SysML to ARENA Translation for Manufacturing Process Modeling

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SysML to ARENA

Translation for

Manufacturing

Process Modeling

Gregory Pollari Advanced Manufacturing Technology

Rockwell Collins

Global Product Data Interoperability Summit | 2012



Acknowlegements

•  At Georgia Tech •  Dr. Leon McGinnis, Eugene C. Gwaltney Chair in

Manufacturing Systems and Professor •  Dr. Ola Batarseh, Researcher •  Dr. Volkan Ustan, Researcher

•  At Rockwell Collins •  Jim Lorenz, Manager Advanced Industrial Engineering •  Dan Turner, Material & Process Engineer •  Todd Boyle, Material & Process Engineer

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Model Based Manufacturing Challenge

•  Desire early Manufacturing involvement during system design

•  Requiring systems engineers to “speak manufacturing” is a challenge

•  How can Manufacturing engage during the systems design phase without “getting in the way?”

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Today’s Manufacturing Analysis Workflow

•  Two problem classes •  Analytical (mathematical relationship, or rule, can be verified) •  Visual (difficult to write a rule, but easy to see)

•  Start at detailed design •  ECAD (Electrical Computer Aided Design) •  MCAD (Mechanical Computer Aided Design) •  Rule checkers (geometric features) •  Reports

–  Auto-placed components –  Preferred parts –  Cost rollup

•  Manufacturing Readiness Assessment (MRA) •  Virtual Prototype Models (visual) •  Manufacturing process modeling (discrete event

simulation) •  Automate where possible

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Early DFx and Producibility Analysis

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System Architecture

Detailed Design Build Verify &

Validate Deploy Requirements

Requirements Models

Architecture Models

Implementation & Analysis

Models

Database (DOORS®)

Factory & Supply Chain

Models

Architecture Languages

(OMG SysML™, AADL,

DODAF)

MCAD, ECAD, DFx, Producibility,

Visualization, Cost

Discrete Event Simulator (ARENA®)

Today’s Focus

Start Here In the Future

•  Evolve from focus on “in series” analysis of detailed design to include . . .

•  . . . “in parallel” input during architecture trade studies . . .

•  . . . Driving need to speak the language of Systems Engineering

Reduce Cost Impact

OMG SysML is a trademark of Object Management Group, Inc. in the United States and/or other countries.




Enablers for Early Manufacturing Involvement

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•  NDIA Manufacturing Division AMEC Committee

–  Spur funding to research pre-CAD physics-based producibility measures

•  Georgia Tech “Domain Specific Language” project

–  OMG SysML is the “hub” for early involvement

•  SAVI (System Architecture Virtual Integration)

–  Formal methods supplement visualization

System Architecture

Detailed Design Build Verify &

Validate Deploy Requirements

Architecture Models

Architecture Languages

(OMG SysML, AADL,

DODAF)

Start Here In the Future




OMG SysML “Hub” An Integrated Modeling Vision

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Galorath SEER®-H Parametric Cost Estimating tool

ARENA® Discrete Event

Simulator

“Pin 1 Problem” & Design Rule Evaluation

OMG SysML “Front End”

User Interface

mecha Mechanical Architecture

«Mechanical...HERMES

«HWCI»Remote_Control «HWCI»

Vehicle«HWCI»

Data_Loader_V

«HWCI»Data_Loader_RC

«LRM»Motor with

Encoder

«LRM»Sensor

«LRM»NXT

«LRM»Sonar

«LRM»Color

«LRM»Compass

«LRM»Gyro

«is-a»«is-a»«is-a»«is-a»

«references-a»

0..4

«references-a»

0..3

«references-a»

0..1

«references-a»

0..1

«references-a»

1..4

«references-a»

0..*

«references-a»

AADL, etc. Supports Formal Methods Analysis

SAVI Inter-Model

Shared Property Consistency

SAVI

Model 1 Model 2

Signature 1

Signature 2

Shared Property

Signature 2

2

1

ICD

Single Truth

Architecture ModelSP

2

1Reference

Model

Auto-generate

Data Exchange

Signature 1

© Copyright 2012 Rockwell Collins All rights reserved.

Manufacturing Process Model in OMG SysML

•  Contains all the necessary inputs needed for an ARENA® model –  BOM, production schedule, resource,

process routings/times

•  Shows the graphical representation of the BOM (Bill of Material) and each part’s process routing

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OMG SysML to ARENA® Translation Process

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OMG SysML model (.uml)

Formatted XML (.xml)

Access® database (.mdb)

ARENA® model (.doe)

ARENA® metamodel

(.ecore / .ecore_diagram)

UML®

metamodel (.url)

ATL translation (.atl)

XML definitions for ARENA®.

ATL translation code based on the

manufacturing DSL.

UML®/OMG SysML definitions.

XSL (.xsl)

Unformatted XML (.xml)

Java® (.java) 1

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Using the Atlas Transformation Language (ATL) translation engine within the

Eclipse™ framework, translate the OMG SysML model with the ATL translation script. During translation, the model’s

UML constructs are compared with manufacturing DSL and the appropriate XML semantics for ARENA® are chosen.

Create an OMG SysML manufacturing model in MagicDraw® and then export the OMG SysML

file (XMI® export). XML format definitions.

Java® script to format XML file.

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Using the Java® engine within the Eclipse™ framework, format the

translated XML to a format importable by Access with a Java® script. This

formats the XML data based on Extensible Stylesheet Language (XSL)

definitions.

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Import the formatted XML file into a pre-built Access database. The database

contains tables and relationships that are recognizable by ARENA®. XML data is

placed in the appropriate tables.

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Import the database into ARENA® discrete-event simulation

software. This will create a model for simulation and analysis.

Eclipse Model-to-Model

Transformation™ project

ATL Transformation

Engine

Java® Engine

Eclipse and Eclipse Model-to-Model Transformation are trademarks of Eclipse Foundation, Inc. Oracle and Java are registered trademarks of Oracle and/or its affiliates. Other names may be trademarks of their respective owners.

XMI and UML are either registered trademarks or trademarks of Object Management Group, Inc. in the United States and/or other countries.

Eclipse™ Environment

Eclipse™ ATL

MagiDraw®

Java®

Microsoft®

Access®

ARENA® Simulation




Translating OMG SysML to ARENA®

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ARENA® model

and statistics

•  ARENA® manufacturing model can be simulated to identify system capabilities/constraints

•  Production (overall/monthly) •  Production lead times •  Resource capacities •  Bottlenecks

•  Using these results, decisions can be made by manufacturing support teams




Who Uses Process Simulation?

•  Boeing •  Used ARENA® to model entire manufacturing and logistics

processes for 787 integration* –  Assembly lines across the U.S. –  Included suppliers of ~50 mechanical components –  Simulated Dreamlifter usage for global logistics –  Demonstrated potential effects of production ramp-up

•  Many medium to large companies use process modeling**

•  Examples: Toyota, Ford, GM, Lockheed Martin, NASA, EADS, Bombardier, Lufthansa, Honeywell, Goodrich, Cessna, Pratt & Whitney, HP, IBM, UPS

•  Colleges and universities •  ARENA® alone is used in over 150 programs in the U.S. and

over 500 worldwide

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* “Boeing: Integrated Production System Modeling Method” presentation at ArenaSphere 2010 conference, May 17-20, Las Vegas, NV ** Internet search November 2010




Benefits of Process Modeling Projects

•  Tactical applications: allows for elements in a system to be adjusted without interrupting the current state

•  Strategic applications: allows for new systems to be created and

examined before key decisions or investments are made •  Provides leadership with a decision support tool to aid in the decision

making process •  Generates data on which to base decisions •  Helps to eliminate “best-guess” scenarios

•  Identifies problem areas so effort can be focused where it will result in maximum benefit

•  Helps communicate, promote change and receive buy-in from key stakeholders

•  Gives stakeholders a better understanding of the entire system as a whole and the interactions that take place within the system

•  A model is essentially a living and breathing Value Stream Map!

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Integration Challenges

•  Human Interface •  Graphical user interface – “language” of systems engineers

•  Formal methods/analysis – requires semantic precision •  Integration

•  OMG SysML is very flexible, graphical interface •  AADL is semantically precise •  MARTE, DARPA META translator: integrate OMG SysML-

AADL •  XMI® implementation for tool interoperability •  Automated connection with ERP (Enterprise Resource

Planning) systems •  Need for producibility measures that can be applied

during system design (research) •  Consistency checking of shared properties across

model environments (SAVI – Systems Architecture Virtual Integration)

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XMI is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.




How Can MBSE Address these Challenges?

•  Promote and drive toward certified XMI interoperability •  Cax-IF (Computer Aided “x” Implementor Forum) model?

•  Architecture language mapping to STEP AP-233 •  OMG SysML to AP-233 mapping – is it complete? •  AADL to AP-233 mapping

•  Develop a layered systems architecture “data interchange” model for interoperability between architecture descriptions

•  Analogous to OSI (Open Systems Interconnection) model for communications architectures?

•  Abstract systems modeling language at the top (MOF®?) •  Concrete data storage model at the bottom (AP-233?) •  Architecture models can take various forms

–  Language –  Instances –  Database –  File storage

14 MOF is a registered trademark of Object Management Group, Inc. in the United States and/or other countries.




Contact

Gregory Pollari Advanced Manufacturing Technology Rockwell Collins [email protected] 319-295-1629

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SysML to ARENA Translation for Manufacturing Process Modeling

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