Smart Assembly Systems Objectives and Agenda Bob Tilove Technical Fellow, Manufacturing Systems Research Laboratory, General Motors R&D Visiting Scientist,

Smart Assembly Smart Assembly SystemsSystems

Objectives and AgendaObjectives and Agenda

Bob TiloveBob Tilove

Technical Fellow, Manufacturing Systems Research Technical Fellow, Manufacturing Systems Research Laboratory, General Motors R&DLaboratory, General Motors R&D

Visiting Scientist, Manufacturing Engineering Visiting Scientist, Manufacturing Engineering Laboratory, NISTLaboratory, NIST

SAFETY PROTOCOLSAFETY PROTOCOL

““Intelligence” in Agile Mfg SystemsIntelligence” in Agile Mfg Systems

Mechanical Systems, Sensors, ControlsMechanical Systems, Sensors, Controls• Adaptive, automated, autonomousAdaptive, automated, autonomous• ““Intelligent” robotics, adaptive process control, Intelligent” robotics, adaptive process control,

etc.etc.

People Systems and Decision MakingPeople Systems and Decision Making• ““Agility” in context of unanticipated change. Agility” in context of unanticipated change.

Reconfigurable.Reconfigurable.• ““Virtual” Product/Process design and validationVirtual” Product/Process design and validation• Diagnostics and prognosticsDiagnostics and prognostics• Enterprise analyticsEnterprise analytics

What is “Smart Assembly”?What is “Smart Assembly”?

Is it Real?Or is it Virtual?Or is it a Hybrid?

Virtual Factory

“Intelligent/Agile Equipment”

Eg: Cooperative Robots

“e-Enabled”Optimized Real-time Manufacturing

Eg: Predictive Maintenance

“Math-enabled”Virtual Product/Process Design and Validation

Eg. Virtual Launch

What If These Worlds Merged?What If These Worlds Merged?

Process PlanningProduct and Mfg Engineering

“Virtual Build” ReviewsLine Balancing

Human Factors/Ergo

Operation and Job Element Descriptions

Virtual TrainingOperator/team leader led workplace optimization

How could we leverage “virtual” capabilities in the plant?

“This is a very nice fly-through that you have shown me. When will I be able to use this on

the plant floor to improve my operations?”(Paraphrased from GM Plant Manager)

What If These Worlds Merged?What If These Worlds Merged?

Equipment Design

Layout Specifications

Asset Tracking

Performance“Observed State”

“I can’t re-use 3-D layouts because they are obsolete soon after the equipment is installed”

(Paraphrased from GM Layout Engineer)

How could we leverage “real time data” capabilities in engineering?

What If These Worlds Merged?What If These Worlds Merged?

Workcell Simulation

Or, maybe even…

This one is “real”

This one is “virtual”

Smart AssemblyVirtualVirtual

Virtual Mfg Eng. & Validation: Math

Tools & Processes

AgileAgile

e-Mfge-Mfg

Flexible Mfg System Infrastructure: Hardware

Tools& Processes

e-Manufacturing: Real-time Optimized

Manufacturing (“m” & “M”)

Smart Assembly SpaceSmart Assembly Space

Purpose Of WorkshopPurpose Of Workshop

To develop a (broad industry/academic) vision and to define the state of the art and needs in “Smart Assembly.”

“Smart Assembly” refers to a next generation capability in assembly systems and technologies which integrate “virtual” and “real-time” methods in order to achieve dramatic improvements in productivity, lead-time, and agility for the design, engineering, validation, construction, installation, launch and operation of assembly processes and systems.

Scope (suggested…)Scope (suggested…) In scope:

• Assembly processes and systems: putting parts/components together to make a product.

• Mfg Engineering and Mfg Operations activities: mfg process planning, design, engineering, validation, construction, installation, launch and operation of assembly processes and systems.

Out of scope (despite importance!)• Product design and modeling for assembly• “Big M” manufacturing: enterprise analytics,

supply chain, etc

Agenda – OctoberAgenda – October 3 31:001:00 Welcome: Dale Hall, Director, Manufacturing Engineering Laboratory, NIST Welcome: Dale Hall, Director, Manufacturing Engineering Laboratory, NIST

1:10 1:10 Workshop Objectives, Format and Agenda: Bob Tilove, Technical Fellow GMR&D and Workshop Objectives, Format and Agenda: Bob Tilove, Technical Fellow GMR&D and NIST Visiting Scientist)NIST Visiting Scientist)

1:30 1:30 Plenary Session Plenary Session

What are some of the problems that you are facing that “smart assembly” might help What are some of the problems that you are facing that “smart assembly” might help to address? What are some examples of future scenarios enabled by smart to address? What are some examples of future scenarios enabled by smart assembly? assembly?

1:30-2:00 1:30-2:00 Bryan Dods, Senior Manager, Advanced Manufacturing Bryan Dods, Senior Manager, Advanced Manufacturing Research & Research & Development; The Boeing CompanyDevelopment; The Boeing Company2:00-2:202:00-2:20 Thomas Babin, Fellow of Technical Staff, MotorolaThomas Babin, Fellow of Technical Staff, Motorola2:20-2:452:20-2:45 Roland Menassa, Laboratory Group Manager, Roland Menassa, Laboratory Group Manager,

Agile Equipment and Processes, GM R&D CenterAgile Equipment and Processes, GM R&D Center

What are the tough research problems (related to the design, engineering, What are the tough research problems (related to the design, engineering, validation, construction, installation, launch, and operation of assembly processes validation, construction, installation, launch, and operation of assembly processes and systems) that must be solved to make “smart assembly” a realityand systems) that must be solved to make “smart assembly” a reality??

2:45-3:152:45-3:15 Jack Hu, Professor of Mechanical Engineering,Jack Hu, Professor of Mechanical Engineering,University of Michigan University of Michigan

3:153:15 Coffee Break Coffee Break

Agenda – OctoberAgenda – October 3 33:40 3:40 Plenary Session - continued Plenary Session - continued

What are the tough implementation problems (infrastructure, What are the tough implementation problems (infrastructure, standards) that must be solved to make “smart assembly” a reality?standards) that must be solved to make “smart assembly” a reality?

3:40-4:103:40-4:10 Charlie Gifford, Director Lean Production Charlie Gifford, Director Lean Production Management, Management,

GE/Fanuc AutomationGE/Fanuc Automation4:10-4:404:10-4:40 Mitch Vaughn, Chief Technology Officer, Production Mitch Vaughn, Chief Technology Officer, Production

Management, UGS Management, UGS 4:40-5:104:40-5:10 Bob Brown, CEO Advisor, DELMIA CorpBob Brown, CEO Advisor, DELMIA Corp

What are the most promising models and opportunities for leveraging What are the most promising models and opportunities for leveraging and collaboration to accelerate the development and implementation and collaboration to accelerate the development and implementation of “smart assembly”?of “smart assembly”?

5:10–5:405:10–5:40 Jim Caie, VP of Consulting, ARC Advisory GroupJim Caie, VP of Consulting, ARC Advisory Group

5:405:40 Wrap up and collection of Break-out Session Preferences – Bob TiloveWrap up and collection of Break-out Session Preferences – Bob Tilove

6:006:00 Shuttle Bus to HotelShuttle Bus to Hotel

6:306:30 Reception, Hilton (Courtesy of USCAR)Reception, Hilton (Courtesy of USCAR)

The plenary speakers have one view … we want to hear from everyone!!

Agenda – October 4Agenda – October 48:308:30 Coffee Coffee

9:009:00 Kickoff Breakout Sessions (Richard Neal)Kickoff Breakout Sessions (Richard Neal)

9:159:15 Breakout Sessions and Working LunchBreakout Sessions and Working Lunch

Session 1: End User PerspectiveSession 1: End User PerspectiveSession 2: Research Science PerspectiveSession 2: Research Science PerspectiveSession 3: Infrastructure/Standards PerspectiveSession 3: Infrastructure/Standards PerspectiveSession 4: Systems Integration and Deployment Perspective Session 4: Systems Integration and Deployment Perspective

Pick up lunch between 11:30 – 12:00Pick up lunch between 11:30 – 12:00

2:002:00 Reports from Breakout SessionsReports from Breakout Sessions

3:403:40 Wrap up – Dale Hall, Bob TiloveWrap up – Dale Hall, Bob Tilove

4:004:00 Adjourn Adjourn

Breakout SessionsBreakout SessionsAnd Focus QuestionsAnd Focus Questions

PreferencePreference1 = First Choice1 = First Choice2 = Second Choice2 = Second Choice3 = Third Choice3 = Third Choice4= Fourth Choice4= Fourth Choice(please rank all 4)(please rank all 4)

End User Perspective – This group will explore End User Perspective – This group will explore what needs to be done and why from the what needs to be done and why from the applications view.applications view.

Research Science Perspective – From the Research Science Perspective – From the standpoint of R&D, where are the missing links? standpoint of R&D, where are the missing links? What technology voids hinder realization of What technology voids hinder realization of smart assembly?smart assembly?

Infrastructure and Standards Perspective – What Infrastructure and Standards Perspective – What foundational tools are required to realize smart foundational tools are required to realize smart assembly? What standards are needed to enable assembly? What standards are needed to enable interoperability and cost effectiveness?interoperability and cost effectiveness?

Systems Integration and Deployment – This Systems Integration and Deployment – This group will explore pathways to successful group will explore pathways to successful development of smart assembly systems and development of smart assembly systems and broad deployment of those systemsbroad deployment of those systems

Break-out Section Preference FormBreak-out Section Preference FormYou will find a form like this in your packet. Please complete it and

return it to a facilitator before you leave today!!

ParticipantsParticipants(Attendee List in Packet)(Attendee List in Packet)

Special Thanks To ..Special Thanks To ..

For hosting, organizing, ….

For reception