Modularisation and functional safety in mechanical and plant engineering

Modularisation and functional safety in mechanical and plant engineering

Wideburg Solutions Ever since our founding in May 2011, our primary objective has been to transfer successful concepts and methods from series production to mechanical and plant engineering. The portion of system parts unique to a specific customer is reduced systematically based on proven models, such as those used in the automotive industry. This significantly reduces order throughput times and minimises manufacturing costs while increasing quality at the same time. Academic solution approaches and established standards, lateral thinking and pragmatic solutions enable us to attain cost-effective, stable and innovative results. The more I know, the better the solutions will be. This slogan reflects the intensive relationships we maintain with our business partners for maximum customer benefit. We value transparent internal structures and clear organisation. In doing so, continuous professional development, teamwork, internal transfer of expertise, open communication and personal freedom set our specialists apart from the pack. PLM Product Lifecycle Management at Wideburg Solutions Many companies equate Product Lifecycle Management with CAD integration. As a result, the demand for a PLM system is born of necessity. The functionality is reduced to document management for design engineering data in order to counter the chaos of disorganised drawing versions. This makes connecting CAD systems to the PLM world just one of many tools used in a PLM system. We take a comprehensive view of PLM with all of its disciplines mechanical systems, electronic systems, software and so on. Each discipline defines its own processes, tools and methods in the lifecycle of the product. A large amount of potential for optimisation usually exists in the interfaces between the disciplines. There are a great number of these interfaces in every enterprise, and they are usually the greatest weak points. The PLM 3 Triangle Wideburg Solutions created the PLM Triangle. Each side symbolises one dimension of PLM. The bottom of the triangle is defined by the tools that support the implementation of processes and are used for the methodical product or project development approach. Raising PLM to the power of 3 (PLM 3 ) across the three sides of the PLM Triangle represents Management of data for Modular Mechatronic Systems PLMMM in Product Lifecycle Management. Methods Quality Deployment (QFD) Analysis (FMEA) Hazard and Risk Analysis (HAZOP) Modularisation methods Combining modules... Document management Variant management PLM³ Project management managemente Project control Approval process Integration of authoring systems Change process Business Processes s analysis... Tools

Modularisation in mechanical and plant engineering Effective modularisation The challenge Machine and plant manufacturers often face a conflict of interest in meeting customer specific requirements while also avoiding having to produce costly and time-consuming individual pieces. In reality, however, every customer has special requests. Even in the quotation phase, these lead to higher costs, more effort and long throughput times. Once the customer has made the decision, this added cost and effort are passed on unfiltered to order processing. This causes increased complexity in production planning and resulting high costs on the one hand and the risk of high rework costs on the other. The solution provided by modularisation/variant configuration A high degree of product range standardisation can be achieved by putting a machine or plant together from reusable units / modules. The customer-specific portion of a product is reduced substantially, which is an extremely efficient method of cutting costs. Standardising the product also provides a critical increase in manufacturing quality. Advantages of modularisation Drastically reducing portion of customer-specific content Lowering costs by minimising part variety Using standardisation to increase quality Basis for possible product configuration Basis for automatic creation of production documents Fast quotation processing Fast order processing What we contribute Modularisation has far-reaching effects on the organisation within the company. In many companies, the introduction of variant configurators and thus the modularisation fails because: It is seen as a cure-all, and the effort is underestimated as a result The introduction usually takes place in order processing The organisation in the company is not adjusted accordingly Product management is the control centre that defines variants. Variants start emerging as early as the development stage and have to find their way into production from there. Sales and order processing benefit from the configuration options. Take advantage of our experience. We provide comprehensive support in implementing your modularisation and validation projects.

Organisation in modularisation Traceability in functional safety al structure structure Development Purchasing/ Sales Hazardous incident Product management Funcion Organisational units involved Production planning Hazardous incident In the organisation of a compony the product management is the main control center for modularisation projects. Deriving requirements to reduce hazardous incidents and allocating them to the functional structures. Safety-related aspects are labelled. for implementing the requirements of the tests Development process Configuration Order processing Input for specification Safety requirement Test requirement s Test scenario Test scenario Production Processes involved Defined requirements and functional structures are input for the design specifications and the definition of the associated test scenarios. Configuration information is the central component of the most important corporate processes of production companies. for implementing the requirements Product structure Product Customer Order processing Iterative development Mechanical system Mechanical system Mechanical system Productmanagement Productdevelopment Configuration rules Order configuration Electronics Electronics Role of the PLM system is usually neglected Configuration rules originate in product development and are used in order processing. Production preparation Production Spezifikation Software Electronics Software Implementing the specified design leads to the product structure, which can be tested afterwards. Relationships can thus be traced from start to finish. Safety function, safety requirement Test requirement

al safety in mechanical and plant engineering al safety assured The challenge People and the environment have to be protected from harm. Therefore, manufacturers of machines and plants where the software and electronics are used for control have a fundamental obligation to make them functionally safe. Identifying risks, properly minimising them and complying with applicable standards are all critical. IEC 61508, the basic standard for functional safety, and the standards derived from it impose stringent requirements on the management of functional safety. DO 178B Airborne Systems DIN EN 5012xx Railway environment DIN EN 61513 Nuclear Power Plants DIN EN 60601 Medical electrical equipment ISO/DIS 26262 Road vehicles IEC 61508 DIN EN 50156 Fire-heated equipment DIN EN 61511 process industry DIN EN 62061 machinery DIN EN 60335 household electrical appliances The solution through a functional approach supported by data management software Standards for software qualification require traceability of the imposed requirements at all times. A methodical approach to requirements management allows functional structures to be allocated to the requirements so that they can be implemented and tested in the software later. Likewise, electronic system components and subassemblies can be allocated to the functional structures, allowing easy traceability of errors propagated in the safety functions caused by component defects. Benefits of our approach Easy traceability of each imposed requirement down to the implemented function in the software and hardware Facilitates testing of individual functions and thus of the imposed requirements Simplifies carrying out an FMEA based on the assignment of components to functions Creation of assignment matrixes (implementation matrixes) that contain all inputs and outputs at the end of a phase, allowing them to be validated easily Easy marking of safety-related functions and thus of safety-related requirements, components, tests, etc. Facilitates effects analyses for changes Documentation can be generated mostly automatically and thus kept consistent over the life cycle What we contribute In many companies, projects for software qualification fall apart due to issues involving documentation and failure to comply with quality plans created at the beginning of the project. We share our expertise with you at every stage, from introducing management of functional safety to compliance matrixes and safety concepts, all the way to validation of the system. We would be happy to provide expert support with organisational structures, process definitions or technical solution concepts and their implementation.

Aras Innovator certified partner for PLM software Wideburg Solutions GmbH & Co. KG Keltenstraße 13 85111 Adelschlag Tel +49.8424 88135 kontakt@wideburg-solutions.de www.wideburg-solutions.de Image credit: Nataliya Hora/Bigstock, Oleg Golovnev/Bigstock, Bernardo Varela/Bigstock, complize/photocase, kemai/photocase, o-zero/photocase B130174 blickfang - www.biwa-media.com