Rapid Product Innovation: Improving Processes for Production System Design Implementation and Operations Rapid Product Innovation: Improving Processes for Production System Design Implementation and Operations Design, Implementation, and Operations Design, Implementation, and Operations Digital Manufacturing and Collaborative Digital Automation Collaborative Digital Automation February 8, 2010 Greg Gorbach Vice President ARC Advisory Group [email protected]
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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
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
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
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)
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
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
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.
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