Dallas, Texas / May 18-21, Welcome

Transcription

1 Dallas, Texas / May 18-21, 2015 Welcome Realize innovation.

2 Zvika Weissman / SPLM SW / MFG. Eng. SW Solutions / A&D Industry Lead Aerospace & Defense Manufacturing - Right the First Time Realize innovation.

3 Manufacturing Engineering SW Solutions - a SPLM SW Product Segment Tecnomatix & NX CAM - real solutions for manufacturing Page 3

4 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 4

5 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 5

6 Aerospace and Defense Trends Difficult business climate Declining Defense and Space Spending Worldwide decline in spending U.S. defense spending 5X more than #2 nation Sequestration: U.S. defense budget is still ~$1.5 Trillion Growing Commercial Aircraft Backlog Pressure on supply chain Talent development knowledge management Quality and safety Technology innovation Complex Global Business Dynamics International suppliers, risk sharing partners and customers Import/export regulations Environmental regulations Increased competition Poorer Program Performance All major aircraft programs have cost overruns, schedule delays: 40% of programs over budget 25%+ $296B overrun on $1,600B portfolio 2-year delay to initial operation GAO reports for US DoD Page 6

7 Manufacturing Engineering Concerns How am I going to ensure that my part suppliers work according to the standards I have requested? How will we meet the timeline for start of production if the product design has not been released yet? Why don t we see product features that were defined by the product designers? Page 7

8 Manufacturing Engineering Concerns For our next major product, how can we plan for a fast launch, without finding major issues during ramp-up? How can we make sure that all of the product parts will actually be assembled on the shop floor? How do we make smarter make vs. buy decisions? Page 8

9 Shop Floor Concerns How do I know that I am using the most up-todate process information on the shop floor? How can we reduce scrap and lower inventory on the shop floor? How do I escalate a process problem to the engineering team and ensure a timely response? Page 9

10 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 10

11 Build & Operate the Factory of the Future Using Industry 4.0 concepts 1 Product and Production Design Reducing time to market by the integration of both processes 2 Production Network Flexible supply chains with cross-company just-in-time decisions 3 Cyber-Physical Systems Flexible production based on modular, autonomous production units Page 11

12 What If You Could Access All This Information, Up to Date, Anywhere in the Enterprise? Page 12

13 Maximize Production Facilities Utilization By implementing collaborative manufacturing concepts Product Design Manufacturing Engineering Production Bridge the gaps with the platform Page 13

14 Our Vision - the Digital Twin Be the Digital Twin of the Production System Process planning and engineering Production system planning and engineering Simulation, optimization and validation Towards a fully synchronized Virtual-Real world Page 14

15 Deliver On Time & Quality By shifting left manufacturing engineering activities Cost $ Goal is to SHIFT LEFT Perform manufacturing planning activities earlier Cost of change Investment Engineering Release Concept Design Plan Validate Build Launch Page 15

16 Maximize Production Facilities Utilization By leveraging lean manufacturing concepts 7 Inappropriate Processing 1 Over Production 2 Unnecessary Stock Page 16 6 Rejects & Defects 5 Waiting Times 4 Unnecessary Motion 3 Inefficient Transportation

17 Siemens PLM SW - A&D Mission and Vision Program Execution Excellence Empower our customers to develop product requirements and engage in a collaborative design & analysis environment. Capture full product and process knowledge to drive the production process to ensure that our customers develop and produce the right product; Designed and built right the first time and every time on-schedule and at cost. Page 17

18 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 18

19 The Bill of Process (BOP) Define the complete manufacturing process Routing and sequence Product and material consumption Tool usage Process duration Documents Manufacturing requirements Page 19

20 Manufacturing Bill of Material (mbom) & Bill of Process (BOP) Definition ebom mbom Top Level mbom Center Assembly BOP Lower Assembly Upper Assembly Product Designer Manufacturing Engineer Page 20

21 Product Manufacturing Information (PMI) Leverage PMIs from product design to shop floor Downstream processes leverage the PMI defined in the model PMI mapping from NX to TC, supporting change cycle Assignment of PMIs to inspection operations Definition of shop floor data collection Page 21

22 Process Time Management & Analysis Customized and industrial data cards Classification Setup/Execution, Manual/Automated Calculation of Batch production Time equations Page 22

23 Validate the Planned Shop Floor Processes 3D Simulation with Process Simulate Collaborative multi-user digital mockup (DMU) platform, enabling 3D simulation, analysis and documentation of manufacturing processes Assembly Human Robotics & Automation Process Simulate Teamcenter Manufacturing Process Planner Page 23

24 Automated Airframe Assembly Design, management & simulation Product Design Structural Change Request Joint Design Update Process Planning Design Release Design Verification Simulation Post Processing Work Instruction Page 24

25 Typical Robotics Applications Supported Deburring Blade Polishing Pick-n-Place Arc Welding Page 25

26 Engineering Package the virtual engineering deliverables Release to Manufacturing Execution Page 26

27 Manufacturing Feed the shop floor execution Page 27

28 Engineering / Manufacturing Collaboration Through integrated environment Page 28

29 TC Electronic Work Instructions (EWI) An intuitive shop floor viewer Integrated as part of the engineering change cycle More visual, less textual Easy shop floor access to a configured content Straightforward content update mechanisms Page 29

30 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 30

31 Advanced Automation Using a Cobot (Cooperative Robot) E.g. dual arm robot Page 31

32 Hybrid Manufacturing 3D printing of real parts Page 32

33 Robotic Machining NX CAM robotics Program, simulate, and post tool path for industrial robots within NX CAM. Tight loop between part modeling, part programming, robotic information, simulation, and post processing Integrated with Teamcenter Page 33

34 Easily Layout Your Plant NX-based manufacturing layout solution, integrated with TC Production system design from early requirements to production Re-usable best-practices/libraries, synchronized across PLM Same environment for product, tool and production system design Page 34

35 How REAL Is Your Shop Floor Info? Hybrid environment combining virtual & real worlds Scan the plant and visualize it Hybrid Plant Model Mixing scanned data with CAD data for feasibility studies Updating 3D layout to match plant installation Pre-study of a new model Redesign directly on scanned data Dynamic simulation of how the product moves through the plant Page 35

36 How Green Is Your Plant? Lower energy costs and carbon footprint Digital Factory Master Facility Model Digital Factory Facility Physical Factory Facility Factory Equipment Plan Energy Commissioning Production Equipment Plan Factory & Equipment Model Equipment consumption Automation and Sensors Example Energy Data Types for Planning and Monitoring Facility Information Equipment Information Plan & Predict Monitor & Report Energy Prod./Dist. Energy consumption Lighting Boilers/Chillers/HVAC Air Compression Water Consumption Hydraulic Consumption CO2 Emission Optimize Energy Consumption Optimize Energy Price Integrate Optimization of Production With Energy What if simulations (Discrete Event Simulation) Reduced Energy Cost Increased Sustainability Compliance Page 36

37 Leverage Emerging Technologies in the Shop Floor E.g. work instructions in Google Glass Page 37

38 Avner Ben-Bassat, President & CEO, Plataine Technologies Composites Material Tracking, Planning & Cutting Optimization for the A&D industries Realize innovation.

39 Plataine: Intelligent Automation, Mobility and the IoT Push the Productivity Envelope in Manufacturing Global install base and market recognition: A&D OEMs and Tier-1 customers, including: GE Aviation, General Atomics, Hitco, IAI, SpaceX JEC Innovation Award for Software 2014 (JEC encompasses 550,000 composite industry professionals worldwide) Siemens PLM Foundation Partner Core Solution: IoT driven, Context Aware Software Optimization Cloud Based, SaaS Offering Bridging the gap between ERP, PLM/CAD and shop-floor systems Patent Protected, based on Algorithms in development since 1991 Immediate, tangible and measurable ROI: Proven 3% - 8% Savings in raw material Increased throughput & reduced labor costs Improved quality and quality control Page Plataine Ltd. All Rights Reserved For Authorized Use Only

40 Core Problem Addressed by Plataine s TPO System: Business, production and engineering teams operate separately; systems are loosely integrated ERP Order & Inventory Management Production Floor Software (MES) PLM/CAD & other Engineering Tools The Result An inflexible production plan with poor visibility and costly changes: Slows reaction time and extended lead times Wastes resources: time, labor and material Produces excess WIP and raw material Inventory Puts quality & customer satisfaction at risk Page Plataine Ltd. All Rights Reserved For Authorized Use Only

41 Step 1: Guarantee Visibility and Control on the production floor, leveraging RFID to automatically track inventory and assemblies Cutting Machine Layup Autoclave IR/RF Part ID Station Time Kit # Autoclave Cutting Layup freezer 13:55 08:35 11:58 13:04 14:17 10:12 Kit # Cutting Layup Freezer Autoclave 14:17 11:58 15:01 10:12 13:04 13:55 Kit # Freezer Layup Autoclave Cutting 15:01 15:22 11:58 13:04 13:55 14:17 Kit # Layup Autoclave Cutting Freezer 15:22 16:18 13:04 13:55 14:17 15:01 Kit # Autoclave Cutting Freezer Layup 16:18 15:22 17:43 13:55 14:17 15:01 Kit # Freezer Cutting Layup Autoclave 17:43 15:22 18:20 14:17 15:01 16:18 Kit # Cutting Layup Autoclave Freezer 18:20 18:36 15:22 15:01 16:18 17:43 Kit # Layup Autoclave Freezer Cutting 18:36 15:22 18:59 16:18 17:43 18:20 Kit # Freezer Autoclave Cutting Layup 18:59 18:36 19:17 16:18 17:43 18:20 Kit # Page Plataine Ltd. All Rights Reserved For Authorized Use Only Autoclave Cutting Layup Freezer 19:17 18:36 19:42 17:43 18:20 18:59 Plataine tracks mobile assets such as raw material, WIP, tools and assemblies, in addition to classic use of tracking machines (stationary units) on the factory floor

42 Wealth of Information Can Be Integrated to Enterprise Systems for Reporting, Auditability and Traceability Material utilization Customer order planning Labor reporting Roll sq feet Roll sq feet TPO Suite Reporting CW CW ERP (Inventory, management HR and Accounting), PLM (Costing, Planned/Actual, ERP Physical HR & to Accounting Virtual) Page Plataine Ltd. All Rights Reserved For Authorized Use Only Backend systems

43 Step 2: Alert & Optimize A rich digital context is the basis for context-aware software, generating real time alerts and optimization Plataine takes a HOLISTIC approach to consider all elements of the problem at once ERP MES Customer Requirements Inventory on hand Product Design (Parts, Geometry) Integrated Optimization, taking a holistic view Production Orders - WHICH Order will be processed - WHEN - With WHICH Material - using WHICH machine -.. CAD Production Floor Production Situation & Constraints Page Plataine Ltd. All Rights Reserved For Authorized Use Only Production Alerts

44 Example #1 Composites Management and Utilization Optimization: Plataine s real time context-awareness escalates alerts for human intervention and take automatic, optimized action Roll/Kit ID Lot # Material Type Location in Freezer Temp Roll Length Remaining Out Time (hrs) Expiration Date Roll # Carb Fbr B12-22c 42m 53 Mar 15, 2015 Kit # C7-24c 153 Apr 8, 2016 Roll # Gls Epoxy D13-18c 7.2m Optimized 33 Action Apr 22, 2015 Roll # Gls Fbr A3 4c 13.2m 72 May 8, 2015 Kit # 6198 Roll # E11-24c Software automatically 114 May 16, 2016 Roll # 6892 Remaining 567 Shelf Carb Fbr Life: 20 A9 hrs -24c 2.2m allocates Roll 187 #4698 to next May 25, 2015 Kit # D19-24c production 29 job, before it expires Jun 6, 2015 Roll # Gls Fbr C16-24c 50m 63 Jun 9, 2016 Roll # Carb Fbr B3-4c 22.1m 158 Jun 18, 2015 Roll # Gls Epoxy C14-24c 4.3m 22 June 29, 2015 Page Plataine Ltd. All Rights Reserved For Authorized Use Only

45 Example #2 Optimized Cut-Planning: Given full production schedule, BOM integration and tool availability in real time, Plataine s software automatically optimizes production & material yield Default approach: producing each job separately requires of material Part # #100 #200 #300 Tool ID T-1000 T-2000 T-3000 Total length: (in.) Length: (in.) (in.) (in.) Optimized Approach: combining all 3 jobs yields 19.47% material savings, reduces labor #100 #200 #300 Total Material used for all 3 job combined: Page Plataine Ltd. All Rights Reserved For Authorized Use Only

46 Example #3 Assembly: Real-time tracking, plus ERP & PLM (BOM) integration create rich context and triggers Plataine alerts and action Order #100, Part ID 2487 is missing for assembly Page Plataine Ltd. All Rights Reserved For Authorized Use Only

47 Plataine / Teamcenter Manufacturing Integrated Product 3 Use Cases: 1. Process planning & simulation 2. Dynamic Production Planning 3. Real-Time Information Feedback to TPO and Teamcenter Page Plataine Ltd. All Rights Reserved For Authorized Use Only

48 Plataine s Production Optimization For TCM - Integrated product optimizes composites raw material usage CAD / Fibersim Part Design Teamcenter Manufacturing (incld. EWI) Technical Package Process Planning Work Instructions Optimized Package Kits design Material restrictions Teamcenter Optimizer Bridge TPO Total Production Optimization Cut time Material utilization planned vs actual Reported issues Inventory selection Dynamic nests Raw material inventory Order data Actual work order data Used material Issues Actual cut time ERP MES Orders Optimized Order Data Cut & Kit Instructions Page Plataine Ltd. All Rights Reserved For Authorized Use Only

49 SPLM Solutions and Plataine TPO: Target Users and Workflow Design the Product Materials Engineering Product Designer Materials Engineer Production Manager Shop floor Operator Optimize, Execute and Track Production Manufacturing Process Planning Manufacturing Engineer Prototype Demo Movie Legend: Teamcenter Manufacturing TPO NX/Fibersim Page Plataine Ltd. All Rights Reserved For Authorized Use Only

50 Use Case 1: Process Planning & Simulation TCM user simulates planned processes with TPO TCM Manufacturing Engineer Plataine TPO Seamless Integration Identify relevant parts Kit Design TPO estimates material and cut time Choose composites simulation and approve Required material and cut time TPO creates view in TCM Plan the manufacturing process Page Plataine Ltd. All Rights Reserved For Authorized Use Only

51 Use Case 2: Dynamic Production Planning TPO retrieves latest controlled product information from TCM MES (Shop Floor) Machine Operator TPO TPO-User TCM (Seamless Integration) TPO creates dynamic nests and cut path TCM holds kit design BOM components Kit design Produce Dynamic nests and cut path Page Plataine Ltd. All Rights Reserved For Authorized Use Only

52 Use Case 3: Real-Time Information Feedback to TPO and Teamcenter Allows Planned vs. Actual reporting, revised planning MES (Shop Floor) Machine Operator Plataine TPO Seamless Integration TCM Manufacturing Engineer Reporting Actual material utilization, cut time TPO updates material inventory and reports Planned vs actual, reported issues View composites process Actual material utilization, cut time, issues Page Plataine Ltd. All Rights Reserved For Authorized Use Only

53 Benefits on Plataine/SPLM integrated offering Increased automation, flexibility and accuracy of manufacturing-planning: what-if simulations and cost-estimations Increased automation and improved quality control in manufacturing: seamlessly integrating (version controlled) product design and manufacturing process data to the manufacturing floor, including cutting, kitting and other work instructions Improved material yield and reduced labor costs leveraging Plataine TPO algorithms and optimization approached Feedback loop from production (Plataine) to planning (TCM): planned vs. actual analyses Page 54

54 Summary 1. Siemens PLM SW is providing solutions, helping to integrate different groups within an organization 2. The TPO solution is modular - standalone / integrated 3. A Prototype of integrating Plataine TPO to Teamcenter Manufacturing is being worked-out First Beta customer shared A&D customer Page Plataine Ltd. All Rights Reserved For Authorized Use Only

55 Agenda Opportunity Our Vision Our Solution Innovation Summary Page 56

56 Siemens A&D Product Realization Executive summary Enabling a dramatic increase in on time / quality product realization Product Realization Integrating product, process, tools and production plants for smoother production Plan the production process, using production best practice Validate and optimize production process, before sending it to the shop floor Carry-on product requirements from product design, through manufacturing engineering, up to production. Page 57

57 Stay Connected!! Enhance your conference experience. PLM World App Like our page! Tecnomatix & NX for Manufacturing Explore advanced manufacturing. Manufacturing 360 App Join the online community. Tecnomatix Community NX Manufacturing Forum Page 58

58 Presenters Contact Zvika Weissman A&D Industry Lead, Siemens PLM SW Avner Ben-Bassat President & CEO, Plataine Technologies Realize innovation. Page 59

59 Thank you. See you next year! Realize innovation.