Manufacturing: new trends in production systems design and operation. Globalization (production, suppliers, r&d,.) new leaner technologies Product / process competitiveness Outsourcing (logistics, engineering, production) Customer satisfaction and retention concerns.
Manufacturing: new trends in production systems design and operation. Globalization (production, suppliers, r&d,.) new leaner technologies Product / process competitiveness Outsourcing (logistics, engineering, production) Customer satisfaction and retention concerns.
Manufacturing: new trends in production systems design and operation. Globalization (production, suppliers, r&d,.) new leaner technologies Product / process competitiveness Outsourcing (logistics, engineering, production) Customer satisfaction and retention concerns.
Manufacturing: new trends in production systems design and operation. Globalization (production, suppliers, r&d,.) new leaner technologies Product / process competitiveness Outsourcing (logistics, engineering, production) Customer satisfaction and retention concerns.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online from Scribd
Download as pdf or txt
You are on page 1/ 22
Manufacturing: new trends in production systems design and operation
Industrial key trends and main drivers The actual design and manufacturing environment Currents RTD efforts Future trends in Digital Manufacturing
Zurich, November 2007
Key Industrial Market Trends
Globalization (production, suppliers, R&D, ) New leaner technologies Product / Process competitiveness Outsourcing (logistics, engineering, production, ) Customer satisfaction and retention concerns
Zurich, November 2007
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
Zurich, November 2007
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
Zurich, November 2007
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
Zurich, November 2007
Why Digital Manufacturing?
Zurich, November 2007
Digital Manufacturing solutions: a seamless end-to-end workflow
PROCESS ANALYSIS: Process macro-cycle is a preliminary hypothesis on needed plant room, time cycle, panels to be loaded
Stocastic spotwelds analysis (Optimisation/RD)
Zurich, November 2007
10
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
Zurich, November 2007
12
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
Zurich, November 2007
13
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
Zurich, November 2007
14
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.
Zurich, November 2007
15
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)
Zurich, November 2007
16
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
Zurich, November 2007
17
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
Zurich, November 2007
18
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
Zurich, November 2007
and Support of Knowledge-based Factory and Services
19
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
Zurich, November 2007
20
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
Zurich, November 2007
21
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
