Manufacturing Systems Modeling

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1 Manufacturing Systems Modeling KSEE 2011 Slide 1 Manufacturing Systems Modeling

2 Volvo Group 2010 Turnover: 265 billion SEK Number of employees: 90,400 Volvo Trucks Renault Trucks Mack Trucks UD Trucks Buses Construction Equipment Volvo Mack Trucks Penta Volvo Aero Financial Services Slide 2 Volvo Group

3 Volvo Aero Components for aircraft engines and gas turbines Military aircraft engines Sub systems for rocket engines Engine Services Turnover: 7,7 billion SEK Number of employees: 2880 Slide 3 Volvo Aero

4 Vanes Shafts T-cases X-Cases Slide 4

5 Volvo Aero is a partner in several commercial aircraft engine programs Snecma CFM56 GE GEnx GE CF6-80 Snecma GE 90 P&W PW6000 P&W PW2000 P&W PW 4000 PW/MTU PW4000 Growth P&W JT8D-200 P&W V 2500 R-R Trent 1000 R-R TAY R-R BR715 R-R T500 R-R Trent Pounds Thrust Slide 5 Volvo Aero

6 Background - Product Lifecycle Management (PLM) Managing the entire lifecycle of a product from its conception, through design and manufacture, to service and disposal Wikipedia Slide 6 PLM

7 Why Architecting - why modeling? Products Business processes (WIP) Create/change processes Rework (MRB,... ) Machines / Workcenters Tools, Gauges Fixtures Heat Treatment procedures NDT Robots Quality standards (AS9100C)... SAP - Enterprise Resource Planning DMS Teamcenter (PDM / PLM application) OpPlan - Legacy Operational database NX6.05 (CAD) SolidWorks (CAD) AutoCAD (CAD) Vericut (NC simulation) NC program library Calypso (CMM) Quindos (CMM)... Slide 7 Systems of PLM

8 Four Traditional Methods of Architecting: Normative Hard rules are provided, success is defined by following the rules Participative Solution from group process / group consensus Rational Solutions derived from objectives Heuristics Develop solutions from lessons learned (guidelines, rules of thumb,...) In practice, successful architecting is a mixture of rational and heuristic methods, with some participative and normative used in particular situations Mark W. Maier Slide 8 Methods of Architecting

9 Model organization Six-View Modeling Slide 9 Model organization

10 Two opposite approaches to modeling The Bottom-Up approach Methodologies Data Mission Roles Products Databases People Processes Workflows Cost Strategy Budget Objects Threats Value Chains Stakeholders Objectives Risks Requirements Values Models Information Applications Constraints Machines The Top-Down approach A Model is an abstraction of Reality Raw Materials Products Slide 10 Bottom-Up vs. To-down

11 The Top-Down approach Taguchi: Signal Factors (M) Noise Factors (x) Respons (y) Selected view and level of abstraction depends on the "viewpoint" Control Factors (z) Burlton's IGOE: Slide 11 The Top-Down Approach

12 "Viewpoint": Product Lifecycle Management Raw Materials Products Three domains: System Architecture Manufacturing Enterprise Resource Planning (ERP) PLM Virtual Manufacturing Slide 12 Domains

13 Characteristics of the System Domains Manufacturing ERP Virtual Manufacturing Production issues Physical and electronical Real world Stochastic variations Administrative issues Electronical Commercial Stochastic variations Technical issues Electronical Ideal world No stochastic variations Slide 13 PLM System Architecture

14 System Architecture - System of Systems QDAS Calypso Quindos MES Manufacturing VBH ProMark Rektron Jærtech CSup ERP (SAP) DMS TeamCenter NX Virtual Manufacturing Calypso Vericut Software in Manufacturing should be selected based on functionality - not their "affinity" to SAP Preferred system elements in manufacturing have high internal complexity and low external complexity (high cohesion and low coupling) Slide 14 PLM System Architecture

15 Heuristics: Datastructures Examples: Materials, BOMs, Processes, WorkCenters, Machines, People, Organization,... Manufacturing ERP Virtual Manufacturing The ERP system (SAP) should define the structures and export them to the other domains Slide 15 Datastructures

16 Heuristics: Information flow Manufacturing ERP (SAP) DMS Virtual Manufacturing (VM) In order to control the information flow, let it flow through the ERP system Slide 16 Information flow

17 Information flow & "Mapping" Manufacturing Domain ERP / DMS Virtual Domain The ERP/DMS system maps information from the virtual domain to the manufacturing domain, and vice versa. Slide 17 Mapping of information

18 Information flow: Change Operation Manufacturing ERP Virtual Domain MaterialAdm 3D models 2D drawings Process-structure Process-structure Operation Order DMS Operation Documents Slide 18 Information flow: Change Operation

19 Process: "Change Operation for pre-production" Manufacturing ERP Virtual Domain Start change process New Change Number New revision in TcM Make changes in TcM Run the operation Update order in SAP Release for pre-produksjon NO OK? YES Process: Release for produksjon Slide 19 "Change Operation"

20 AS9100C - Process Approach 0.2 Process Approach This International Standard promotes the adoption of a process approach when developing, implementing and improving the effectiveness of a qualilty management system, to enhance customer satisfaction by meeting customer requirements What is a process? One or more activities in sequence Have a defined customer Uses resources in the organization Tranforms "inputs" to "outputs" "Outputs" from one process is often "inputs" to other processes A process can be integrated in other processes Slide 20 AS9100C

21 OMS - Operational Management System Slide 21 OMS

22 Process based navigation Difficult to navigate Unclear structure for users Difficult to integrate or connect processes Varying levels of abstraction... Slide 22 Process based navigation

23 Object based navigation An alternative to Process based navigation Identifies objects in the manufacturing system Assumes that each object has Attributes describing the object Methods associated with the object (create, change,...) iphones, ipads,... use object based navigation! Slide 23 Object based navigation

24 New OMS at VAN Products Business-support General support Ledelse Kvalitetssikring Personal Markedsføring / salg Program- / Kontraktstyring Forberede tilvirkning Kontinuerlig forbedring Prosjektledelse Økonomistyring Produksjonsplanlegging Produksjonsoppfølging ERP (SAP) Logistikk, innkjøp Vedlikehold bygg og maskiner PLM (SAP + TcM) IS/IT-støtte Slide 24 Prototype 1

25 OMS - different "views" Networks, interconnections Year-planner "Objects" iphone-gui Processes, Flow Charts "Deployment" Roles, responsibilities Slide 25

26 Questions? Slide 26 Questions

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