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ARC's Dick Slansky's PLM with Shop Floor Operations Presentation at ARC's 2008 Industry Forum
- 1. Integrating PLM with Shop Floor
Operations:
Validating As-Built to As-Designed
Dick Slansky
Senior Analyst
ARC Advisory Group
dslansky@arcweb.com
- 2. 2
© ARC Advisory Group
Evolution of the Design/Build Process
90s
Integration of Production
Process Design and Shop
Floor Operations
80s 2000 2008…..
3D
Digital Mockup
Digital Manufacturing
3D User Experience
2D
TechnologicalAdvance
Design, Simulation,
& Validation of
Manufacturing
Processes
- 3. 3
© ARC Advisory Group
Today’s PLM: Holistic Approach to Product & Process
• Product, Processes, & Resources have become
“Virtualized”: 3D Experience from Concept to Customer
• PLM Scope has expanded: Design/Build has become
Design/Simulate/Validate/Automate/Build
• PLM Solution Sets Interface with most Enterprise Business
Solutions: ERP, SCM, EAM
• Digital Manufacturing Solutions Extend Virtual
Manufacturing Processes to the Factory Floor
• Integration of PLM with Operations Mgmt Validates the
As-Built to the As-Designed
• Validation of As-Built Product Closes Loop between the
Virtual Build and the Physical Build
- 4. 4
© ARC Advisory Group
0% 10% 20% 30% 40% 50% 60% 70%
3D CAD
Product Data Mgmt (PDM)
Project/Program Mgmt
Parts Fabrication (CAM)
Product Test (CAE)
Mfg Process Mgmt (MPM)
Knowledge-Based Engr. (KBE)
Digital Manufacturing
2D CAD
Service/Support/Content Mgmt
What PLM Solutions Companies are Using
Growing Adoption Rate
- 5. 5
© ARC Advisory Group
0% 10% 20% 30% 40% 50% 60% 70%
Mfg Process
Definition/Creation
Process Planning
Production Mgmt/Shop
Floor Execution
Workcell/Production Line
Simulation & Validation
Automation & Controls
Simulation & Validation
Not Important
Somewhat Important
Important
Essential to MPM/Digital Mfg
What is the Importance of Digital Mfg & Shop
Floor Operations Requirements?
- 6. 6
© ARC Advisory Group
Manufacturing Planning
• Define High-Level Manufacturing Processes
• Process Planning (Assembly & Installation)
• Define Work Instructions & Work Flow
Detailed Process Design & Analysis
• Detailed Resource Modeling & Simulation
• Process Definition and Validation
• 3-D Factory Layout
• Equipment, Tool & Fixture Simulation
• Ergonomic Simulation
Validation & Virtual Commissioning
• Control Logic Simulation & Validation
• Kinematic (Robotic) Simulation & Validation
• Quality Assurance/Process Improvement Validation
• Sensor/Metrology Placement Validation
• Virtual Commissioning & Validation of Automation Systems
• Knowing that the Production System Works Prior to
Launch: Priceless.
Digital Manufacturing Covers the
Entire Build Process
3D
3D
- 7. 7
© ARC Advisory Group
Digital Manufacturing Enables Product &
Process Validation
• Product Design (CAD) tools
are used to define “What" is
to be built
• Manufacturing Process
Design tools are used to
define “How" it is to be built
• Integration of Product &
Process Design directly
supports concepts such as
Concurrent Engineering &
Mfg Process Validation
Digital Manufacturing facilitates the Holistic
view of Product and Process Design as integral
components of the overall product life cycle
- 8. 8
© ARC Advisory Group
Integration of PLM and Shop Floor Operations
Enables Validation of the As-Built Product
Managing the Manufacturing Process
Integration of Product Design with Mfg Processes (Digital Mfg)
Enables Production Management & Shop Floor Execution to be
Integrated with the PLM Solution Set
Manufacturing Process Design coupled with Digital Mfg
Simulation Integrates the Definitions of the
Product, Processes, Factory, and Resources into a
Comprehensive and Consistent Manufacturing Solution
Manufacturers want a more direct and horizontal integration
between their PLM/PDM design/build environment and their
shop floor operations. PDM Integration with ERP is not bi-
directional
- 9. 9
© ARC Advisory Group
Shop Floor Systems Should be an Extension of PLM
Manufacturing
Processes
Product Lifecycle Processes
Create
Processes
Plan
Processes
Simulate & Validate
Processes
Execute
Processes
Digital Manufacturing Solutions + MES
As – Built RecordsEngineering Design
Validate
Design Simulate Automate BuildValidate
- 10. 10
© ARC Advisory Group
Tailored Work Package
• Process Configuration
• Work Instructions
• Work Flow Routing
• Operations Scheduling
• Shop Floor Requirements
• WIP Tracking
• Process Control
• Quality Assurance
• Labor/Parts/Tooling
PLM Integrated with Shop Floor Execution
PLM
Process
Creation
Product
Design
• E-BOM
• M-BOM
• Bill of Process
• Product Config.
Maintenance
& Support
“As Designed”
Product Data
Production Mgmt
Shop Floor
Execution
(MES)
“As Built” Records
“As Designed”
Process Data
ERP
- 11. 11
© ARC Advisory Group
Closing the As-Built to As-Designed Loop
FEEDBACK LOOP: Operations Mgmt/PDM Integration
Product & Process
Reqmts: As-
Designed
Simulation Analysis Validation Execution
(Build)
Knowledge:
As-Built Records
Manufacturers Want to Know they are Building
the Product they Designed
- 12. 12
© ARC Advisory Group
CAD
Product Design
Process Models,3D
Simulations, Work Order
Instructions
Process
Execution
Shop Floor Execution (MES)
Quality
Assurance
Unit Data &
Work History
Data Vault
3D Models
E-BOM Process
Modeling
Digital Manufacturing/MPM
Process
Simulation & Validation
Process
Planning
Inventory
Mgmt
Work Orders
Release & Status
Financials
Invoicing Shipping
Labor
Reporting
Receiving
Parts
Purchasing
ERP
Production
Scheduling
Work Order
Release
Work Order
Status
Material /
Parts
Job Sign
On/Off
Digital Mfg + Shop Floor Execution = Validation
of As-Built to As-Designed
Closing the Loop From As-Built
Records To As-Designed
Master Routings, M-BOM
E-BOM
PDM
Product Data Management
Collaborative
- 13. 13
© ARC Advisory Group
What are Manufacturers Using for OM/MES
Today and Plan to Use in the Future
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%100%
In-house developed custom solutions
Vertical Industry Solutions from
OM/MES application providers
OM/MES solutions from Automation
provider
OM/MES solution from ERP provider
OM/MES solutions from PLM provider
OM/MES solutions from Supply Chain
Mgmt provider
Current
Future
- 14. 14
© ARC Advisory Group
At What Stage are Manufacturers with PLM-
OM/MES Integration
0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50%
Operations/Inspection Records Interface
with some Engr/Business Systems
Operations/Inspection records do not
Interface with any Engr/Business Systems
Have some limited connection between
Work History (Operation/Inspection)
records and PLM/PDM
Have basically closed the loop between As-
Built and As-Designed
Have an accessible Data Repository for
Operations/Inspection (As-Built) records
Best Practice
- 15. 15
© ARC Advisory Group
0% 10% 20% 30% 40% 50% 60% 70% 80%
Work Flow Routing
Work Order (WIP) Tracking
Quality Assurance Mgmt
Operations & Inspection Records
Production Data Acquisition
Product Tracking & Tracing
Tooling Mgmt
Future
Currently
What Shop Floor Operations Interface with
your Engineering/PLM Solutions?
- 16. 16
© ARC Advisory Group
What Business & Engineering Systems do your
Operations & Inspection Records Interface with?
0% 10% 20% 30% 40% 50% 60%
ERP
PDM (As-Designed Source)
Other (In-House Systems, etc.)
SCM
CRM
Best Practice
- 17. 17
© ARC Advisory Group
Effective & Efficient Use of Digital Mfg & OM
Tools: Guidelines for Users
Integrate Use of DM Tools into the Manufacturing Design Process
• Set and Implement guidelines for application of DM technology
• Provide DM training for Mfg Engineering Discipline & Resources
Emphasize Re-use & Commonality
• Re-use dependent on a strategy of Common Process design
Reuse of Virtual Processes is a Key Enabler
Establish a Library of virtual production systems & equipment
• Use modular approach for efficient use of Virtual Simulation
Establish basic Virtual Production Equipment building blocks
Build Virtual Production Systems with Common Virtual Equipment
Integrate DM Tools with Shop Floor Operations
• Virtual Models Developed & Maintained by multiple engineering
disciplines (Product, Manufacturing, Tooling, Controls)
• Use Latest Production Process Data for Virtual Simulations
- 18. 18
© ARC Advisory Group
Thank You.
For more information, contact the author at
dslansky@arcweb.com or visit our web pages at
www.arcweb.com