Role, Challenge, and Value of Configuration Management in a Model Based Enterprise(MBE)

Transcription

1 Role, Challenge, and Value of Configuration Management in a Model Based Enterprise(MBE) Badari Panuganti, PLM Consultant, Charlotte, USA October Copyright 2017 HCL Technologies Limited

2 Aerospace & Defense Automotive Consumer Electronics Industrial Mfg Medical Devices Telecom Service Provider Semiconductors Telecom Networking & Storage Office Automation ISV and online HCL Overview along with ERS Line of Business Snapshot HCL Enterprise $7B HCL Technologies $6.2B ENGINEERING and R&D SERVICES A $1Bn+ UNIT UNDER HCL TECH IN REVENUE 115,000 EMPLOYEES 32 COUNTRIES Top 3 Global Engineering Services Company 40+ Years of Complex Engineering Experience 24,000+ Engineers 55 of Top 100 Global R&D Companies as Customers 100+ Client Development Centers and 110+ Customer - Specific Labs 1,250+ Patents Filed for Customers $25M+ Worth Investments in Laboratory Facilities FPGA, ASIC and SOC Design Embedded Systems Hardware & System Design Mechanical Design GeometricPLM Software Product and Platform Engineering Product QA and V&V 2 Copyright 2017 HCL Technologies Limited

3 Introducing GeometricPLM GeometricPLM is a cross vertical service line under the ERS line of business of HCL Technologies with a dedicated Sales and Delivery Organization It is amalgamation of all PLM business (from Geometric and HCL) and Technology solutions portfolio To address the characteristics of the 21st Century Enterprise GeometricPLM will continue to offer integrated solutions in extended PLM space. GeometricPLM helps companies make their extended PLM vision a reality by aligning People, Process and Technology to enable Visibility, Interconnection and Collaboration across product development lifecycle. 3 Copyright 2017 HCL Technologies Limited

4 Content What is MBE? What is Configuration? Configuration Management vis-à-vis MBE Engine 2000cc Gas 1600cc Diesel 1200cc Gas Transmission 5MT 6MT 4AT Challenges & Some best practices Conclusion 4 Copyright 2017 HCL Technologies Limited

5 MBE Definition Model-based enterprise (MBE) is a term used in manufacturing, to describe a strategy where an annotated digital threedimensional (3D) model of a product serves as the authoritative information source for all activities in that product's lifecycle. [1][2] Source: Wikipedia Concept Engineering Manufacturing Production 1. Model Based Enterprise / Technical Data Package Summit Report. NIST Technical Note Retrieved 27 June Gupta, Isha. "3D Product & Manufacturing Information Implications for Design for Manufacturing". Product Design and Development. Advantage Business Media. Retrieved 28 June Maintenance Operation 5 Copyright 2017 HCL Technologies Limited

6 But, what are the implications of MBE in a typical product life cycle? 6 Copyright 2017 HCL Technologies Limited

7 The information in a model affects every facet of the enterprise across the lifecycle Feasibility Concept Engineering Production Operation Manufacturing xx xx xx xx Market Analysis RFx Tech. Studies xx xx Requirements Portfolio Prototype xx xx Plane Braking ABS Brake Disc Functional Design xx x x x xx BR17762B BR17762A Configurations xx Assembly Plan Viewpoint DMU Release, Mfg. ProcessLogistics xx xx Operations, Stations xx Service Bulletins, Tech Pubs Conceptual. BOM WIP BOM EBOM MBOM Production BOM As Built BOM Service BOM Technological Links, Tolerances Features Analysis, Compatibility, Technical Feasibility among variants S/W Weld points, Machining paths, Robot Programs Routing paths Assembly Process Mech. MODEL BIM Elec. Technical Publications Maintenance procedures Operational Telemetry The information in a model affects every facet of the enterprise across the lifecycle 7 Copyright 2017 HCL Technologies Limited

8 OK. But, what is Configuration? 8 Copyright 2017 HCL Technologies Limited

9 Configuration Definition con fig u ra tion The form, as of a figure, determined by the arrangement of its parts or elements Source: American Heritage Dictionary Source: U.S. Department of Transportation( 9 Copyright 2017 HCL Technologies Limited

10 Configuration Management The broader definition and focus of this paper In the interest of time, this presentation focuses on the following two aspects of CM There are many different types configurations(sales, Engineering etc.) and for the sake of the presentation, we will use them all together Engine 2000cc Gas 1600cc Diesel 1200cc Gas Transmission 5MT 6MT 5AT Destination China Europe USA Source: Department of Defense Handbook - MIL-HDBK-61A CONFIGURATION MANAGEMENT GUIDANCE Figure 4.1 Top level Configuration Management Activity Model 10 Copyright 2017 HCL Technologies Limited

11 Configuration burden on the Model in the context of Automotive Product Variants Product Variants Product and Features Product Line Model Feature Inclusions Exclusions Option Restrictions Type Defining Features Mutually Exclusive Options ModelType Modules Functional Group Sub-group Variant Usage Condition Module Variants Variant Assembly1 Variant Assembly2 Variant Assembly3 Parts Parts 11 Copyright 2017 HCL Technologies Limited 11

12 The configuration affects every product information across the lifecycle Feasibility Design to Target (Weight/Cost) Technical Feasibility among variants Concept Option based Geometry Jigs/Fixture Design Model based Configured Configured Technical Assembly Process Pubs Configured DMU Option based Tool Path Model based service Clash Management Configured Weld points instructions Modularization Temperature Telemetry Engineering Manufacturing Production Operation xx xx xx xx Market Analysis RFx Tech. Studies xx xx Requirements Portfolio Prototype xx xx Plane Braking ABS Brake Disc Functional Design xx x x x xx BR17762B BR17762A Configurations xx Assembly Plan Viewpoint DMU Release, Mfg. ProcessLogistics xx xx Operations, Stations xx Service Bulletins, Tech Pubs Conceptual. BOM WIP BOM EBOM MBOM Production BOM As Built BOM Service BOM Technological Links, Tolerances Requirements Mgt. Technical Feasibility among variants S/W Weld points, Robot Prog. MODEL BIM Mech. Elec. Machining paths, Routing paths Assembly Process Technical Publications Maintenance procedures Operational Telemetry The configuration of a model affects every facet of the enterprise across the lifecycle 12 Copyright 2017 HCL Technologies Limited

13 Model Model Based Enterprise Architecture and all the data that needs to be configure managed Engineering Manufacturing Service & After Sales Experience Requirements PDM BOM Sourcing Process Planning ERP Quality MES Warranty DMS Service CAD CAE Scheduling Compliance As-designed Events As-built Events As-serviced Events Physical Twin As-experienced Events Requirements Req Req Req Function Logical Physical Func Logical Part Func Logical Part Func V&V Data Acquisition Process Resource Schedule Routings Execution Performance Safety Reliability Process Resource Schedule Routing Execution Process Resource Schedule Execution Routing Execution Data Aggregation Digital Thread Platform I/IOT Platform Analytics Engine Cyber Security Product (Performance, Product Safety & Reliability) Value Chain Platform Engineering Supply Chain (DFx) Mfg. Supply Chain (QA) Dealer/Service Network Customer Network Low Fidelity Digital Twin Digital Twin Digital Twin High Fidelity The information in a model helps build the Digital Thread and all this information is configured 13 Copyright 2017 HCL Technologies Limited

14 All of this sounds like a lot of jargon Can you give me some examples??? 14 Copyright 2017 HCL Technologies Limited

15 Configured Model Based Styling Challenge Need three different shapes of Hood for different Destinations & Engines Proliferation of class A surfaces for different variations of the hood Expensive Cloud data to generate & test Costly re-work/maintain (almost) duplicates Solution 1. Breakdown hood into individually Configurable Class A surfaces 2. Manage, in PLM, option dictionary(engine, Transmission& their options), and their dependencies(mutually exclusive, inclusive ) 3. Attach configuration rules to Hood surfaces 4. Generate styling surface based on configuration 5. Configured DMU to build On demand model Hood Shapes Hood Config Rule1 Config Rule2 Config Rule3 Shape1 Shape2 Shape3 Hood Model (1600cc,China) MidHd1 Product modules, Options, and dependencies Engine Destination Transmission 1600 China 5MT 6MT Europe USA 5AT Shape1 MidHd1 MidHd3 Shape4 (1600cc,USA,5AT) MidHd3 Resolve and generate Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT Generate Surface for Destination=USA & Engine=1600cc&5AT) 15 Copyright 2017 HCL Technologies Limited

16 Configured feature based models Challenge Different fillets based on Engine Different labels based on destination Different positions of the hole based on Transmission 27 possible configurations of the model High cost of maintenance of duplicate models Solution 1. Build granular model with all possible features(ex: Different Labels, Holes ) 2. Attach configuration information at the Feature level(label bbbb if US Market ), Hole, or Fillet) 3. Build a Configured DMU methodology and specify which configuration parameters you want in the final model 4. PLM system builds model on demand depending on configuration parameters 27 Possible variations H1 H2 H3 Assembly c b a Configured holes and Configured Mfg. process f1 f2 f3 Product modules, Options, and dependencies Engine Destination Transmission China Europe USA 5MT 6MT 5AT Label:ccc Label: bb Label:aa.. Fillet: f1 Fillet:f2. Configuration rules Configured Fillet(3 variants) aaaaaa bbbb cccc Configured Labels & Configured Stamping Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT 16 Copyright 2017 HCL Technologies Limited

17 Configuration based Part Positioning( Option based geometry ) in the model Challenge Same fuel tank, in multiple positions based on configuration of truck, on the same chassis Solution 1. Design chassis modularly to hold fuel tank in different positions on the chassis 2. Define different holes on chassis based on different positions of fuel tank 3. Attach Configuration rule for every hole position(position1: if VNL400,6X4,70INCH, Position2: if VNL740,6X4,70INCH etc) 4. Attach every part instance of fuel tank with multiple positions per instance; one per configuration rule(like the holes above) 5. Use configured DMU to pick right positioning for the fuel tank and the holes 123 (VNL400,6X4,70INCH) (VNL740,6X4,70INCH (VNL860,6X4,70INCH) Fuel tank can be in positions based on configuration of chassis Multitude of possible truck configurations demand different fuel tanks on the same chassis 17 Copyright 2017 HCL Technologies Limited

18 Model based generative Technical Publications(User/Service Manuals) Challenge Despite information inside the model, costly creation of TechPubs for each Variant Constant changes to TechPubs pubs as design changes Lack of re-use & automation Solution 1. Break technical publications into granular elements 2. Link elements to the IP in the model 3. Configure the links with variant usage conditions 4. Generate tech pub «on demand» supplying needed variant options Relevant information dynamically extracted for each configurable components xx xx xx xx Techpub broken into configurable components xx xx Configure and generate Model Model Model Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT Generate user manual for XC model, 5AT, USA, GPS, LaneAssist, xxx,xxx,xxx Copyright 2017 HCL Technologies Limited

19 Configured workflow (100%) Feature based workflow (150%) Part/Feature Dependencies Model Based Change management of configurations Challenge High degree of engineering changes Invisible dependencies among models and their features ignored Late detection of changes costly Solutions: 1. Expose part to part (feature to feature) technical dependencies to PLM; indicating configuration rules 2. If any IP inside a model changes, let PLM examine the technical dependencies network and generate a change management configurable work flow 3. Use configuration parameters( 2000cc+5AT ) to let PLM generate needed workflow for a given product variant(model Type) Engineering Change Request for Change Caliper housing Rules Model Based Workflow generated by PLM Rules Technical links Brake shoe Piston1 Piston2 Piston3 Caliper housing Model Based Configured Workflow generated by PLM Caliper housing EC 7654FG542 Technical links Technical links Technical links Wheel hub Brake disc1 Brake disc2 Piston Boot Brake lining Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT 19 Copyright 2017 HCL Technologies Limited

20 Configure and Generate digital instrumentation panel from a software model Challenge 27 Possible variations of digital instrumentation panel definition to develop, change, store, revision, manage, and flash into the car ECU Highly complex, error prone Solutions: 1. Apply marketing and technical configuration rules and reduce possible variations 2. Breakdown software module for digital instrumentation panel into subcomponents to handle all possible variations(s/w BoM) 3. Configure the S/W BoM attaching variant designations(conditions) 4. Dynamically build the binary code for a given product (VIN)based on selected options Digital Instrumentation Panel Housing Software Model Dials Tach. Odo. Fuel. Speed Base. RedS. RedL. KMPH MPH AT 5 MT/6MT China/Europe USA Generate Redline depends on engine choice Engine 2000cc Gas 1600cc Diesel 1200cc Gas Digital Instrument Panel Module Transmission 5MT 6MT 5AT Resolve MPH/KPH depends on destination choice Destination China Europe USA AT gear selection depends on gearbox choice Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT Generate binary code for Engine:2000cc,De stination:usa, Transmission:5AT) 20 Copyright 2017 HCL Technologies Limited

21 MBE and Configured on-demand Digital Process Definition for Smart Factories for Industry 4.0 Challenge Manufacturing process steps, resources etc dependent on the configuration(plant, line, product variant etc) A separate Bill Of Process for each variant of an assembly will cause number of BOPs to grow exponentially Model Process Engine 2000cc Gas 1600cc Diesel 1200cc Gas Destination China Europe USA Transmission 5MT 6MT 5AT Configuration Rules Solution 1. Digitally model the 150% process associated to a product using configuration control on all process elements(steps, Welds, Tools, Instructions, OLP) 2. Extract manufacturing information from model into PLM and pass to digital manufacturing system(welds, materials, DMU, Tolerances etc) 3. Attach variant designations to manufacturing plans(partinstance tools, to OLP, to Process steps) 4. Generate manufacturing process on the fly based on configuration Request Engine 2000cc Gas 1600cc Diesel 1200cc Gas Transmission 5MT 6MT 5AT Destination China Europe USA Generate process flow & tools needed for Engine:2000cc,Destinatio n:usa, Transmission:5AT) 21 Copyright 2017 HCL Technologies Limited Generate L3 L

22 What you saw so far are only a small set to illustrate the idea. We can help with more Feasibility Design to Target (Weight/Cost) Technical Feasibility among variants MBE methodology Consulting Concept Option based Geometry Jigs/Fixture Design Model based Configured Configured Technical Assembly Process Pubs Configured DMU Option based Products: Tool Path GeometricEDGE for Model Digital based Thread service Clash Management Configured Weld points integrations instructions Modularization Temperature Telemetry Engineering Manufacturing Production Operation xx xx xx xx Market Analysis RFx Tech. Studies xx xx xx Requirements Portfolio Prototype xx Plane Braking ABS Brake Disc Functional Design xx x x x xx BR17762B BR17762A Configurations xx Assembly Plan Viewpoint DMU Release, Mfg. ProcessLogistics xx xx Operations, Stations xx Service Bulletins, Tech Pubs Conceptual. BOM WIP BOM EBOM MBOM Production BOM As Built BOM Service BOM Technological Links, Tolerances Products: Geometric DFM(Design For Mfg.) Features Analysis, Compatibility, Technical Feasibility among variants Weld points, Robot Prog. MODEL Machining paths, Routing paths Assembly Process Technical Publications Maintenance procedures Operational Telemetry The information in a model affects every facet of the enterprise across the lifecycle The configuration affects every product information across the lifecycle Products: MBE for manufacturing instructions 22 Copyright 2017 HCL Technologies Limited

23 Model Based Enterprise across product life cycle xx xx Feasibility xx xx Plane Braking BR17762B Assembly BR17762A Product variability drives the Design Plan complexity Brake Configurations Design Complexity goes into the Model xx x x x x x ABS Disc Viewpoint that drives the enterprise xx Design to Target (Weight/Cost) Technical Feasibility among variants Market Analysis RFx Requirements Tech. Studies Portfolio Prototype processes xx xx xx Concept Functional Design xx x x x xx xx DMU Release, Mfg. ProcessLogistics xx xx Operations, Stations xx Service Bulletins, Tech Pubs Conceptual. BOM WIP BOM EBOM MBOM Production BOM As Built BOM Service BOM Technological Links, Tolerances Features Analysis, Compatibility, Technical Feasibility among variants Option based Geometry Jigs/Fixture Design Model based Configured Configured Technical Assembly Process Pubs Configured DMU Option based Tool Path SUMMARY Model based service Clash Management Configured Weld points instructions Modularization Temperature Telemetry Engineering Manufacturing Production Operation Market demands necessitate Product Variability Enterprise processes, without configuration management of the model, proliferate the configuration complexity and make business inflexible and hard Weld points, Robot Prog. MODEL Machining paths, Routing paths Assembly Process Technical Publications Maintenance procedures Operational Telemetry Configure Manage the Model and thus the enterprise The information in a model affects every facet of the enterprise across the lifecycle The configuration affects every product information across the lifecycle 23 Copyright 2017 HCL Technologies Limited

24 24 $7 BILLION ENTERPRISE 110,000 IDEAPRENEURS 31 COUNTRIES