Download ModArt – Model Driven Parts Manufacturing

ModArt – Model Driven Parts Manufacturing
The purpose of ModArt is to create an innovative and efficient way of developing production
systems for parts manufacturing. It will be a model driven IT-support environment for
practical and industrial development. This will be done in a close collaboration between
manufacturing industry, academy and IT-companies. Work procedures will be defined and a
digital model infrastructure and information platform will be developed. IT-tools from
leading vendors will be taken advantage of The main results are Web-based production
development manuals that will spread experiences, routines and information in relation to
well defined work processes in process planning, factory design, production investments,
production and IT-investments.
Figure 1 ModArt: Model driven parts manufacturing with web-pilots spreading the results
Motivation
There is a great potential to reduce cost, decrease lead times and secure quality by utilizing new
development processes for production system development.
The purpose of ModArt is to rationalize the development of production systems by a model driven
work processes and methods:
o Coordinated work process and a systematic utilization of IT adapted to the demands from
production
o Coordination and reuse of information and models
Expected results
1.
Work procedures in manufacturing development, which are well coordinated, and utilize
IT-systems in a manner that is systematic and adapted to the routines and activities.
2. An information backbone based on information standards such that models can be reused
between activities and different IT-systems.
3. Web-based “Pilots”, that is, digital handbooks that spread experiences, routines and
information in relation to well defined work processes.
4. Education in model driven manufacturing.
Industrially, the implemented Pilots, and the knowledge of how to realize model driven
manufacturing development with the right IT-system for the task at hand are the most important
results. Academically, the principles for model driven manufacturing development with the
definition of how to structure and model manufacturing domain information and work processes
are the most important result.
Project realization
The project is organized as five sub projects for the development of the production development
pilots, each describing the digital models and IT-tools for a specific activity, with information
shared in a common information infrastructure:
o ABL: Process Planning Pilot
o FPL: Factory Design Pilot
o PIL: Production Investment Pilot
o FBL: Continuous Improvement Pilot
o MIL: Modeling and IT-investment Pilot.
The work is divided into a number of basic work packages:
Study of current industrial manufacturing activities; Study and evaluation of existing methods and
tools; Definition of the future model driven work processes; Identification of needs for methods
and tools; Development of new methods and tools; Implementation of pilots; Development of
integration platform; Education, courses and seminars.
Each of the sub processes address these work packages by studying the activities, developing work
flow, studying relevant IT-tools for their purpose together with the IT-suppliers, defining model
driven manufacturing and finally implementing pilots and education around it.
ABL - The process-planning pilot
Process planning is a central and complex activity in a producing company. During the activity of
planning how a part is to be manufactured, many decisions are made based on experience e.g.
concerning the choice of the right type of process, the fixture design, etc. Process planning may
also result in the needs for changing the factory layout or investing in new machines.
In ModArt, a process planning work procedure is defined which utilize models of the product and
the manufacturing resources and processes.
Models, of parts, tools, machine toos etc. should as far as possible be based on international
standards for product data, e.g. feature based process planning, standards for cutting tools and
feature based NC-programming.
FPL – Factory Design pilot
To enable a fast design and redesign of the factory, models and experience concerning material
flow, layout and installation is required. In FPL, the experience of the participating companies
concerning designing and realizing the factory flow and layout is taken care of, and new methods
and tools are introduced.
Both new and existing knowledge is documented and formalized using digital modeling,
simulation, requirement management and decision support systems, with the results presented in
the FPL.
A generic factory design process is defined based on the companies’ experiences. Digital models
of the factory are used to verify all relevant manufacturing requirements. .
PIL – Production Investment Pilot
Investing in large machines often mean a large economic risk, thus the success of new investments
is critical to most companies. At the same time the equipment in a factory is often complex, many
standards and regulations for e.g. machine security has to be followed, and it is far to easy to make
erroneous decisions causing costly redesigns and delays. The purpose with PIL is to support
machine investment with a quality secured process that leads to investments that meet the
production goals and with decreased lead-time from identified problem to equipment running
optimally in operation. A model driven machine investment method is useable for large and
smaller companies and various types of equipment. A digital requirement model is developed in
steps, based on requirements from process planning and factory design, as well as applicable
standards and regulations. The digital requirements are then verified with models of the equipment
designs in each step of the work.
FBL – Continuous Improvement Pilot
In FBL, the production operations, control and maintenance are in focus. The major thought is by
manufacturing system monitoring and measurements partly improve the manufacturing system and
partly provide input for improvement of the earlier processes in the article development. FBL will
create opportunities for a focused and resource effective improvement and development work
through guiding the user by supplying knowledge and methods in a “do-like-this” manner. The
Improvement pilot will contain support that purposes are to define, assess and develop the
improvement work. The different parts in the pilot that will be developed are:
 Establish of a local manufacturing standard
 Implementation and development of manufacturing monitoring
 Establishing of Key Performance Indicators
 Establishing and development of improvement groups
 Choice and implementation of improvement methods and tools
 Assessment tool to support a continuous evaluation of the improvement work itself
Furthermore a “vision” will be presented with the latest support methods and tool concerning
model driven article manufacturing.
MIL - Modeling and IT-investment Pilot
General issues concerning defining and implementing the model driven activities and pilots are
focused in MIL. All pilots are to be based on the same architecture, an architecture that also
should support modules for education. While the main goal for MIL is to define the IT-architecture
for model driven manufacturing, the modeling and IT-group also provides tools for implementing
the other pilots, and identifies common IT-tools within the sub projects.
MIL will be evolving into a tool that supports the investment in IT-systems for model driven parts
manufacturing, providing answers to what the requirements are on systems to support a successful
model based manufacturing process.
Results and effects so far
A Web portal based on the content management freeware Plone has been established:
http://modart.iip.kth.se. All relevant project information is collected there and project
administration and document management is handled through this web portal.
Within each of the pilot-projects, workflow models have been developed based on studies of the
activities in the participating companies – see figure 2.
ABL
Participants in process planning project were divided into identified sub areas.
The process planning processes have been studied at Scania, Sandvik Coromant, ITT-Flygt and
NMW, and documented in the work process models. Comprehensive courses in the applicable ITtools are planned and scheduled.
FPL
FPL participants were organized in working groups for: Process modeling, Production layout,
Simulation and flow analysis and material supply. A one week course was held in Process
Engineer (a IT-tool from Dassault Systemès) used for the development of production systems. The
factory design process has been studied at Scania, ITT Flygt and a handful of other companies.
The workflow has been modeled on a high level, with more detailed models to come early 2007.
PIL
The web based PIL application developed earlier within Woxéncentrum was improved with a
focus on generality, user friendliness and practical functions for controlling access privileges:
http://pil.iip.kth.se. The investment process was studied at ITT Flygt och Scania.
Produktutvecklingsprocess
TG1
TG2
TG3
TG4
TG5
PAR-beslut
Utfallsprov
gjutet ämne
Godkänt
utfallsprov
Artikelberedningsprocess
Processverifieringsdata
Processverifiering
Grov beredning
Artikel för
beredning
 Operationsföljd
 Uppskatta
produktionskostn.
 Produktionsgranskning
 Verktygs-
Preliminärt
beredd artikel
& fixturbeställning
 NC-programmering
 Upprätta arbetsinstruktioner
 Processverifiering
Serieuppläggning
Beredd artikel
med verifierad
process
 Fastsällande
av OP-data
av process
 Fastställande
Produktionsfärdig artikel
VTG-data
Artikelnummer
Preliminär
Artikelritning
Preliminär
beredningsdata
OP-data
Produktionsanpassad
artikelritning
Utfallsprov
bearbetning
Instruktioner
Verifierad
OP-data
Verifierad
VTG-data
NC-program
IT-resurser:
Artikeldatasystem (K012)
Ritningsarkiv / Pro Intralink
Arbetsarkiv / Pro Intralink
OP-dataregister (T050)
VTG-dataregister (T030)
Lokalt PC-Lan
Lokal PC
Figure 2 Workflow model of the process planning work process.
FBL
A target model of the FBL has been defined. Analysis of the current state and the needs in
operations has been performed on several of the participating companies. This method for state
analysis is the same as will be utilized in the FBL pilot, thus the participating companies are
provided with a method for self-evaluation and for analyzing the work- and information processes
within the company.
MIL
Courses in activity and concept modeling were provided to the ModArt participants. General,
summaric education has been given on the systems from Unigraphics Solutions and Dassault
Systems. A requirement specification and system analysis for the pilot system architecture was
defined. Based on these requirements, conceptual models, information models and an
implementation specification were defined. One important result is the common view on the
production pilots that is evolving within the ModArt group.
Participating parties and Contact person
Manufacturing and Engineering Companies:
Scania, Sven Hjelm, [email protected], Project Leader
Sandvik Coromant Jan Axelsson
ITT Flygt Jan-C Larsson
Haldex, Urban Fagrell
NMW, Torbjörn Danielsson
Epsilon, Roger Bäckström
IT-providers:
Eurostep, Håkan Kårdén
UGS, Lars Sveding
Dassault Systèmes, Jonas Fredriksson
PTC, Mats Fredriksson
MicroTech, Mikael Wikner
Research and standardization:
IVF, Mats Lundin
SIS, Mattias Lafvas
KTH/DMMS, Torsten Kjellberg,
KTH/DMMS, Research coordinator: Gunilla Sivard, [email protected]