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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]