1. Rapid Product Innovation:
Improving Processes for Production System
Design, Implementation,
Design Implementation and Operations
Digital Manufacturing and
Collaborative Digital Automation
February 8, 2010
Greg Gorbach
Vice President
ARC Advisory Group
ggorbach@arcweb.com

2. Today’s Business Environment
Makes Innovation and Responsiveness A Necessity
A Turbulent Marketplace: Impact on Production:
Global Competition • Re-tool for new products
p
• Rapid Introduction of New
Customers have many alternatives Production Processes
Price pressure • More Automation
More products and variations needed • More Plant Software
More product info: Traceability, • Re tool to Reduce Energy &
Re-tool
Pedigree, Carbon footprint, etc. Emissions
• Re-Tool for Green Packaging
Consistently high quality is critical • Re-tool for more flexibility
Fast turnaround
Complex delivery terms and schedule
Green
Increasing Costs
Energy
Natural resources
Regulatory Pressure
Growing Climate Change Pressure
Other Environmental/Safety
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3. Today’s Product/Process Innovation Bottleneck
Product
Lifecycle
Physical
Production DESIGN BUILD OPERATE
System
For certain manufacturing segments (especially discrete and portions
of hybrid), introducing new products or improving the manufacturing
process usually requires creating or modifying production systems
Many production system problems are not discovered until late in the
design/implementation process, which introduces delays and cost
d i /i l t ti hi h i t d d l d t
Once in operation, virtual reference models, if available, could aid in
performance monitoring, process optimization, problem diagnosis,
operator training, and continuous improvement
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4. Limitations in Today’s Digital
Manufacturing and Automation Tools
Design Modeling/Simulation
Typically, many different design Product Component Physics-Based
and modeling environments are
g Mechanical
Design
3D Solid
Models
Component
Models
used. They often don’t integrate Mfg Systems Equipment Physics-Based
well. Mechanical
Design
3D Solid
Models
Equipment
Models
Limited tools have been Mfg Systems Queuing/
Process Network
available for designing and Design Models
simulating the implementation Chemical
Process
Energy &
Emissions
of control systems and devices, Model Model
and the behaviors of the control Product
Electrical
Product
Electrical
systems as they interact with es g
Design S u at o
Simulation
the electromechanical systems Inspection &
Test Systems
Inspection &
Test Systems
Design Models
Control Engineers need to be Mfg Systems Equipment
able to collaborate and interact Electrical Electrical
Design Models
with other manufacturing Mfg Systems Controls &
engineers and their models and Controls, Logic I/O
Emulation
Logic Design Models
systems Mfg Systems HMI & MES
Software Software
Design Models
Models/Simulations Can Improve
Design, Build, and Operate Phases
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5. Digital Manufacturing
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6. Developing Production Systems
Requires Parallel Engineering Activities
PRODUCTION PROCESSES
Industrial • Equipment Layout
Engineering • Queuing/Throughput
Models
• Human Factors Models
• etc.
Mechanical Electrical
El t i l
Design & Controls
Production
GEOMETRY System
y AUTOMATION SYSTEMS
• Mfg Equipment Design • Electrical & Wiring Design
• Mfg Equipment 3D Model(s) • Electrical & Wiring Models
• Controllers & Control Devices
• Controller & Control Device
Models
• Control Code
Virtual, Science
Science- • etc.
t
Based Modeling & BEHAVIORS
Simulation • Core Manufacturing Process
Models
• Equipment Modeling
• Kinematics
• Simulated Work Environments
• etc.
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7. Digital Manufacturing: Modeling and Simulating
Geometry, Processes, Behavior, and Automation
Digital Manufacturing & Production
PRODUCTION PROCESSES
Industrial • Equipment Layout
Engineering • Queuing/Throughput
Models
• Human Factors Models
• etc.
Digital
PROCESS
Mechanical Models Electrical
Design & Controls
Digital Collaborative
GEOMETRY Digital
(3D) ProductionAutomation
GEOMETRY System AUTOMATION SYSTEMS
• Mfg Equipment Design • Electrical & Wiring Design
• Mfg Equipment 3D Model(s) Digital • Electrical & Wiring Models
BEHAVIOR • Controllers & Control Devices
Models Controller & Control Device
• C ll C l i
Management & Integration Models
• Control Code
• Project Management Virtual, Science- • etc.
• Data Management Based Modeling & BEHAVIORS
• Portfolio Management Simulation • Core Manufacturing Process
• Connectivity Models
• etc. • Equipment Modeling
• Kinematics
• Simulated Work Environments
• etc.
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8. Digital Manufacturing: Model-Based
Development of Production Systems
Product
Lifecycle
Physical
Production DESIGN BUILD OPERATE
System
Concept & Design Validation and
Validation and Problem-Solving
Optimization through Start-up
System Design Models & Simulation Production System
Conveyor Robot Conveyor Robot Conveyor Robot
Digital CAD,
Simulation
Mfg etc
Environment
DEVELOP & USE USE & REFINE
Physical Production Cell
Virtual Models Virtual Models
Typical DM Scope
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9. Manufacturers Need Better Tools for
Digital Manufacturing and CDA
Production Systems
• Assembly Lines
• C
Conveyors
• Work Cells
• Safety Systems
• Packaging Lines Collaborative
• Batch Vessels Digital
• Power Plants Automation
• etc.
• All with Mechatronics:
• Electrical Systems & Wiring
• Controllers, Sensors &
Control Devices
• Plant Software, etc.
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10. Collaborative Digital Manufacturing (CDA)
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11. What is Collaborative Digital Automation?
The application of digital tools, simulation, and CDA
virtualization to the process of developing,
p p g,
implementing, and operating production systems
Especially involving the interaction of control devices
a d sys e s
and systems with the electromechanical co po e s
e e ec o ec a ca components
that constitute the production system
Design Virtual Simulation Physical System
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12. Collaborative Digital Automation (CDA)
in the Design – Build Phases
DESIGN VALIDATE IMPLEMENT
Manufacturing Process, Process, Interference, Build, Test, & Deploy
System, & Components Kinematics, Controls, etc. Physical System
Software Design Software System Software System
alidate Physic Installation
n
Visibility Visibility Visibility
EMI EMI
Execution Execution
Execution MES MES
Controls Controls Controls
Interface Interface HMI Interface HMI
Control Control
ign
Control Logic Virtual Controller Logic Controller Logic
cal
CDA
Validate & Optimize Desi
Electrical Design Electrical Model Electrical System
Sensor I/O Block Drive Sensor I/O Block Drive Sensor I/O Block Drive
O
missioning: Va
Safety HOA MCC Safety HOA MCC Safety HOA MCC
Mechanical Design Mechanical & Mechanical System
Environmental Model
Virtual Comm
Conveyor Robot Conveyor Robot Conveyor Robot
CAD,
Simulation V
etc
Environment
Production Cell Design Virtual Production Cell Physical Production Cell
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13. Collaborative Digital Automation (CDA)
is an immature but rapidly developing space
Processes Software &
Human Interfaces
Collaborative
Geometry Live Production
Digital
Systems
A t ti
Automation
i
Virtual Simulation Other Systems
Electrical & Wiring Model Execution Logic
Control Devices Models MES/CPM Configuration
I/O Emulation Virtual Commissioning
Control System Design Connectivity to:
Control Logic • Process Models
• Geometry Models
Controller Code
• Simulations
Controller Emulation
C ll l i • Mgmt & Integration
HMI Configuration etc.
Standards, Libraries Tools
Standards Libraries, Tools,
Interoperability, etc. Are Needed
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14. Virtual Production Systems
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15. Virtual Production System
Extend Digital Mfg to Operations
Virtual Physical
Design Production
Production
Systems System System
Execution &
Visibility S/W
Interface
• Performance Deviations
• Optimization
• Process Improvements • Diagnose Problems
• Problem Resolution • Operator Training
• Alternate Designs • Maintenance Activity Modeling
• etc • etc
Product Data Process Data Product Data Process Data
Metrology Faults Metrology Faults
Quality Throughput Quality Throughput
Inspection Shift Data Inspection Shift Data
Signoffs CAPA Signoffs CAPA
Etc. Etc. Etc. Etc.
Asset Data Material Data Asset Data Material Data
Maintenance Supplier Quality Maintenance Supplier Quality
Cycle Count Inventory Levels Cycle Count Inventory Levels
Etc. Rejections Etc. Rejections
NCR NCR
Etc. Etc.
Virtual Results (As- Actual Manufacturing
Designed & Simulated) Results & As-Built
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16. DM, CDA, and VPS
Model-Based Development & Operation of Production Systems
Product
Lifecycle
Physical
Production DESIGN BUILD OPERATE
System
Production System
Concept & Design Validation and
Simulation Enables
Validation and Problem-Solving
Continuous
Optimization through Start-up
Improvement
Virtual
Production
System
Digital
Manufacturing
(DM)
DEVELOP & USE USE & REFINE USE & EXTEND
Virtual Models Virtual Models Virtual Models
Collaborative
Digital
Automation Digital Manufacturing and CDA
(CDA)
• Steady State Design • Virtual Commissioning • Performance Deviations
• Dynamic Simulation
D i Si l ti • Diagnose Problems
Di P bl • Optimization
O ti i ti
• Design Optimization • Process/System Validation • Diagnose Problems
• etc • Operator Training • Operator Training
• etc • Maintenance Activity Modeling
• etc
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17. Issues Faced by Users
There are lots of different pieces involved, it’s hard to
know how to proceed
p
How do I get to the point where I can re-use things -
such as models and control code – for equipment that I
use frequently?
eque y
What will we encounter when we start down this road?
What don’t we know?
Integration and Interoperability
What are the costs? What are the benefits?
Etc.
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18. Issues Faced by Suppliers
How to persuade manufacturers to try CDA apps
• Seems complicated, risky, and costly
complicated risky
• Who drives buying decision?
How do I justify creating device models and solution
components?
t ?
• Is the market ready?
• Can I afford NOT to participate at this stage - will that
effectively cede the market to others and negatively impact
my automation business?
Etc.
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19. Summary: Key Points
Digital Manufacturing is becoming more important in
creating competitive advantage
g p g
ARC advocates extending Digital Manufacturing to the
Operating phase (Virtual Production System)
Collaborative Digital Automation (CDA) unlocks the
true potential of Digital Manufacturing
Digital
Digital PROCESS
Models
Manufacturing
& Production Digital Collaborative
GEOMETRY Digital
(3D) Automation
CDA
Digital
BEHAVIOR
Models
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20. Digital Manufacturing With CDA Helps
Create Competitive Advantage
Enterprise
Products
Equipment
Processes
Engineering Operations
Digital
Mfg
Digital
Automation
Collaborative Solutions for Digital
Automation are Beginning to Emerge
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21. Thank You
For more information, contact the author at
ggorbach@arcweb.com or visit our web pages at
www.arcweb.com
www arcweb com
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