Digital Twin Digital Thread in Aerospace David Riemer Unrestricted Siemens AG 20XX Realize innovation.
Siemens Focus is to Enable Excellent Performance on Every Program Program Execution Excellence Fully support a Model Based Enterprise, Digital Twin Digital Thread to better meet cost, technical and schedule program goals Provide pre-configured technology to focus on the automation of specific A&D value streams to provide a potential competitive advantage Page 2 Leverage the smart innovation Portfolio to enable product knowledge & definition to be shared to improve performance in production, support and future bids
Industry 4.0 What Is It? The history of the industrial revolution Industry 4.0 Mechanical loom End of 18th century 1. Industrial revolution Introduction of mechanical production plants using water and steam power Siemens single-phase generator End of 19th century 2. Industrial revolution Introduction of mass production based on the division of labor using electrical energy 1970 Programmable Logic Controller 3. Industrial revolution Introduction of electronics and IT to increase the level of automation 2015-2020 4. Industrial revolution Intelligent automation and integration of physical & virtual world Page 3 An industrial revolution was always driven by new enabling technologies
Industry 4.0 Defining the way forward in industry in the internet age Page 4
Why Hasn t the Digital Age Yielded the Benefits Expected? What s the difference? No difference Page 5
Digital Thread Maturity Why Hasn t the Digital Age Yielded the Benefits Expected? Digitize Digitalization Where is Your Organization? Digitize Digitize Problem Digitalization Not only is the Today physical the world digital virtually information verified prior we to store design, is not connected process, tooling, any of etc. the commitment inputs or requirements all the inputs, outputs making and it difficult process to used fully to create understand the information a proposed are change. completely traceable. A&D has unique product life spans that require full traceability Digital Twin Maturity Page 6
Digital Thread Creating the Digital Twin Program Plan and Execution Systems Physical MCAD Structure As-tested Customer SOW Functions Regulatory Work Pkg. Logical ECAD MBOM As-built Design Schedule Architecture BOP As-maintained Build Cost Verification Page 7
Program Execution Excellence Value Stream Solutions Generate Competitive Advantage Program Execution Excellence Value Streams on the Smart Innovation Portfolio Systems Driven Product Development Integrated Prog. Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and OPTIMIZATION & INNOVATION A systems driven product development approach to leverages system and 3D models from idea thru support. MEETING COST, SCHEDULE AND TECHNICAL REQUIREMENTS A systems approach to project planning a fully planned, resourced,budgeted and executed program management solution. EFFICIENT FIRST TIME RIGHT Design with advanced materials, integrated CAD/CAE, maximize reuse, advanced configuration management. EFFECTIVE SUPPLIER MANAGEMENT Enabling traceability from OEM requirements to suppliers. Proactive supplier management. FASTER TIME TO CERTIFICATION Enabling traceability from requirements thru virtual and physical test to ensure product verification. MEETING COST & PRODUCTION GOALS Shift left manufacturing planning to ensure cost, schedule & safety goals are achieved with fully integrated factory. INTEGRATE SERVICE WITH THE FACTORY Design for support. Plan for support. Manage service planning. Closed loop support with manufacturing and design. Page 8
Program Execution Excellence Using world class capabilities to generate business value Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 9 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Program Execution Excellence Systems Driven Product Development Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 10 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Connected and Integrated Data Digital Thread Digital Twin Systems Simulation Physical Customer Regulatory Design Build Function Logical Architecture Verification Behaviour Reliability CAE Manufacture Support MCAD ECAD Assembly MBOM Process As-tested As-built As-maintained Benefit: Ability to completely trace a requirement through the design to the shop floor Provide the knowledge base to manage the product throughout its extended life(~>40 years) Complete and thorough change management Absolutely know ALL the impacts of a proposed change Page 11
The Reliability Digital Thread Environmental Usage Architecture Mission Reliability System Reliability Economic Service Life Design Process Control (CP k ) Fault Isolation No-Fault Found Mean Time to Repair Page 12
MADe how it supports the V End-item System Component Design Component Verification System Verification End-item Verification Failure Hazard Fault Tree Common Cause * Failure Hazard Preliminary Fault Tree Common Cause * Logical Architecture Preliminary Fault Tree Common Cause * Physical Hardware Update Fault Tree Common Cause * Failure Mode & Effects Summary Failure Mode & Effects Update Fault Tree Common Cause * Failure Mode & Effects Summary Failure Mode & Effects Update Fault Tree Common Cause * Also includes: Teamcenter Integration RAM tools Prognostics & Health tools Page 13
WHY ALM + PLM Each domain has unique needs ALM Each solution provides unique benefits EE PLM Embedded ALM+PLM Hardware PLM Design dependencies cross domains Customers require engineering synergy Domain expertise needs to be seamlessly integrated Page 14 PLM & ALM must work in unison to address product development demands
Systems Driven Product Development Integrated ALM + PLM Product Line Multi-Domain Lifecycle Domain Traceability and Configuration Domain Realization Decomposition Teamcenter Traceability of physical requirements to the BOM Physical Lifecycle Intelligently assess the impact of requirements or design changes Teamcenter ALM Connector for Teamcenter Ensure requirements are met from design through manufacturing & service Systems Architecture and Modeling Systems Level Impact Traceability of software requirements to test cases, work packages and code ALM (Ex: Polarion) Intelligently assess the impact of requirements or design changes Ensure requirements are met from design through coding, testing build & release Lifecycle Page 15
Program Execution Excellence Integrated Program Planning and Execution Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 16 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Integrated Program Planning and Execution Only Integrated Solution Program Digital Thread Phase 1 Catalyst Late fall 2016 Process uses a Common WBS to organize all bid/program information Bases on set of criteria applied to the Common WBS a Program WBS is created Work Package includes requirements, processes, inputs, deliverables, logical, functional and physical architectures Complete support for Integrated Master Plan, Integrated Master Schedule and third party EVMS systems Complete configuration management of all program artifacts IPP&E Process diagram Page 17
Organize Common and Program Around WBS Totally Integrated and Traceable IMP Milestone Functional Element IMP Accomplishment Product Element Logical Element IPT IMP Criteria WBS Element Program / Contract Contract Modification Functional Organization Deliverables Functional Work Package CLIN Employee CDRL Process Cost Risk / Opportunity Risk / Opp Cost Cost Other Direct Travel Page 18
Program Execution Excellence Supplier Source Selection and Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 19 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Supplier Source Selection and Solution Description Change source selection from document manual process to electronic requirements based Provide traceability to contract or company requirements Change supplier management from re-active ad-hoc to proactive process based Integrate supplier schedules with program schedule Since the Executive Council Meeting Initial process diagram complete Big Block diagram in work Ready for customer vetting Page 20
Program Execution Excellence Verification Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 21 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Current Verification Documentation is Segmented and Disconnected between Virtual and Physical Environments Test Planning Test Request Page 22 Virtual As-Designed Test Article Instrumentation As-Analyzed Test Article As-Analyzed Test Procedure Test Article Build Physical Test Article As-Tested Test Data Test Execution Solution Description Integrated requirements verification management process Complete traceability of all artifacts Tie production ebom to test article ebom for rapid change impact awareness Manage test article configurations Ensure analysis models are based on latest design model Status Process diagram complete Big Block diagram complete Customer vetting complete V1.0 Catalyst deployed customer installed V1.1 Catalyst development Release in April Enhanced verification by analysis Supports A&D template doc centric
Verification Closed Loop to Compliance Qualification Digital Thread Virtual Production As-Designed Production As-Analyzed Test Article Build Physical Test Article As-Tested Test planning Test article Test article As-analyzed Test Data CORRELATE Test request Test Procedure Test Execution Page 23
Program Execution Excellence Product Realization Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 24 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Product Realization to Digital Thread Solution Description Full end to end process Focus on driving manufacturing requirements into Concept to Build Concurrent maturing of manufacturing processes, tooling, plant layout with design maturity Simple effective as-engineered to as-built for delivery assurance Closed loop process ensures continuous improvement Design reviews are not just of product but also manufacturing processes, tooling, planning drive concurrent development Since the Executive Council Meeting Process diagram complete Big Block diagram complete Initial customer vetting complete Page 25
Program Execution Excellence Product Support Planning and Smart Innovation Portfolio Digital Enterprise Foundation Smart Ideation Smart Realization Smart Utilization Capabilities Industry Value Streams Page 26 As-designed BOM Reporting and Analytics Model Based Systems Configuration and Change Mgt 1D / 3D Simulation and Test Mechanical Design Model Based Definition Electrical and Electronics Design IP Protection and Export Control Advanced Aerostructure Design Reliability and System Safety Document (CDRL/SDRL) Supply Chain Collaboration Schedule, Cost & Risk MBOM and Bill of Process Automation Design & Commissioning 3D Electronic Work Instructions Part 3D Massive Model Visualization CAM / Tooling / Fixtures End-item Delivery (DD250 or Airworthiness) Material and Compliance Execution Operations Plant Design & Optimization Assembly Advanced Quality ERP Integration Systems Driven Product Development Integrated Program Planning and Execution Product Design Supplier Source Selection and Verification Product Realization Product Support Planning and Technical Publications (S1000D) Logistics Support Spares Definition and Condition of Supply Obsolete Planning As-Maintained BOM Simulation Ergonomic Optimization Failure Reporting & Corrective Action GSE/EGSE Design Service Bulletins Field Experience Feedback MRO Integration
Digital Thread in Product Support Planning and Execution Design and Development Testability Reliability Maintainability Supportability Customer Logistics Support Support Concept Environment & Operational Supply Support Technical Data Training and Training Equipment Personnel Support Equipment Infrastructure Plan Page 27
The Digital Enterprise Connecting to Digitalization Cornerstones A Digital Enterprise uses transformative technologies to drive significant improvements in efficiency and agility + The Siemens Digital Enterprise Suite is built on classleading PLM, MOM & Automation portfolios The Teamcenter Collaboration platform underpins the Digital Enterprise and : Drives inter-departmental collaboration Synchronizes Suppliers and Customers Coordinates the network of production facilities The rock-solid, bulletproof automation technology for Speed, Reliability, Safety, Security and Sustainability Page 28
Digital Enterprise Suite - The Siemens answer to Industry 4.0 requirements Page 29
Summary Digital Twin provides virtual verification of the product and process Digital Thread ties critical information to its inputs, processes and outputs Siemens provides a unique solution set for Industrie 4.0 and the digital-thread / digital-twin Siemens is a hardware manufacturing company using our solutions to deliver customer value Page 30