the virtual environments EASY DATA AND INFORMATION TRANSFER between the real and the virtual worlds and vice versa Effectiveness in MANAGING DIVERSIFIED SOURCE OF INFORMATION: economics, product, process, mechanical, control, piping and wiring, hydraulic, pneumatic, etc. Capability of MANAGEMENT CUSTOMERS NEEDS from process planning, to production operation, to system maintenance and re-tooling

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