Computer Network in Manufacturing System Nanang Ali Sutisna

Computer Network in Manufacturing System Nanang Ali Sutisna Master Eng. in Computer Integrated Manufacture Senior PLM Consultant, IBM Indonesia Senior Manager, Product Development Multistrada Arah Sarana 1 © ARC Advisory Group

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e-Manufacturing Systems Suppliers/ Vendor Customer Support Human Resource ISO Approval Review, Design Release • • Supplier chain • Pre/Post Sales Support • • Purchasing • • Digital Design Review View & Markup Recognition Audit • • Sales & Marketing Account / Finance Training Corporate Communication Staff Development Virtual Learning • Costing • Define incentiv e program • • • e-Manufacturing Engineering Design • CAD/CAM • CAE / FEA • Prototyping IT Research & Development • Technology • Methodology • Integrating Factory Manager/ Production Planner Manufacturing/ Assembly Shop floor BOM Quality Control • Product Assembly/ • Actual vs. schedule • Defect Analysis Disassembly Sequencing • Scheduling • Quality Control • Robotic/Work Cell Animation • Work-to-lists • Route cards • Digital Factory PLM Quick Response Marketing Proposal Easy to quote Presentation Product Launch Distribution • Fulfillment • Delivery 3 © ARC Advisory Group

Product Lifecycle Management Product Engineering Lifecycle Management & Decision Support Manufacturing Engineering PLM is a set of capabilities that enables an enterprise to effectively and efficiently innovate and manage its products and related services throughout the entire business lifecycle, lifecycle from conception through recycling or disposal. 4 © ARC Advisory Group

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Production System The production system is the collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company (or other organization). 6 © ARC Advisory Group

Production System Facilities: - Factory - Equipment Manufacturing Support Systems The facilities of the production system consist of the factory, the equipment in the factory, and the way the equipment is organized. Manufacturing support Systems This is the set of procedures used by the company to manage production and to solve the technical and logistics problems encountered in ordering materials, moving work through the factory and ensuring that products meet quality standards. Product design and certain business functions are included among the manufacturing support systems. 7 7 © ARC Advisory Group

Production System Facilities • The facilities in the production system are the factory, production machines and tooling, material handling equipment, inspection equipment, and the computer systems that control the manufacturing operations. 8 8 © ARC Advisory Group

Production System Facilities • Facilities also include the plant layout, which is the way the equipment is physically arranged in the factory. The equipment is usually organized into logical groupings (equipment arrangements) and the workers who operate them as the manufacturing systems in the factory. 9 9 © ARC Advisory Group

Manufacturing Systems • Manufacturing systems can be individual work cells, consisting of a single production machine and worker assigned to that machine. • We more commonly think of manufacturing systems as groups of machines and workers, for example, a production line. The manufacturing systems come in direct physical contact with the parts and/or assemblies being made. They "touch" the product. 10 10 © ARC Advisory Group

Manufacturing Types One of the most important factors that determine the type of manufacturing is the type of products that are made. • Discrete products manufacturing: including automotive, aircraft, appliances, computers, machinery, etc. • Process manufacturing: products that are in liquid or bulk form, such as chemicals, pharmaceuticals, petroleum, basic metals, food, beverage, electric power generation, etc 11 11 © ARC Advisory Group

Production Quantity In discrete products manufacturing, the quantity produced by a factory has a very significant influence on its facilities and the way manufacturing is organized. The annual part or product quantities produced in a given factory can be classified into three ranges: 1. Low production: Quantities in the range of 1 to 100 units per year 2. Medium production: Quantities in the range of 100 to 10, 000 units per year 3. High production: Production quantities are 10, 000 to millions of units per year 12 12 © ARC Advisory Group

Product variety Product Variety vs Production Quantity Low Prod. Medium High Prod. 100 10, 000 1, 000 Production quantity 13 13 © ARC Advisory Group

Facility and Layout Product variety Fixed Position Layout Process Layout Cellular Layout Job Shop Batch Production Product Layout Cellular Manufacturing Quantity Flow Line Production __________ 100 10, 000 Mass Production 1, 000 Production quantity 14 14 © ARC Advisory Group

Manufacturing Support System t Business Function - sales and marketing, order entry, cost accounting, customer billing t Product Design - research and development, design engineering, prototype shop t Manufacturing Planning - process planning, production planning, MRP, capacity planning t Manufacturing Control shop floor control, inventory control, quality control 15 15 © ARC Advisory Group

Digital Manufacturing 16 © ARC Advisory Group

Today’s Business Requirements Drive Change & Determine Real-time Enterprise Needs t Globalization t Rapid Product Innovation t Process Innovation t Collaboration t Synchronization t Lean t Continuous Improvement t Compliance t Risk Management t Performance t Flexibility t Pull-based Production t Etc. 17 © ARC Advisory Group

Evolution of the Design/Build Process Knowledge Capture Technological Advance Design & Validation of Manufacturing Processes Digital Mockup Digital Manufacturing 3 D 2 D Integration of Product Design and Production Process Design 80 s 90 s 2000 2006…. . 18 © ARC Advisory Group

What is Digital Manufacturing? “Digital Manufacturing represents an integrated suite of PLM tools that supports manufacturing process design, tool design, plant layout, and visualization through powerful virtual simulation tools that allow the manufacturing engineer to validate and optimize the manufacturing processes. “ 19 © ARC Advisory Group

Where Does Digital Manufacturing Fit? Product Lifecycle: Design/Build/Automate/Maintain Product Domain Org R&D Design Engr Processes Materials & Product Research Product Design CAD/CAE (Digital Def. ) Function (Systems) Specs, E-BOM, M-BOM Production Domain Mfg Engr Process Planning Industrial Engr Work Flow, Mfg Processes Controls/Tool Engr Factory Operations/ Production Systems Design, Produce Tools, Jigs, Fixtures, & Automated Systems Obtain, Operate, Control, & Maintain Equipment & Automated Systems to Manufacture Products Digital Mfg/Production Process Design, Virtual Factory Simulation CAM/NC Automated Assembly Operations Mgmt Scheduling Resource Mgmt Mfg Intelligence Q/A Collaborative PDM Visibility PLM Solutions: Interoperability & Collaboration Supply Chain Operations Engineering 20 © ARC Advisory Group

What Does Digital Manufacturing Do? t Manufacturing Planning • Define High-Level Manufacturing Processes • Process Planning (Assembly & Installation) • Define Work Instructions & Work Flow t Detailed Process Design & Analysis • • • Detailed Resource Modeling & Simulation Process Definition and Validation 3 -D Factory Layout Equipment, Tool & Fixture Simulation Ergonomic Simulation t Validation & Virtual Commissioning • • • Control Logic Validation Kinematic (Robotic) Validation Quality Assurance/Process Improvement Validation Sensor/Metrology Placement Validation Virtual Commissioning/Validation of Automation Systems Knowing that the Production System Works Prior to Launch: Priceless. 21 © ARC Advisory Group

Digital Manufacturing Redefines Concurrent Engineering • Product Authoring (CAD) tools are employed to define “What" is to be built. • Manufacturing Process Design tools are used to define “How" it is to be built. • Integration of Product & Process Design directly supports the concept of Concurrent Engineering Digital Manufacturing facilitates the Holistic view of Product and Process Design as integral components of the overall product life cycle 22 © ARC Advisory Group

Managing the Manufacturing Process PLM/Digital Manufacturing are Process-Centric t Integration of Product Design with Mfg Processes allows Production Management & Execution Applications to be Integrated with the PLM Solution Set t Manufacturing Process Design coupled with Digital Mfg Simulation Integrates the Definitions of the Product, Processes, Factory, and Resources into a Comprehensive and Consistent Manufacturing Solution t Manufacturing Process Mgmt (MPM), as a Component of the PLM Solution Set Generates traditional Operations Management Functions such as Process Planning, Work Instructions, and Operations & Quality Assurance Records Scheduling, Workflow, Resource Mgmt, WIP, and Visibility 23 © ARC Advisory Group

Global Manufacturing Operations Enterprise Infrastructure Operations Infrastructure Design/Engineering Infrastructure = Manufacturing Node = Design Node 24 © ARC Advisory Group

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Operations Management Definition: Operations Management is the management of the people, business processes, technology and capital assets involved in: • Procuring and receiving raw materials and components - Especially as it relates to obtaining, storing, and moving necessary materials/components in a timely manner and of suitable quality to support efficient production • Implementing product designs, specifications, formulations, or recipes by manufacturing products - Including manufacturing process planning and validation • Distributing these products to customers - Especially as it relates to sequencing and in-house logistics • And for some products, supporting them through their Endof-Life Let Business Requirements Drive Technology Solutions 26 © ARC Advisory Group

Today’s Dynamic, Demanding Environment Places a Premium on Information and Synchronization Industry Classic MES New Requirements Semiconductor Complex Routing, Resource Allocation, Quality, WIP Tracking, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, KPIs, Performance, Change Mgmt, Security, Electronic Manufacturing History etc. Pharmaceutical Compliance, Quality (Direct and Enforce Production), Electronic Batch Records, Electronic Signature, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History etc Continuous Process Collection of Apps: Optimization, Historian, Advanced Process Control, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etc A&D (Complex Discrete) CAPP, Quality, Resource Allocation (Operators, Workstations, Tooling, etc. ) WIP Tracking, Traceability, Work Instructions, NCR Resolution, etc. Visibility, Analytics/Decision Support, Outsourced Manufacturing, Supplier Quality Mgmt, Change Management, Security, Electronic Manufacturing History, etc Automotive Supplier Quality, Resource Allocation (Operators, Workstations, Tooling, etc. ) Work Instructions, Just-in Sequence Manufacturing/ Packing/ Shipping, Error-proof Packout and Labeling, etc. Visibility, Analytics/Decision Support, Orchestrate Inventory Replenishment by Operation, Traceability and Recall Management, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, etc Automotive OEM Visual Alarms, Stack Lights, and Marquees, Line Control & Broadcasting, Supplier Component Sequencing, etc. Visibility, Outsourced Manufacturing, Global Manufacturing, Business System Synchronization, Performance, Change Mgmt, Security, Electronic Manufacturing History, Traceability and Genealogy, etc 27 © ARC Advisory Group

CMM Applications Map Let’s Get on the Same Page re: MES and OM Business ERP HR FIN ort pp Su CRM SCM Suppliers Customers Enterprise Infrastructure CAD es D ign CAM WMS MI Quality MES Sched EAM HMI MES Gen 1 (Standalone, Industry. Specific Application) Equipment & Automation Production (SOA) TMS Operations Infrastructure MPM Gen 4 T&A etc. Lean/CI Operations Gen 3 (Integrated Apps, Management Infrastructure, & Connectivity) MES Gen 2 (Collection of Applications) 28 © ARC Advisory Group

Production Mgmt Systems are Extension of PLM Product Lifecycle Processes Build Design Automate Maintain Manufacturing Processes Digital Manufacturing Solutions + MES Create Processes Plan Processes Engineering Design Simulate & Validate Processes Execute Processes Validate As – Built Records 29 © ARC Advisory Group

PLM Integrated with Shop Floor Execution ERP Tailored Work Package “As Designed” Process Data Process Creation • E-BOM • Process Configuration Production Mgmt • Work Instructions • Work Flow Routing • Operations Scheduling • Shop Floor Requirements • M-BOM • Data Exchange • Bill of Process • Performance Analysis • Product Config. • Quality Assurance Shop Floor Execution (MES) “As Built” Records • Labor/Parts/Tooling Product Design “As Designed” Product Data PLM Maintenance & Support 30 © ARC Advisory Group

Digital Mfg + Shop Floor Execution = Validation of As-Built to As-Designed Product Design CAD Closing the Loop From As-Built Records To As-Designed Collaborative PDM Product Data Management 3 D Models E-BOM Digital Manufacturing/MPM Process Planning Process Simulation & Validation Process Modeling Shop Floor Execution (MES) Process Models, 3 D Simulations, Work Order Instructions Process Execution E-BOM Master Routings, M-BOM Quality Assurance Unit Data & Work History Data Vault Work Order Release Material / Parts Job Sign On/Off Work Orders Inventory Release & Status Mgmt Production Scheduling Labor Reporting Work Order Status ERP Invoicing Shipping Financials Parts Purchasing Receiving 31 © ARC Advisory Group

Merging Virtual Simulation and Automation Simulation to Control: Making the Final Step from Virtual to Real Process Design Virtual Simulation Collaborative Environment for Control Design & Digital Validation Production System Real Operations Digital Validation Produces Real Control Execution 32 © ARC Advisory Group

Interoperable Virtual to Real-World Environment for Manufacturing and Control Engineering PHYSICAL VIRTUAL Control Design DESIGN Mfg Process Modeling Code Generator Target PLC or Controller Platform Developed with Automation providers VALIDATE Post-Processed Machine Logic Production Simulation Validate Control PLC/Controller HMI OPC Client/Server 33 © ARC Advisory Group

Merging Virtual Design and Automation Shortens Time to Launch 3 D Mechanical Design Control Engineering (Design) Line Building & Installation Control Engineering (Commissioning) Current workflow…. Workflow…with Virtual Automation 3 D Mechanical Design Production Startup Line Building Control Engineering Validation & Virtual Commissioning Production Startup 34 © ARC Advisory Group

Effective & Efficient Use of Digital Mfg (DM) Tools: Guidelines for Users t Integrate Use of DM Tools into the Manufacturing Design Process • Set and Implement guidelines for application of DM technology • Provide DM training for Mfg Engineering Discipline & Resources t Emphasize Re-use • Re-use dependent on a strategy common process design t Ø Common components is a key enabler Ø Establish a library of virtual production devices & equipment • A modular approach is key for efficiently building virtual models Ø Start with basic virtual devices building blocks Ø Build virtual production systems by combining virtual devices Integrate DM Tools into the Information & Control Architecture • Virtual models can be developed & maintained by multiple engineering disciplines (Manufacturing, Tooling, Controls) • Use latest Production Process data for Virtual Simulations 35 © ARC Advisory Group

Digital Manufacturing Landscape t Manufacturers are focusing on Optimization of Production Processes t Reducing Time to Product Launch and Cost of Commissioning Production Systems t Today’s PLM Suppliers now offer robust Digital Manufacturing Solutions t Large Manufacturers Are Adopting End-to-End PLM Strategies, including Digital Manufacturing • A&D: Boeing, Lockheed-Martin, Northup-Grumman • Automotive: GM, Chrysler, Ford, Toyota, Nissan, BMW, Mercedes Benz • Heavy Equipment: Caterpillar, John Deere, Cummins Companies are Transforming how they Define their Manufacturing Processes 36 © ARC Advisory Group

Key Benefits of Digital Manufacturing t Integration of Product Design and Manufacturing Processes t Reduce Cost and Development Time for Process Design t Shorten Time-to-Launch for New Product Introduction with Faster Ramp-up for Production Systems t Provide Manufacturability by Simulating Manufacturing Operations before the Start of Production t Increase Quality by Validating Production Process Design t Reduce and/or eliminate Prototypes and Physical Mockups with Virtual Simulations t Improve Collaboration with Suppliers by Providing Early Access to Design, Production Process, and Resource information t Improve Concurrent Design Methods by Linking Product Design to Manufacturing & Controls Engineering t Validate Manufacturing Processes, Production Systems, and operational resources through Virtual Commissioning prior to physical implementation 37 © ARC Advisory Group

Thank You. For more information, contact the author at dslansky@arcweb. com or visit our web pages at www. arcweb. com 38 © ARC Advisory Group