Digital Solutions for Complex Manufacturing TXT e-solutions S.p.A.

Transcription

1 Digital Solutions for Complex Manufacturing

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3 TXT NEXT is the engineering division of TXT Group, international specialist in high-value software and solutions for large enterprises. Over the past 30 years, TXT NEXT has collaborated with Clients in the Aerospace, Transportation and High-tech Markets, providing advanced software solutions and services that empower their capabilities. These worlds deal with complex systems and TXT NEXT works throughout the entire value chain, from product design, to manufacturing and post sales. In these pages, we will focus on Manufacturing, explaining our Digital Manufacturing Paradigm increasingly connected with the new revolution of Manufacturing 4.0. INDEX 1. Complex Manufacturing How much complex is "complex manufacturing"? The Digital Manufacturing Paradigm 2. The role of TXT NEXT Our pillars - our references - our methodologies & architecture - our solutions Our Portfolio 3. References & Case Histories

4 COMPLEX MANUFACTURING HOW MUCH COMPLEX IS COMPLEX MANU- FACTURING? Discrete manufacturing might become a highly complex task when it applies to products like for instance airplanes, helicopters, excavators, trains as well as some machineries. The complexity lies not only in the product itself which may be made of many thousands of components but also in the way that product is to be designed, tested, its components procured and produced, assembled, distributed and served at customers side. Complex manufacturing is therefore to be considered as a distinctive industry sector, requiring well-suited practices, expertise, methodologies and IT supporting tools. Companies operating in Complex manufacturing context require adequate supports in terms of methodologies and IT tools. Their partners should have a specific expertise that comes from a deep knowledge of problems and a long collaboration experience. On the other side, the complexity of these contents requires a background of competences and experiences to be properly tackled that cannot be underestimated. THE DIGITAL MANUFACTURING PARADIGM Digital Manufacturing approach in product definition and process design The Digital Manufacturing Paradigm (DM) is a fully integrated, non-traditional approach to the different phases of design, manufacturing and assembly of complex systems, combining a dedicated set of tools and methodologies. They support design, simulation and analysis of part of a complex system, their manufacturing processes as well as the final assembly planning. Combined use of DM tools and methodologies can enable significant improvements in both products and process. 4

5 Digital Manufacturing links what to manufacture to how to manufacture DM therefore is a key strategy element for manufacturing organizations: allows, working in a virtual environment, design, test and manufacturing activities to proceed concurrently overcoming the traditional sequence of product development phases and breaking the classical company design, engineering and manufacturing silos. Expected benefits are faster time-to-market and the reduction of problems in post design-phase that can be anticipated and solved early in the product lifecycle. DM requires a high level of collaboration between different parties: Department inside the company and across the company and its suppliers. High level of collaboration is essential in Digital Manufacturing 5

6 THE ROLE OF TXT NEXT TXT NEXT has developed a deep experience in complex manufacturing, through a large number of succesful projects with leading clients, mainly in the aerospace and transportation industries. Our clients have increased their operational efficiency through the adoption of the DM paradigm along their entire value chain, enabled by stae-of-art IT solutions we have deployed. Several references prove TXT NEXT capabilities. OUR PILLARS With expertise and IT solutions, TXT NEXT offers a comprehensive portfolio of specific solutions and services to manage the overall manufacturing process in order to reach effectivenss and efficiency. 6

7 TXT NEXT s proposition for Digital Manufacturing is based on three main pillars: 1. References: More than 25 years of work with different clients, gave us a strong domain knowledge in complex manufacturing. 2. Methodologies and Architecture: Leveraging on Lean Manufacturing methodologies, we focus on eliminating or reducing non value adding activities of company's processes in manufacturing procesess. Deploying tailored IT Solutions, exploiting the most advanced trends, we provide an intuitive support to manufacturing operations. 3. TXT Portfolio of packaged Software solutions: - Vertical Solutions a. Final Assembly Solution by TXT (FAST) b. Manufacturing Execution System (TXT EXECUTE) c. Advance Planning System (TXT MAKE) d. Sales & Operation Planning (TXT PERFORM) - Manufacturing Analytics Modules a. Business Intelligence for Manufacturing b. Big Data for Manufacturing 7

8 VERTICAL SOLUTIONS a. FINAL ASSEMBLY SOLUTION by TXT (FAST) FAST is intended to provide the company with a comprehensive, effective set of tools to manage the industrialization, production and assembly of products according to a digital manufacturing paradigm. The TXT NEXT solution allows manufacturing engineers to manage new drawings from the engineering department, analyze their impact on existing configurations, create or update the technical specification documents and job cards. With FAST, Manufacturers can benefit from TXT s deep knowledge in digital manufacturing approaches, gaining tight collaboration between Configuration, Design, Planning and Industrialization Environment and increasing their efficiency and effectiveness. b. MANUFACTURING EXECUTION SYSTEM (TXT EXECUTE) TXT EXECUTE is a solution that operates across multiple function area, providing a «single version of the truth» that enables a synchronized and highly coordinated flow of information. Based on this, TXT EXECUTE can provide the right information at the right time for the right people and in the right format, giving to each worker (from technician to manufacturing decision maker) all the information he needs in order to achieve his tasks. Additionally, the TXT EXECUTE can render to Management how the current conditions on the plant floor can be optimized to improve production output The TXT s MES solution works in real time in order to provide a full control of the manufactured product (e.g. progress activities, related issues, as-built report). The goal of TXT EXECUTE is significantly reduce the number of non-value added hours performed by employees and to maintain the productivity necessary to meet production and delivery objectives. Furthermore, the products produced with the TXT s MES solution met all the customer s quality requirements from the very first manufactured product, bringing the company closer to the goal of maximizing efficiency and quality. 8

9 c. ADVANCED PLANNING SYSTEM (TXT MAKE) TXT Advanced Planning System is a configurable, modular solution that support the end-to-end planning from sales to production machine. The software solution combines ASP with master planning, procurement/warehouse/sales and process control directly onto the solution for manufacturing companies. Through a real-time simulation, it provides a holistic view of the production situation, considering resource capacity (machinery, staff, and tools), availability of materials and the current process status of all production orders. TXT Advanced Planning System allows the control of the production starting from existing demand (sales orders, planned and/or minimum inventory) and supports various scenarios for defining production orders, their scheduling and execution. The solution supports procurement (ordering process, receiving, and inventory management), sales (offer and order management, customer orders) and stock management (warehouse management, inventory management and valuation). 9

10 d. SALES & OPERATION PLANNING (TXT PERFORM) TXT Perform Suite supports Complex Manufacturing companies facing their unique challenges thanks to an exclusive combination of Integrated Planning and analytical capabilities spanning many critical business processes: Forecasting and Demand Planning Inventory Optimization Sales & Operations Planning In planning the value chain from end to end, TXT tackles the unique challenges of the manufacturing: Management of complex production environments including subcontractors Supplier collaboration Available to promise Made to order or repetitive Stock Replenishment 10

11 MANUFACTURING ANALYTICS MODULES a. BUSINESS INTELLIGENCE (BI) for Manufacturing TXT adopted a portfolio of tools, applications and methodologies that enable organizations to collect data from internal systems and external sources, prepare it for analysis, develop and run queries against the data, and create reports, dashboards and data visualizations to make the analytical results available to corporate decision makers as well as operational workers. b. BIG DATA for Manufacturing TXT considers big data a new frontier to answer questions no longer in a merely numerical way but facing hypothetical scenarios. The possibilities of big data continue to evolve rapidly, driven by innovation in the underlying technologies, platforms, and analytic capabilities for handing data, as well as the evolution of behavior among its users as more individuals live digital lives. In particularly, Big Data are been used especially in manufacturing and maintenance areas. TXT integrates know-how and experience in Big Data in its services. 11

12 REFERENCES & CASE HISTORIES Here below a selection of reference case history for the digital manufacturing world. AgustaWestland - CAPP AgustaWestland is a leading international manufacturer of civil and military helicopters with procuction activities located in Italy, United Kingdom, Poland and USA. In the last years AW makes important investment in order to transform its plant in "center of excellence" characterized by high quality and high efficiency in production processes. CAPP - Computer Aided Process Planning is a specialized solution from TXT NEXT that has the goal to provide a production routing and BOM management system Through the CAPP application, TXT provides to AW s manufacturing engineers a standard way to define the process instructions, ensuring a greater consistency of the data. CAPP guarantees a tight connection between routing and its documentation i.e. tooling, drawings, specifications and operative sheets increasing the quality and the efficiency in production of gearboxes and other mechanical components. Pirelli - SLIC Pirelli is a company pioneer in the production of tyres for cars, SUVs and commercial vehicles, with a wide range of solutions designed to achieve the highest performances and comfort on all roads and in all weather conditions. The long experience in the tyre's field, the unflagging commitment by the company during research and development stage and the extensive sales network enable to reach the top in every single product. TXT NEXT supports Pirelli with its SLIC (Specification and Line configuration) application, a solution managing the definition (Different kind of tyre: PZERO Nero, PZERO rosso, etc...) and configuration of tyre (Production sequence, assets, machines for use, material, work cycle, etc..). SLIC connects and communicate directly with production plant (Robot, extruders, CNC, etc...) to send production cycle and production sequence. Thanks to SLIC, Pirelli can produce infinite variant of tyre without stop production, in the same time can run in production more than one variant tyre. Alenia Aermacchi DBT AleniaAermacchi is the Italian leader in aeronautics and among the world s top players in the design, development, manufacture and support of commercial and military, trainers and unmanned aircraft systems. TXT NEXT supports Alenia process in several plants with its DBT (Technological Data Base) application, a solution managing the technological database of production cycles and production tracking information. Through a web-based interface, Alenia engineers of the manufactur- 12

13 ing engineering department, in cooperation with Boeing technical services, create and maintain detailed production cycles including tooling, drawings and other multimedia information that are applied in production activities. Process parameters and production related information are then collected and linked to production cycles, to be used as production tracking data. Agusta Westland - FAST TXT NEXT supports Agusta Westland with FAST (Final Assembly Solution by TXT) providing a solution able to help the production area and in particular the final assembly one. The TXT NEXT solution allows Agusta Westland to have a complete integration of all the processes, from the routing definition to the machine configuration, passing by the configuration and change management. Thanks to its flexibility and its deep integration with the production environment, FAST is in use by a lot of Agusta Westland's plants, such as Vergiate (IT), Tessera (IT), Philadelpiha (US), China, Yeovil (UK), Swidnik (PL) and Russia with a total amount of more than 2000 users around the world. Alenia Aermacchi - PMS The Grottaglie (Taranto) site is one of the world s most innovative industrial plants. Alenia Aermacchi adopted the Plant Management System (PMS) to integrate with SAP and to trace the workforce costs on its eight plants. Alenia Aermacchi and TXT approached the identified production process through the paradigm of Digital Manufacturing, and developed a highly user-oriented, modular, and fully integrated solution. - Operation Progress Declaration : The provided solution works in real-time, placed side by side with the operators, which use it in order to register the activity they are doing and providing the right information to the right people at the right time - As Built : The system keeps track of every production step (adding, changing, removing operation), records the operators who worked in 13

14 it and records component installation/uninstallation with their s/n. The as built is collected and stored for each aircraft. - Digital Content Management : The system allows the operators to get the Electronic Work Instructions by the Manufacturing Engineers, in order to accomplish the assigned task. No more paper. In order to accomplish all its functionalities, the MES solution is interfaced in real time with the main legacy systems to reach a fully integrated system. AgustaWestland - MES The TXT s partnership with AgustaWestland involves not only the production department but also the Final Assembly one. In this context, TXT NEXT implemented for AW a Manufacturing Execution System (MES) based on Lean concepts that helps the streamline operations and further minimizes non-value added tasks in the production process. Placed side by side with the shopfloor operators, the system provides a simple and intuitive way for electronically tracking both activities and materials, supplying the entire structure of manufactured product. Moving in the direction of a paperless production, the system lets operators get all information they need for their task directly from MES and, to do that, we build an architecture able to guarantee the connection in real-time between Manufacturing Engineering and ShopFloor. With TXT NEXT s solution, AgustaWestaland reduced of almost 67% the time spent for technician for declaration and registration and, thanks to the alignment between MES and ShopFloor, a synchronized and highly coordinated flow of information has been detected. Alenia Aermacchi - JSF TXT Plant Management System monitors the execution activities in all the plants in order to collect and analyze the workforce production cost and return the final data to the ERP. As the planned design and the final product could vary, TXT-PMS has been extended with a complete As-built tracking and management system. This module keeps track of every step during the 14

15 manufacturing process: serial numbers, changes in routing, installation and uninstallation of parts, process parameters and so forth. The information will be available to the manufacturer and the contractor to provide the exact record of how any production step has been actually carried out and highlights the differences between the planning and the actual result. The PMS and its modules, alongside with ERP and PLM systems, represents one of the pillars of the manufacturing execution system in Alenia Aermacchi. Brembo Production and Distribution Planning Brembo is an international group producing braking system components, with 36 production sites in 12 countries of three continents. On behalf of Brembo, TXT has developed a solution in order to derive optimal production and distribution plans: the goal is to find the best production plants and warehouses in order to satisfy the demand of customers along the complex company distribution network, with the best cost ratio, taking into account production, transportation, stock keeping and purchasing costs. Based on TXTPERFORM suite, the solution combines demand planning and forecasting capabilities with sophisticated production and distribution planning optimization features. Daimler Truck Engine Design Testing As the biggest globally active manufacturer of trucks above 6 metric tons gross vehicle weight, Daimler Trucks develops and produces vehicles in a global network under the brands Mercedes-Benz, Freightliner, Western Star, Thomas Built Buses, Fuso and BharatBenz. The collaboration with TXT involves DaimlerChrysler s engine testing division for trucks. Within that division, new product developments are accompanied by intensive and highly sophisticated tests. The design of a new part by the design engineer drives a prototyping phase in which the product sample needs to be tested under real conditions. Design engineers generate a test order including a number of measurements and assessments to be carried out on the new part. Once they have identified which measurement to be undertaken, the test order is placed to the internal customer office. DaimlerChrysler uses TXTMAKE APS with its components to tackle its order management challenges. Integrated with the group s Product Data Management system and Warehouse Management systems, TXTMAKE APS is an end-to-end order management solution that supports the whole 15

16 lifecycle of an order. The solution efficiently manages the complexity of different types of orders and suborders in a way that minimizes users'efforts. This system reduces the level of manual work and repetitive tasks required for order management, standardizes communication among users and eliminates paperwork. The testing division staff now has complete visibility of order progress and a transparent view over the testing activity. Dema Plant Management TXT NEXT has provided Dema with a specialized Manufacturing Operations Management system, in order to manage and support all its production activities and to provide a comprehensive reporting system in a fully integrated way. Through this system, plant managers can upload and manage routing data, load and assign working orders, track production and workforce; operators can declare the progress on work orders; quality operators can manage exceptions. The system provides operational reporting and analytics through business intelligence (BI) tools. Messier-Bugatti-Dowty S&OP Messier-Bugatti-Dowty (Safran) is the world leader in aircraft landing and braking systems. Company capabilities encompass the full life cycle of our products, ranging from design and manufacture to in-service support, repair and overhaul. Messier-Bugatti-Dowty is a partner to 30 leading commercial, military, business and regional airframers, and supports more than 25,000 aircraft making over 40,000 landings every day. The company employs more than 7,000 staff working in locations across Europe, North America and Asia. Messier-Dowty has developed a company-wide Sales & Operations Planning (S&OP) solution applying TXTPERFORM suite. The solution combines independent demand planning focused on determining the most accurate forecast for all types of demand (OEM, spare parts, retrofits) with a mid-long term assembly and production planning focused on determining the internal and external load of resources over time required to fulfill the expected demand. The overall, combined information allows the establishment of a formal validation process of sales & operation planning: all involved actors from different company functions can interact on the basis on a unified, global vision and take consistent business decisions, also supported by simulation features. 16

17 AHEAD BY INNOVATION During the last decade, TXT has always been putting innovation high on its investments agenda, with the mission to constantly study, develop, integrate, deploy and adopt innovative methodologies, software and practices in Complex Manufacturing domain. Our customers and partners as a distinguishing competency and by us as an un-valuable competitive advantage and key success factor in the market have recognized this strong investment in innovation. Innovation is not a choice, and the need for continuously innovating the company footprint is leading us to an intense participation in EC-funded research projects, where new ideas could be shared, nurtured and experimented in collaboration with the most advanced EU research institutes and enterprises. TXT strategy to approach EC funded Research Projects has recently evolved from an initial focus on emerging technologies (in the 90s) till to the current major objective to design and develop new business-technical services, by fully adopting new concepts such as collaborative service innovation, blending them with Future Internet technologies such as Internet of Things, Big Data, Augmented Reality and Mobile-Wearable computing, for a new bouquet of solutions all targeting the Manufacturing Industries. A brief description of the most recent projects and results is reported here below. FITMAN (Future Internet Technologies for MANufacturing industries - The mission of the FITMAN project is to test and experiment FIWARE software technologies ( to 10 industry-led use case trials in the domains of Smart, Digital and Virtual Factories of the Future. FIWARE technologies include around 40 Open Source software generic enablers covering different chapters of the Internet of the Future (e.g. Internet of Things, Big Data Analytics, Cloud Computing, Security, and Service Marketplaces). 17

18 FITMAN integrated their functionality by additional 15 Open Source components (Specific Enablers) supporting more than 50 manufacturing business processes, such as Workplace monitoring & Zero- Quality manufacturing (Smart Factory); Product Collaborative Design & Reputation / Brand Analysis (Digital Factory); Enterprise Systems Interoperability & Business Ecosystems Digital Assets Management (Virtual Factory). FITMAN Trials (4 conducted by Large Enterprises, 6 by SMEs) are being testing and assessing the suitability, openness and flexibility of such components (generic and specific) while contributing to the STEEP (social-technological-economical-environmental-political) sustainability of EU Manufacturing Industries. The use case trials belong to several manufacturing sectors such as automotive, aeronautics, white goods, furniture, textile/clothing, LED lighting, plastic, construction, and manufacturing assets management. TXT is the project and technical coordinator, leading the whole initiative (36 partners 18Mil. costs) while specifically providing IT support to the AgustaWestland trial, dealing with smart control of tools management for Foreign Objects Damages avoidance during helicopter maintenance (Smart Factory) and with lifecycle digitalization of the helicopter Logbook, interoperating as-designed, as-built and asmaintained configurations of the aircraft (Digital Factory). MSEE (Manufacturing SErvice Ecosystem - www. msee-ip.eu) The major goal of the MSEE project is to research novel service-oriented management methodologies. In fact, the servitisation process moving more and more attention to the services offered on top of the manufactured product is a reality. The vision of the MSEE project is that the new technologies and methodologies oriented to services will enable European virtual factories and enterprises to selforganize ourselves in new forms of collaboration pushing even more the services offered on top or on substitution of the product. The first big challenge of the MSEE project is to make SMEs and enterprises able to adopt the Factory of the Future technologies; the second big challenge is to transform current manufacturing hierarchical supply chains into manufacturing open ecosystems to support collabora- 18

19 tive innovation in a secure industrial environment. TXT is the project and technical coordinator having the responsibility of the project (19 partners). Moreover, TXT is the responsible for the trials work package, guiding and supervising the implementation of the experiments. PSYMBIOSYS (Product-Service symbiotic SYSytems - The PSYMBIOSYS projects is an evolution of MSEE and concentrates on the improvement of the product-service design in manufacturing removing some identified barriers currently preventing service innovation to be pervasively adopted by all EU manufacturing industries, SMEs included. Service Innovation for the Manufacturing Industry (or servitisation) is an evolutionary process, which progressively aims at enriching physical products with smart services, which often at the end of the servitisation process could represent the main traits of the company s distinctive offer and become its real competitive advantage. For instance, post-sales maintenance and training services for complex products such as power plants, trains or aircrafts is becoming the most profitable and growing activity for the manufacturers and often represents a key differentiation factor with respect to the competitors. The main concept of the project is that physical products and related services should evolve in symbiosis in order to be innovative and effective and overcome current five barriers and tussles which concern i) the product and service lifecycles concurrent evolution; ii) the continuous reconciliation of the digital world of the design and the real world of the manufacturing; iii) the mediation between the professional knowledge of engineers and the sentiment/ feedback from customers/crowd; iv) the federation and interoperability of Service-Oriented and Event-Driven architectures and v) the harmonization of new disruptive business models with the current business strategy. TXT is the technical project coordinator responsible for the whole project architecture and specifically for Big Data and Virtual Reality implementation as well as exploitation manager aiming at create the commercial offers from research project results. 19

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