MANufacturing and supply chain management SYStem

Transcription

1 MANufacturing and supply chain management SYStem The aim of ManSYS: A complete decision making system and robust supply chain management system for metal additive manufacturing; enabling the production and delivery of quality assured, highly customised products and services

2 Program and Take-aways Program Outline Mansys project Mr. Utkarsha Antkalkhope, TWI ManSYS supply chain network Ir. Gijs Duivenvoorde, Berenschot Standards for Additive Manufacturing Ir. Henk Buining, TNO Design optimisation Mr. Tyler London, TWI Quality assurance and control Dr. Luis Portoles, AIMME Risk analysis framework Dr. Dennis Coleman, Smith & Nephew System integration Dr. Tristan Kuijpers & ir. Inge Haesaerts, Materialise Q&A Ir. Irma van Roest, Berenschot Take-aways The ManSYS-project and consortium offer a unique example of the possibilities the new digital manufacturing environment will give us. In the future systems and production facilities will be in place, allowing for the on-demand and on-location production of certified and quality assured highly complex optimized parts and products. Additive manufacturing (AM) is an important enabling technology in this future manufacturing arena. This workshop offers you the possibility to learn from expert leaders from industry, about the current and near future possibilities of AM, specifically with regards to solutions in the Aerospace, Medical and Dental industries. The workshop will demonstrate multiple tools and approaches to help determine Your strategy and planning with regards to investing in digital manufacturing; The state-of-the-art in quality assurance; Benefits and challenges associated with AM; Ways to upload parts and simulate the production and associated costs; How to organize a closed loop AM set up in your own environment. The Q&A session at the end assures you will leave with all your questions answered.

3 14.30 Outline ManSYS project Mr. Utkarsha Antkalkhope - TWI With AM technologies, only the material required is used, bringing the amount of waste down to practically zero. But there are other benefits of 3D printing, such as: Three key elements will be developed in the ManSYS project: Decision support software supporting end users to decide whether 3D printing is applicable in their specific situation; Supply Chain Management system that allows for easy adoption and management of 3D printing in the production process; Support network to (re-)design improved or new products realising user oriented high value added solutions. Complex parts can be designed and produced without assembly; New geometries can be created, that traditional methods cannot produce; Prototypes can quickly be produced; Individualisation is possible at low costs; Small series of unique or redesigned parts become an economically viable option. The ManSYS project is an initiative of 12 partners, supported by the European Commission (EC), to develop an online platform for the design and procurement of 3D printed parts and products. To demonstrate the benefits of ManSYS, essential parts from Smith & Nephew, Wisildent and GE Aviation will be produced via the platform. To ensure that the quality of the products complies with market and customer requirements, much attention will be given to the development of the quality assurance and quality control processes. Also, the software to integrate various supply chain and business management systems will be developed. LPW Technology Smith & Nephew Berenschot TWI TNO Poly-Shape BCT Materialise Twocare Wisildent GE AIMME Partners of ManSYS

4 14.40 ManSYS Supply Chain Network Development Ir. Gijs Duivenvoorde Berenschot The ManSYS supply chain architecture is developed together with all consortium partners. In this workshop an explenation of the different modules of the supply chain required to complete AM supply from service bureau to customer. The goal of the work package is to create an integrated supply network architecture based on full process description and information flows of all partners involved in the supply chain. The ManSYS network will be designed to provide streamlined material flow between all partners, reducing lead time and cost of waiting for raw materials, sub-assemblies, sub processes and finished products to the customer. To get here, customer requirements were specified through interviews with the demonstrator companies to gain insight into the functional requirements. After prioritizing, the requirements were used as input for the set-up of the information exchange and the logistics network required to form the bond between the companies and the technology. A full description and implementation methodology of the ManSYS integrated supply chain network has been developed and will be shared on headlines. Currently the supply architecture is being evaluated using discrete event simulation (DES) goal of this simulation is to define bottlenecks and to determine the AM capacity required to meet demand.

5 15.05 Standards, Formats and Interfaces Ir. Henk Buining - TNO Since AM is a relative new and innovative production technology and still has not yet reached the TRL level to meet the high quality standards for applications where 100% reliability is required, Quality Management and Standardisation requirements are defined. These should guarantee reliable and traceable products that meet the requirements of the customers. Standardization and quality requirements cover the procedures on exchanging data and materials. The ManSYS partners investigated the current international standards for testing and analysis as well as the applicability of existing standards to the ManSYS objectives. In order to present the most up to date information, it was decided that the AMF (Additive Manufacturing File format) would be incorporated in assessment and evaluations. Main requirements for standardisation include: Cost savings: Helping to optimize and improve operations; Customer satisfaction: Improving quality, enhance customer satisfaction and increase sales; New markets: Preventing trade barriers and open up global markets; Increasing market share: Assist in increasing productivity and competitive advantages; Benefit environmental issues: Reducing negative impacts on the environment. Automation and control of AM will be based on the only commercially available tool for AM supply chain management, which was brought to market in April 2012, by Materialise (Streamics). This software system integrates both AM automation and control. The demonstrators will be used for testing the AM automation and control system and guide the design of the AM Validation System for the ManSYS concept. Standardisation activities in ManSYS will be aligned with ongoing initiatives from CEN, ASTM and ISO.

6 15.30 Design Optimisation Mr. Tyler London - TWI ManSYS aims to contribute to a European standard for AM. Depending on the initial stage of development present, it is considered to prepare a background structure for a European Standard, a Technical Specification or a Technical report. The end users requirements developed during the process of Supply Chain Network development will be used as input. Guidelines for design optimisation for AM have been formulated, and three demonstrator component designs have been optimised. Topology optimisation of a jet engine bracket has been performed, using different numerical algorithms and different target volumes. Both 80% and 75% volume reductions have been obtained for the bracket whilst maintaining stress levels in the component below 75% of the yield stress. Topology optimisation of an intramedullary nail indicated that up to a 24% reduction in weight can be obtained whilst maintaining the stresses below 50% yield magnitude. Topology optimisation of a Wisildent dental bar indicates that a new part, with a weight reduction of 22% could feasibly be obtained from the original design. The resulting optimised geometries require processing by additional software in order to prepare the geometries for manufacture. The resulting geometry of GE bracket from topology optimisation has been further processed using 3-Matic software to improve the geometry for manufacture. In this workshop, the responsible team members will share their findings and main results.

7 15.55 Quality assurance and control Dr. Luis Portoles - AIMME Quality Management is investigated and coordinated. Hereto, the relevance of QA-requirements has been mapped, in close cooperation with the ManSYS demonstrator partners. Surface quality and possibility to make lightweight parts are the most relevant quality aspects expected from AM parts. From the mechanical properties, fatigue, tensile and flexural strength are highly relevant as well. The main implication to the supply chain is the necessity to include post processing steps such as machining and thermal treatment, in particular HIPing, since it clearly improves fatigue properties of AM parts. The end users have marked other mechanical properties as relevant such as modulus and elongation. These two properties are strongly influenced by the chemical composition evolution, in particular oxygen content which implies that there is a strong interest in strict control of powder recycling. Also, production capacities such as build envelop and maximum part size have been marked as quite important, especially by end users from the aerospace industry, which is why higher build capacities should be available in the supply chain. As expected, biocompatibility is sine qua non condition for biomedical end users while it is quite irrelevant for aerospace end users. However, Ti64 which is the subject of this project is a biocompatible material used for endo implants and fits perfectly the needs of the sector. From additional quality issues, melting point and the evolution of mechanical properties with temperature were named by aerospace users, while the absence of loose particles was stated as quite relevant by biomedical users. Based on these requirements, a process specification will be developed, requiring the monitoring and control of raw materials, and process parameters with resultant mechanical properties, especially for highly regulated sectors, such as medical devices and aerospace applications. General QA/QC procedures, Operational instructions for EBM/SLM based supply chain, Control procedures for EBM/SLM based supply chain are defined; validated and applied to demonstrators.

8 16.20 Risk analysis framework Dr. Dennis Coleman Smith & Nephew Since failure of one of each subsystems may lead to failure of the entire (global) ManSYS supply chain, a thorough risk analysis has been performed. Both internal and external commercial, managerial, physical and technical risks were identified, categorized and evaluated. A mitigation and contingency plan was then formulated, and translated into resolution actions, to reduce the identified risks to a minimum. One of the findings of this first exercise was to ensure reliability and robustness of the platform, additional suppliers should be found for each stage of the supply chain (suppliers of powder, finishing and AM services). Therefore, the gathered information was used to develop eligibility criteria for additional suppliers, meeting the specific needs of each of the proposed user groups (dental, medical, aerospace). The ManSYS team described eligibility criteria on several aspects: financial terms, suppliers profile (stability, reputation etc.), safety and environment issues, quality, delivery time and related topics, and global factors, such as location and political environment. Besides listing eligibility criteria, the team has in practical terms described the way to use these criteria in the management of the ManSYS platform, using sign up forms and selection stages. Since each end user has different specific needs and terms, matchmaking metrics will be embedded to ensure suppliers meet those user requirements. For each supplier it should be clear what services can be delivered: manufacturing methods, design validation, optimization and suitability for specific end user markets are aspects to regard. Capacity criteria will be used in this matchmaking process as well, to guarantee the feasibility of in-time delivery of batches. The development of a production planning tool will however be task of one of the other ManSYS teams. To continuously confirm the rightness of supplier selection, in cooperation with end users, a review process will be implemented in the system as well. Likelihood 1 Extremely unlikely 2 Unlikely 3 likely 4 Extremely likely 5 Almost certain 1 Insignificant (1-2 Days) Severety 2 Minor Disruption (Several DAYS) 3 Notable Disruption (1-2 WEEKS Significant Disruption (1 Month) Major Disruption Several Months

9 16.45 System integration Dr. Tristan Kuijpers & Ir. Inge Haesaerts - Materialise This sub-project team has focused on the ManSYS systems integral design requirements, both technical and non-technical. Per use case, starting with login, through the ordering steps, up to tracking of the delivery, all requirements were listed. Possible scenarios were envisioned, to be able to track all possible error situations and non-clarities, to which the system should be able to respond, to guide to user through the process. Non-functional requirements are related to security, performance and scalability. Some more general non-functional platform requirements have been listed as well. User interface designs for each scenario have been designed, and a deployment diagram was sketched, indicating the relations and connections between servers. ManSYS portal will be the frontend of the platform, accessible to the end-users via the web interface. The production process within the suppliers will be covered by Streamics, AM automation and control system deployed on their premises. Streamics is a backbone system which provides the suppliers with central data storage, process control, automated process steps, machine integration and quality management of their entire AM business. It consists of a whole set of tools and configurable workflows and brings supplier traceability in all aspects. Streamics can be integrated at the suppliers with other processes and business software. Next to this all, an investigation has been performed to which user inputs are required in order to judge the processability of the part with metal AM. Also, algorithms to translate user requirements into technical data for both the decision making tool and the supply chain management tool, were developed. These include a basic build size check, a file corruption check, and a wall thickness analysis tool. After uploading. The user can than adapt his file and try again. In a later stage, additional checks will be added. After completing this preliminary check, the user can have his design optimized by a selected ManSYS supplier, before placing an order, again, by a selected supplier.

10 Contact Project Coordinator Amanda Allison TWI ltd. Exploitation Manager Onno Ponfoort - Berenschot [email protected] The research leading to these results has received funding from the European Community s Seventh framework Programme, under grant agreement [email protected]