HMIs Direct the Manufacturing Process

Transcription

1 s Direct the Manufacturing Process Chris Anderson ATK Sr. Manufacturing Analyst Bill Baker ATK Sr. Software Engineer October 1, 2014 ATK is a registered trademark of Alliant Techsystems Inc. 1

2 Mobile App: Please take a moment Check into Session by: Select Detailed Schedule Select the specific session Click on Check in Take Session Survey by: Select Detailed Schedule Select the specific session Scroll Down to Survey and Provide Feedback 2

3 Agenda About ATK Discuss the evolution of s Concept Stage Prototype Stage Release Stage Continuous Improvement Tangible Benefits Reduced (Eliminate) Errors Reduced Process Time Review Really Cool s Process Flow System Interfaces s 3

4 ATK at a Glance- They Made Me Do it Headquartered in Arlington, VA, with approximately 16,000 employees $4.8B in sales and $5.8B orders Company/customer funded R&D $750M More than 60 facilities in 22 states, Puerto Rico and Internationally Representatives in more than 50 countries throughout the world Last 18 months: acquired Savage Arms and Bushnell Other U.S. Government 10% U.S. Air Force 4% U.S Navy 10% NASA 9% U.S. Army 20% Sales by Contract Type Prime Contractor 62% Results are for the fiscal year ended March 31, 2014 Sales by Customer Commercial/ International 47% Sub- Contractor 38% Aerospace Group Defense Group Sporting Group 4

5 About ATK Our Place Aircraft Commercial Center of Excellence (ACCE) Located in Clearfield, Utah Anchor Programs: Airbus A350 / A400M and Roll- Royce Floor Space: 615,000 sq ft 100,000 sq ft Clean Room Capacity 15,000 sq ft Office Space 2,500 sq ft Freezer Capacity Automated Stiffener Forming Capacity Automated Linear Stringer Machines Automated Radial Frame Machines Engine Case Wrap Capacity CNC Milling Machine Capacity Large Diameter Autoclave Capacity NDI Systems - Automated Ultrasonic Inspection (AUIS) Water Jet and Machining Capacity Hot Drape Forming 5 MANUFACTURING AREA

6 About ATK Our Place Freeport Composite Center Located in Clearfield, Utah Anchor Programs: Boeing 787 and Lockheed Martin F-35 Floor Space: 403,000 sq ft Clean Rooms Fiber Placement Machines Case Wrappers Ovens CNC Milling Machines Lathes Autoclaves Automated Ultrasonic Inspection Systems (AUIS) ASFM Machines Pattern Cutter Leica Measurement Systems Laser/Radar Measurement Systems Virtek Projection Systems 6 MANUFACTURING AREA

7 In the Beginning 7

8 Concept Stage - Shop Floor and MFG Systems Goals 1. Keep current MES ish Systems 2. Talk to Shop Floor machines 3. No sneaker-net PLM epic Engineering Desk PC Solumina / Impresa EWI & MRP Oracle 10g Oracle 10g Control PC Solumina Shop Floor PC Shop Floor Machine Barcode Scanner 8

9 Concept Stage - PLM, EWI, Control PC epic Part Program - Name - Revision - Location Engineering Desk PC Solumina Work Order - Part Program - Name - Revision Control PC Machine Designation Part Programs Output Files Output Reports 700+ Part Numbers 9

10 Prototype Stage 10

11 Prototype Stage Take One Machine controls say take a hike Use EWI for interface epic Oracle 10g Engineering Desk PC Solumina / Impresa Oracle 10g ATK network MFG subnet Control PC Part Files MS Win MFG File Server Solumina Shop Floor PC Barcode Scanner Shop Floor Machine 11

12 Prototype Stage Take Two Bug machine controls until they give in Use Local DB for interface epic Oracle 10g Part Files MS Win MFG File Server Control PC Engineering Desk PC ATK network MFG subnet Machine Specific MS SQL Express Solumina / Impresa Oracle 10g Solumina Shop Floor PC Barcode Scanner Shop Floor Machine 12

13 Prototype Stage Let s Go into Production Take Three IT states we re nuts Starting to panic Go with it anyhow Machine Specific Engineering Desk PC Machine Specific Machine G Machine A Machine Specific Solumina / Impresa Machine Specific Machine F Machine B Machine Specific Machine Specific Machine D Machine Specific Machine E 13 Machine C

14 Release Stage Release the Kraken 14

15 Release Stage First Big Tweak Single SQL Server for multiple machines Process Specific s Engineering Desk PC epic Oracle 11g Part Files MS Win MFG File Server MS SQL Server ATK network MFG subnet Machine Solumina / Impresa Oracle 11g Control PC - UI/Interface Wrapper - SQL Calls Solumina Shop Floor PC Barcode Scanner Shop Floor Machine 15

16 Release Stage - s Tool Prep Vacuum Bag 16

17 Release Stage - s Open WO Vacuum Timer Material Usage 17

18 Continuous Improvement There was an engineer, manager and programmer driving down a steep mountain road. The brakes failed and the car careened down the road out of control. Half way down the driver managed to stop the car by running it against the embankment barely avoiding going over a cliff. They all got out, shaken by their narrow escape from death, but otherwise unharmed. The manager said "To fix this problem we need to organize a committee, have meetings, and through a process of continuous improvement, develop a solution." The engineer said "No that would take too long, and besides that method never worked before. I have my trusty pen knife here and will take apart the brake system, isolate the problem and correct it." The programmer said "I think you're both wrong! I think we should all push the car back up the hill and see if it happens again." 18

19 Continuous Improvement Cool Integration Add one heaping batch of Web Services epic InfinityQS (SPC) Engineering Desk PC Oracle 10g MS SQL Server Web Server Web Services Solumina / Impresa Oracle 10g Part Files MS Win MFG File Server - UI/Interface Wrapper - Web Services OAT RFID SQL Server Shop Floor Machine or Control PC Machine 19 Manual Station Barcode or RFID Scanner MS SQL Server

20 Continuous Improvement Sustainable s Control PC - UI/Interface Wrapper 20

21 Continuous Improvement Off the Shelf TC Mapping Solumina epic SOA Platform (Apache Tomcat, Microsoft IIS Webservers) EMS InfinityQS Visual Action Board ArchestrA System Platform MPM-01 ASFM-L04 BAG CAC-01 MC-11 AUIS-7 TOOL PREP ASFM-R02 CART LOAD CART UNLOAD DIM-03 COV-01 21

22 Continuous Improvement OMP TC Mapping EMS Visual Action Board Solumina epic InfinityQS OMP Manufacturing Information Bus ArchestrA System Platform MPM-01 ASFM-L04 BAG CAC-01 MC-11 AUIS-7 TOOL PREP ASFM-R02 CART LOAD CART UNLOAD DIM-03 COV-01 22

23 Now for the good stuff 23

24 Tangible Benefits Failures w/o 24

25 Tangible Benefits Failures w/ 25

26 Tangible Benefits Failures Detail 26

27 Tangible Benefits Cycle Time Improvements 27

28 Tangible Benefits Cycle Time Details 28

29 Review 29

30 s Process Flow 3- Vacuum Bagging Process 1- Tools Arrive Start Tool Prep Process 2- Part Forming Machine Conveyors 30

31 s System Interfaces 31

32 Tool Prep - Start Operation 32

33 Tool Prep Scan Tool to Retrieve WO Scanned tool Applicable work orders 33

34 Tool Prep Perform Work Required Materials Material location on tool Required Software 34

35 Tool Prep Material Usage Consumed Materials 35

36 Vacuum Bag - Start Operation 36

37 Vacuum Bag Scan Tool Scanned tool Applicable work orders 37

38 Vacuum Bag Open WO & Perform Work Graphical Representation of part Software Detail Required Caul 38

39 Vacuum Bag Scan Cauls Cauls Scanned 39

40 Vacuum Bag Vacuum Test Timer Vacuum Timer 40

41 Vacuum Bag Complete Operations All Operations Completed 41

42 Q & A Please be gentle 42