Plan the Aerospace & Defense Factory of the Future

Transcription

1 Plan the Aerospace & Defense Factory of the Future Zvika Weissman, MFE / Industrial Enterprise Solutions Director PLM Europe, October 30 th, 2018 Realize innovation.

2 Agenda Manufacturing digitalization Siemens A&D product realization solution Summary Page 2

3 Digitalization / Digital Transformation of A&D companies Why? To increase the product capabilities To empower employees To increase efficiencies To establish the factory of the future To improve operation performance Page 3

4 Digitalization / Digital Transformation of A&D companies How Nominate a chief digital officer function Build a digital strategy business case Simplify the IT backbone (many times, a patched one) Deploy the key (new) enabling technologies Connect the entire value chain - internal & external Equip employees with new IT solutions and devices to help them be more efficient, and minimize their none-value added activities in their daily operation Page 4

5 Key Technologies Enabling Digitalization Page 5

6 Key Technologies Enabling Digitalization Some countries simply treat this as the fourth industrial revolution Page 6

7 Driving the Digital Enterprise Industrie the next industrial revolution / evolution 1 st Industrial Revolution Water and steam 2 nd Industrial Revolution Electricity, mass production 3 th Industrial Revolution Automation 4 th Industrial Revolution Digitalization Characteristics Technologies Production network Augmented reality Big Data and analytics Autonomous robots Simulation Fusion of virtual and real world Additive manufacturing e.g. 3D printing Horizontal/vertical software integration Cyber-physical systems Cloud Industrial Internet (network of hardwareintegrated sensors) Cyber security Sources: BITKOM, BCG Page 7

8 Agenda Manufacturing digitalization Siemens A&D product realization solution Summary Page 8

9 Digitalize the Product Realization Process An opportunity for aerospace & defense companies Type certificate FCA CDR PDR Digitalize your manufacturing by leveraging a digital thread of data from product design to manufacturing, to create a SRR SDR CONCEPT DESIGN BUILD PRR Production certificate digital twin of your production facilities and processes. REQUIREMENTS DELIVER Libraries, Templates, Docs Checklists Airworthiness certificate PCA Page 9

10 Digital Thread - Connected and Integrated Data Connect the entire value chain - internal & external Requirements Systems Engineering Simulation Engineering Manufacturing Physical Customer Function Behaviour MCAD Assembly As-tested Reliability Regulatory Logical MBOM As-built ECAD CAE Design Architecture Manufacture Software Process As-maintained Build Verification Support Page 10

11 The Production Digital Twin Enables to shift left (execute earlier) activities, by virtually planning and simulating a production line A physical, commissioned production line, and the virtual digital twin simulated with Siemens PLM SW tools Page 11

12 Bill of Process (BOP) The future factory foundation A logical structure that defines the complete manufacturing process Routing and sequence Product and material consumption Tool usage Process duration Manufacturing requirements Inspection plan Relevant documents Page 12

13 Plan Your Future Factory 3Dprint a composite winglet Wing subassembly Winglet manufacturing Composites Inspection DESIGN Wing assembly Wing paint Assembly docs creation Page 13 BUILD

14 Composite Winglet 3D Printing A breakthrough is an option! Definition of robotic paths, to buildup the structure. Advanced OOTB multi-axis deposition algorithms for efficient path planning. Material deposition simulation for thorough process validation. Page 14

15 Plan Your Future Factory Inspect the composite parts for deficiencies Wing subassembly Winglet manufacturing Composites Inspection DESIGN Wing assembly Wing paint Assembly docs creation Page 15 BUILD

16 Ultrasonic Wing Composite Quality Inspection Virtual commissioning & robotics simulation Definition of robotic paths, to include a pattern of inspection points. Complex workcell, which mandates a PLC to synchronize the devices, and control safety interlocks. Definition of the inter-devices signals logic. Page 16

17 Plan Your Future Factory Attach the wings to the fuselage Wing subassembly Winglet manufacturing Composites Inspection DESIGN Wing assembly Wing paint Assembly docs creation Page 17 BUILD

18 Wings Assembly (Attachment to Fuselage) Process & tools validation Kinematics definition of all shop floor tools and jigs. Collision avoidance and ensuring safety distance is kept, while moving large objects. Simultaneous human-tool simulation enables realistic validation Page 18

19 Walk and Explore Your (Virtual) Factory Leverage virtual reality Realistic 3D navigation through the manufacturing process Walk through the plant, and ensure the manufacturing process is feasible. Train manufacturing & maintenance people. Page 19

20 Process Simulate Virtual Reality Teleport Measure Flashlight Play Simulation Highlight Move Objects Guide Robot Page 20

21 Plan Your Future Factory Paint the airplane Wing subassembly Winglet manufacturing Composites Inspection DESIGN Wing assembly Wing paint Assembly docs creation Page 21 BUILD

22 Wing Paint Automate, autonomous Validation of paint and surface coating processes. Robot can be mounted on an external axis (or AGV). Mesh creation for consistent paint pattern. Thickness coverage simulation. Page 22

23 Bring the Tool to the Product The future factory will include mobilized tooling & AGVs Page 23

24 Flexibility Doesn t Mean Reduced Safety Advanced robot and Cobot (cooperative robot) Page 24

25 Plan Your Future Factory Create visualized shop floor work instructions Wing subassembly Winglet manufacturing Composites Inspection DESIGN Wing assembly Wing paint Assembly instructions Page 25 BUILD

26 Up-to-Date, Animated, Templated Work Instructions Leverage augmented reality & smart wearable devices Configured, templated and animated work instructions Guidance and validation of assembly work through digital projection on physical data (AR) Page 26

27 Up-to-Date, Animated, Augmented Work Instructions Leverage smart wearable devices Configured, templated and animated work instructions Guidance and validation of assembly work through projection of digital data, on physical data (AR) Page 27

28 SistAR Teamcenter augmented reality work instruction solution SistAR presents a new use of augmented reality technology to support the assembly, maintenance and inspection processes Content - RealityBOP package, streamlined from Teamcenter Setup AR Work Instructions Assembly Validation Acknowledge SistAR utilizes a seamless connection to the PLM system, and guides the user through the assembly process. The solution is based on Compedia PointAR technology Page 28

29 Service Lifecycle Management Service Asset Management As-Built record of assets As-Maintained life history of assets Part movement and utilization Service Planning Standardized definitions of service requirements, work cards and activities Define necessary resources and measurements Extend use of PLM data items Service Work Instructions Deliver instructions at point of service Capture actions by technicians Flexible mobile platform Page 29

30 Agenda Manufacturing digitalization Siemens A&D product realization solution Summary Page 30

31 Key points to remember Manufacturing digitalization is key to survive, not a nice to have Industry 4.0 concepts lead you through the technology domains Digitalization can be a confusing journey partner selectin is a key. Page 31