Manufacturing: new trends in production systems design and operation. Fulvio RUSINA (Comau), Yves COZE (Dassault Systemes)

Transcription

1 Manufacturing: new trends in production systems design and operation Fulvio RUSINA (Comau), Yves COZE (Dassault Systemes)

2 Table of Contents Industrial key trends and main drivers The actual design and manufacturing environment Currents RTD efforts Future trends in Digital Manufacturing 2

3 Key Industrial Market Trends Globalization (production, suppliers, R&D, ) New leaner technologies Product / Process competitiveness Outsourcing (logistics, engineering, production, ) Customer satisfaction and retention concerns 3

4 Requirements for the Body Shop of Tomorrow 100% flexibility Minimum duration 2 generation of vehicles Optimized cost for investment Zero loss launch Optimized cost per piece Production rate scalability Product improvement 4

5 Design and Production Network Excellence Centers Network COMAU NETWORKED PROCESS Program Management Simultaneous Engineering & Quality Management Make or Buy Policies & Strategies Workload balance Sub-Suppliers Management Innovation and Standardization Management 5 PWT - Assembly PWT - Assembly BWA - Welding BWA - Welding PWT - Machining PWT - Machining BWA - Tooling BWA - Tooling BWA - Transport BWA - Transport Maintenance Svcs Maintenance Svcs ENG - Product ENG - Product ROB Std Product ROB Std Product ENG - Process ENG - Process ROB Applications ROB Applications

6 Manufacturing Systems - Evolution Drivers DRIVERS Factory Cost Flexibility Optimized Shop Floor Mgmt Maintainability Environment & Safety Production System Supplier impact Standard & lean Low cost solutions Modular and re-usable ( agile ) Plug & Play modules Wireless applications in manufacturing New process (e.g. remote laser welding Flexible/Agile Systems Reprogrammable Convertible solutions More robotized systems (< infrastructure) Intelligent and rational use of automation vs. operators Integration of shopfloor automation at plant level Intuitive HMI & field data collection and analysis Virtual engineering & Digital Manufacturing (modeling & simulation) Higher reliability R&M approach Local sensors for process monitoring Remote diagnostics Tele-service (WEB network) Design for safety and ergonomics Innovative process (new joining technologies, MQL machining, ) Dismantling

7 Why Digital Manufacturing? 7

8 Digital Manufacturing solutions: a seamless end-to-end workflow 8

9 Body Quality Program S.O.P. PRODUCT ENGINEERING SIMULTANEOUS ENGINEERING PHASE PROCESS ENGINEERING & BODY GEOMETRY SET UP BODY QUALITY PROGRAM BODY SHOP DIES BODY QUALITY & PRODUCTION TARGETS 9

10 Product / Process Analysis PRODUCT ANALYSIS: Static Fatigue Vibration and noise Crashworthiness Bio-mechanics Optimisations/robust design Multibody Static (Torsional Stiffness) PROCESS ANALYSIS: Process macro-cycle is a preliminary hypothesis on needed plant room, time cycle, panels to be loaded Stocastic spotwelds analysis (Optimisation/RD) 10

11 The standardization process COMAU Standardization Process Knowledge Integration Tools Business Processes Technical Job Management Digital Manufacturing Business Process Procedures (Quality) Design Book Design Book as Easy Catalog Material Management (PBS, WBS, ) WEB sites Proposal Engineer Design Engineer 11

12 EU Platforms: ManuFuture 12

13 RI-MACS R&D Program* RI-MACS is the acronym for Radically Innovative Mechatronics and Advanced Control Systems. The main objectives of the RI-MACS R&D program are the definition of a radically innovative manufacturing control open architecture based on state-of-the-art ICT technologies (in particular wireless technology) and modular mechatronics. All the technology being investigated will conform to open architecture standards. Interfaces must allow for easy integration with the other process units. Other factors considered include increasing factory safety and reducing the environmental impact. *) EU Contract Number NMP2-CT

14 System Integration & Control Architecture Evolution Current Plant Server Eth Future Web based services Cell PLC Line PC Eth Field Bus Line/Cell PC Plant Server Eth Sensors/Actuators Sensors/Actuators 14

15 RI-MACS - Main Project Objectives Make open approaches and the multi-agent paradigm more robust and demonstrate their feasibility (web services/agent-based mechatronics control technology with embedded intelligence); Exploit wireless technology in networking and in novel architectures; Develop flows to support the design and operation of the manufacturing plant of the future with particular attention to the simulation of service oriented services (SoA) and automatic code generation for control; Develop industrial strength test beds. 15

16 Embedded Controls and Wireless Manufacturing Productionbased services WLAN busines s models production planning layer (software) Communication -based services bluetooth WLAN control room new control paradigm collaborative control layer Communication -based services collaborative communication models abstract communication layer (middleware) ZigBee Location -based services input Multihop Multihop UMTS processes logistics maintenance WiFi Bluetoot h WLAN device models manufacturing power output embedded wireless physical layer (hardware) 16

17 RI-MACS Digital Manufacturing Environment Geometry Cinematics Internal Logic Comunication Control Logic Logical I/Os PLC program Pure logicdevices Electropneumatic devices Devices with complex cinematics Virtual cell All the objects could be stored in libraries Objects libraries 17

18 RI-MACS Digital Manufacturing Environment INPUT Integrate Control Engineering Flow OUTPUT - Mechanical description 3D Model - 3D Mechanism creation - Internal Logic (IL) - Normal cycle diagram Control Logic - Control Logic (CL) creation High level simulation Mechanical modification Normal Machine Cycle VALIDATED - Special cycle diagram - I/O Mapping SW Automatic generation - Target PLC SW - Diagnostic alarm list - HMI Specification SW Completation -PLC SW completed - OPC Connection Low level simulation SW PLC VALIDATED INSIDE Delmia AUTOMATION OUTSIDE Delmia AUTOMATION 18

19 Digital Manufacturing: knowledge-based engineering roadmap Integrated Project and Knowledge Management Digital Product Engineering 3D CAD Integration Engineering Tools Digital Prototyping Life Cycle Data Management Config. Management Rapid Prototyping Digital Prototyping Integrated/Networked Engineering Environment Standards Multi-scale Simulation Digital Manufacturing Engineering Factory Data Management Digital Factory Towards the Digital Manufacturing Models of Manufacturing Ergonomics and Process Standards Adaptation to Reality Integration (MES) and Smart (wireless) Factory and Support of Knowledge-based Factory and Services 19

20 Digital Manufacturing: IT Environment requirements Creates a COLLABORATIVE standards-based manufacturing environment Provide VISIBILITY throughout the organization and with suppliers, partners and customers Enables FLEXIBILITY to manage operations remotely and react quickly Ensure SECURITY for all business communications Lower TOTAL COST OF OWNERSHIP 20

21 Digital Manufacturing: Openness/Friendliness requirements OPEN design, simulation and validation framework INTEROPERABLE with market leader Digital Manufacturing software products INTEGRATED Digital Manufacturing environment based on common data models Easy CUSTOMIZATION to include specific customer s needs and solutions Simple reference METHODS and friendly and easy to use SOFTWARE TOOLS to support all stage of the design and development Elementary EDUCATION AND TRAINING ENVIRONMENTS to test and practice new Digital Manufacturing solutions 21

22 Digital Manufacturing: Real vs. Virtual requirements ADHERENCE between the real and the virtual environments EASY DATA AND INFORMATION TRANSFER between the real and the virtual worlds and vice versa Effectiveness in MANAGING DIVERSIFIED SOURCE OF INFORMATION: economics, product, process, mechanical, control, piping and wiring, hydraulic, pneumatic, etc. Capability of MANAGEMENT CUSTOMERS NEEDS from process planning, to production operation, to system maintenance and re-tooling 22