F2006SC23 PPR Information Managements for Automotive Die Shop 1 Yoon, Tae-hyuck *, 1 Kim, Gun-yeon, 1 Noh, Sang-do 1 Department of Systems Management Engineering, Sungkyunkwan University 300 Chunchun-dong, Jangan-gu, Suwon, Gyeonggi, 440-746, South Korea KEYWORDS - Automotive die shop, PLM (Product Lifecycle Management), PPR (Product, Process, Resource), MPM (Manufacturing Process Management) ABSTRACT In order to achieve rapid development while ensuring competitiveness and cost savings, digital virtual manufacturing is essential to die shops. Digital Virtual Manufacturing is a technology that facilitates effective product developments and agile productions by digital environments representing the physical and logical schema and the behaviour of real manufacturing system including manufacturing resources, processes and products. For applying digital virtual manufacturing to die shop, engineering information managements of products, manufacturing process and resources are vital. This paper proposes and implements the PLM approach, for achieving effective engineering collaboration of engineering activities. This paper also presents detailed procedures, examples, and considerations of PPR managements in die shops. 1. INTRODUCTION In recent years, automotive manufacturers have been under a tremendous pressure to improve their responsiveness and efficiency. The time and cost for the product development and production must be reduced considerably to meet the changing demands of customers in a global environment 1). In particular, it is of primary importance for automotive die shops to reduce the production time of press die. This is because the production time of press die consumes 40% of total car development time and has great effect on reducing total production time 2), 3). Die shops contain many processes, including design, pattern, mold, machining and assembly. In order to manage theses processes successfully, it is necessary to use Digital Virtual Manufacturing to optimize design and validate machining and perform Concurrent and Collaborative Engineering among various possesses. Digital Virtual Manufacturing is an integrated computer model which represents the physical, logical schema and the behaviour of the real manufacturing system. It provides manufacturing engineering content and solutions to create, evaluate, monitor and control for distributed agile manufacturing based on 3-D CAD, simulation, databases and computer networks. Generally, Digital Virtual Manufacturing can verify and optimize many decisions, plans and operations
in manufacturing engineering, such as product design, equipment, jig and fixture design, process planning, factory layout design, production and material flow analysis and OLP(Off- Line Programming) of various equipments. As a result, time and cost are both reduced in product development and production 1). The Design and Production of Die can be conducted most effectively using Digital Virtual Manufacturing, verification of panels using press simulation and forming analysis and checking interference of die. As Digital Virtual Manufacturing is a growing trend, PLM is spread over the automotive and shipbuilding industry. PLM (Product Lifecycle Management) is an innovative manufacturing paradigm that leverages e-business technologies to allow a company s product content to be developed and integrated with all company business processes through the extended enterprise. This provides the ability to make business decisions with full understanding of the product and product portfolio including process, resource and plant. In addition, MPM (Manufacturing Process Management) supports the manufacturing process life-cycle from process planning and detailed engineering to full production. In connecting all members of the manufacturing chain into one virtual enterprise, MPM assists manufacturers in building the best practice production strategies and therefore reducing time-to-market. The majority of manufacturers use Both PLM and MPM for management of PPR (Product, Process, Resource) data. As related work, Z Kovas and J-M studied integration of PDM and Workflow Management Systems to support the full product development lifecycle from design through to operation of the final production line 4). <Fig.1> presents the PDM and Workflow Management System framework. <Fig. 1> Framework of PDM and Workflow Management System In addition, Kurian K. Thomas and Gary W. Fischer proposed a method for integrating commercial CAD and CAM software packages to provide an integrated process planning tool that can substantially increase productivity and reduce lead-time. However, when managing product data, these papers only focus on the machining process or production. In other words, the majority of related papers do not study total management of PPR data such as machining
processes, resource. However, it is important to not only manage product data, but to process data and resource data for applying PLM and Digital Virtual Manufacturing effectively. In this paper, the as-is process is proposed for automotive die shops using PLM, and practices are introduced to apply Digital Virtual Manufacturing to the machining process. As a PLM solution, in this paper, Unigraphics of UGS is used for 3-D CAD and Teamcenter Engineering of UGS is used for management of product data. Teamcenter Manufacturing of UGS is used for MPM and management of resource data. In addition, Unigraphics CAM, Unigraphics ISV module and Unigraphics Post Builder are used for CAM, machining simulation and post processing. This paper proposes a process for integrating from design to machining and validating interface among various solutions. 2. THE APPLICATION OF PLM AND MPM ON DIE SHOP 2.1 The Concept of PLM and MPM PLM (Product Lifecycle Management) is one of innovative manufacturing paradigms which leverages e-business technologies to allow a company s product content to be developed and integrated with all company business processes through the extended enterprise. P-Product is core to Manufacturing. The L-Lifecycle refers to manage total lifecycle related to products such as ideas, design and production. The M-Management refers to manage all parts related to collaboration, the extended enterprise OEM and the supplier. PLM extends PDM out of engineering and manufacturing into other areas such as marketing, finance and after sales service, and at the same time, addresses all the product stakeholders throughout the lifecycle. The PLM closes the gap between control and innovation and extends PDM functionalities to include the creation of product definition information as well as management and control of such information 5). <Fig. 2> Area of MPM
The idea of bringing complex and sophisticated products to market, such as automobiles, electronic products, trains or aeroplanes, can be simplified into three major phases (see <Fig. 2>). In the first phase, manufacturers define what they will bring to market. They then establish how the products and all of their components will be manufactured and assembled. Finally, manufacturers have to schedule all of the activities that define when the components must be processed to meet the production schedule. The what and when phases have been well covered by information technologies but the how has lagged behind. However, manufacturing process management (MPM) is a new class of technology that can manage the how efficiently between the what and the when phases. 2.2 Need for PLM and MPM on Die shop PLM can be applied in the automotive industry, shipbuilding industry, aerospace industry and so on, for every business process. In particular, the automotive Die shop uses a small quantity batch production after receiving an order which is similar to the shipbuilding and aero space industries. The die shop produces various products through limited resources and consistent production processes. In this case, PLM systems are required because efficient management with limited resources is extremely important 6, 7). The automobile die shop needs management of various work required for design data, supplied parts from partners and product delivery data. For efficient use of limited resources, MPM sets the optimum production schedule and machining process plan. PLM and MPM are required to achieve economic resource management. 3. DIE MACHINING PROCESS 3.1 Die Machining As-is Process <Fig. 3> shows the Die machining as-is processes and business environments. The machining process is an operation occurring after design. In as-is processes, the difference between 2D machining (Structure-feature machining) and 3D machining is clear. First, in the case of 2D machining (structure-features machining), NC data is generated using NC process generating program. On the other hands, in 3D machining, NC data can be generated after making neutral formats for design files using a common CAM program. NC data generated by the asis process can be used for common machining, but cannot be used in machines supporting ATC (Auto Tool Change). The machine supporting tool change automatically generally needs ATC, because it has various attachments for automatic processing and without human resource. In order to use ATC at these machines, a post processor is required for post processing of NC data and an in-house program generates suitable code for various
attachments to each machines. Then, for efficient machining, the AFC (Auto Feed Change) process is needed to make decisions for machining speed considered cutting quantity. Finally, machining instruction is published and real machining processes are performed after verification of machining, such as machining possibility, tool interference, and holder crashing. Lately, business environment of design has changes to 3-D CAD, and die design data has been shared with 3D CAD format. Therefore, the NC worker s amount of data conversion work is continually increasing. The data format that can be read using in-house software must be converted to generate NC data for Structure-features machining. A distinctive system environment and delay of user training can cause confusion. Therefore, to achieve working efficiency, new process must be made from design to machining, without modification of system and data. <Fig. 3> Die Machining As-is process and Software 3.2 Die Machining To-be Process on new business environment <Fig. 4> shows the process of new business environment. In the to-be process, NC data can be generated from design to machining verification of a consistent system. Data designed by 3-D Cad can be converted to NC data automatically using common CAM without data conversion in as-is processes, and post process can be executed using a post processor. Then, machining simulation can be performed using this NC data and validated NC data with resource, machine and design data in this integrated module 8).
<Fig. 4> Die Machining To-be process and software In this paper, for management of PPR information including machining processes, PDM and MPM solution are selected and applied. In the machining process, PDM and MPM can help management of PPR data and interface of each process, such as management of die design, NC data management, publishing machining indicator, and NC data management. In managing PPR data in new business environments, an environment can be provided to share information relating to each component, from design to machining process data. <Fig. 5> shows the process from design to machining on PPR point of view. <Fig. 5> Machining Process from PPR point of view on New Business Environment
4. THE APPLICATION OF PLM AND MPM 4.1 Management of Product Information In order to produce a panel in the Press Die Shop, Die should be produced, which is used in more than 4 processes such as Draw process, Trim process, and two times Flange processes. As an independent product, each Die includes various components and parts. There is no difference currently between e-bom and m-bom, because the structure of die design data is managed from the top to low level part. That is, the design data of each die has a BOM structure, which can be used for die manufacturing or purchasing at the same time. <Fig 6> shows the BOM structure implemented in this paper. Product data applied PLM and MPM in this paper is real die data used in Die Shop. And this product data is designed using 3-D CAD, Unigraphics. At the PDM, managing this die design data, each data not only supports 3-D geometry data, but also various formats such as 2-D data and data for viewing. The structure stores various data formats in one file. <Fig. 7> is an example of applying registered product design data and information management functions. In this paper, these die design data are used and it is possible to manage the newest data and engineering changes through agreement and approval. <Fig. 6> BOM Structure of Die Design <Fig. 7> Management of Draw Die Product 4.2 Management of Machining Process Information Machining processes are determined by the shape of the mold. In general, for designing die, designers input the standardized machining properties, such as hole and part assembly section. In the machining process, method and tools like feed-rate and RPM are stored in a Database for each shape. And the fundamental machining process can be planned by determining the machining sequence using a process planning template. The next step is the modification of the machining process plan through considering the Setup. The important idea is that the processes should be divided into different Setup. However, if machining is impossible in a single Setup, each shape has the same machining properties. Usually, at least two times Setup are needed for machining structure. The machining process planning is finished by considering the Setup for machine casting shape defined with all factors, such as machining condition, tool length, machine specification, and so on.
After defining modifying the machining process planning document, the machining operation property of each shape is designed, using a detailed machining path, and machining tool from commercial CAM. Then, NC data is generated by loading tool information, managed by MPM through the CAM interface, and generated NC data is managed in CLS file format. <Fig. 8> shows the machining process planning process. <Fig. 8> Process Planning of Machining Process 4.3 Management of Resource Information The Resource of machining process like machines and tools can be managed through the concept of Classes. MPM has a category that can include various machines, and tools, using Classes, and each category manages tool information such as tool length and diameter. The Resource Manager can register the new tools and machines as they select categories of machines or tools, inherit input variables, input the values to variables, and register 3-D data. Resource Manager can use it effectively via a user interface, and change the information of each resource into a database schema using Class. The machining tools such as Face Mill and End Mill, needed for die machining are generated by Resource Manager, but necessary basic data is classified and input to already defined section. In the case of undefined information in Class, data classification is achieved by adding new tool information. <Fig. 9> shows the conceptual relationship between the Class management screen and Resource Manager. <Fig. 9> Relation between in-class and Resource Management
4.4 PPR Modelling of Die Machining Process In machining simulation from managing PPR information, the relationship between PPR information should be defined. That is, the product of machining process and resource information for machining should be related to each other. First, the process is defined, then machining products in each process represented, and finally the process is assigned to tools and machines managed by a Resource Manager. <Fig. 10> shows the Management of PPR information in the machining process. <Fig. 10> PPR Modelling of Machining Process 4.5 Post Processor If NC data is generated in a CAM solution, only CLS files written by GOTO statements are generated. The machines, installed in a real field, have different controller specifications, and therefore, should pass through Post Processing by generating an M Code, and G Code suitable for each machine. If basic information of the axis of machine is input such as in <Fig. 11>, many scripts for associated Post Processing are shown, and Post Processing NC data suitable for machine specification is obtainable by editing these scripts. <Fig. 11> Post Process using Post Processor
4.6 Machining Simulation on New Business Environment For machining simulation, the CAM solution should be defined for generating NC data after machining process planning, Post Processor for post processing, and kinematics information of machine for machining simulation. Then, simulation is implemented through the interface between MPM and the information for process and product. Detailed steps are as following: 1. Machine modelling using 3-D CAD 2. Definition of Machine Kinematics 3. Machine Registering into 3-D CAD Library 4. Definition of registered Machine using Post Processor 5. Library Registering of Controller generated from Post Processor 6. Implementation of Simulation by referencing machine and tool After registering machine defined by kinematics, the machining simulation is possible as the NC path generated from the commercial CAM solution, using machining tools and holders registered in MPM. <Fig. 12> presents machining simulation. It is possible to verify Setup suitability for machining process planning in terms of machining method and machining order. <Fig. 12> Machining Simulation When machines lower parts more than required, collision can occur, such as collision between shape section and tool, holder. The machining software can verify these realistic in early times.
4.7 Verification of Machining Planning The advantage of machining simulation is that modification is possible using visual verification of machining process planning. While process planning in the past was based on the knowledge of workers, NC operation, which is possible for machining any other Setup condition, can be found and modified easily through simulation. That is, because methodology for maximum machining efficiency can be found, the majority of optimized machining process planning can be found to be related to machining time. 4.8 Distribution of Machining Instruction Distribution of Machining Instruction can be used to create further Machining Instruction, making it possible for distribution to workers at the most efficient time. Correct distribution can be achieved using the length information of tool, Feed rate and RPM for each machining operation defined on CAM solution using report auto-generation functions. In the past, in order to make Machining Instruction, machining tool information and RPM information was defined using EXCEL. However, it is possible that automated generation of Machining Instructions can be found using auto-generation functions. The result is generated in webdocuments and in format of business standard. <Fig.13> is an example of Machining Instruction. <Fig. 13> Machining Instruction
5. EFFECT OF PLM AND MPM APPLICATION 5.1 Construction of Integrated Business Environment Past processes experienced difficulty in managing data, because each business such as Die design, NC data creation, and machining process must operate in different environments. In this research, a new environment is presented, able to create and manage data in integrated environments. This new environment can help minimize both cost and time consumption. In addition, it can eliminate unnecessary elements such as data conversion, data management and data collection. 5.2 Efficient Management of PPR Data Generally, PDM manages Die design data for product data management. However, manufacturing process and resource data isn t managed efficiently. This research finds that it is efficient to provide not only product data management, but also process data and resource data management, resulting in an increase in data accessibility. 5.3 Extension Application of Digital Virtual Manufacturing Digital virtual manufacturing requires specific data. In particular, machining simulation requires product data, machining machine data, information about process, and so on. In most cases, data is collected or data is created if not available. Hence, to apply digital virtual manufacturing, a considerable length of time is required to prepare necessary data. Inefficient and time consuming work can be minimized through efficient management of PPR data. When using data efficiently, it is possible to accomplish digital virtual manufacturing.
6. CONCLUSIONS When PPR data is managed, it is important to consider the application range. If the range of application is not decided specifically, more data must be created. Therefore, the minimum range of necessary PPR data should be specified in order to manage the system efficiently. Then, additional PPR data should be input and managed after defining the process. The machining simulation and verification of machining process planning is achieved through efficient management of PPR data. In particular, NC Data can be validated by simulation of interference and collision among tools, holder, attachment and Die. Machining process planning can be optimized by checking previously to Structure-features machining. Finally, construction of a PLM system from initial design to final machining processing provides a consistent and integrated business. This system results in effective collaboration and increase productivity, ultimately reducing time-to-market.
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