ARC's Greg Gorbach Rapid Product Innovation Presentation @ ARC Industry Forum 2010
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Rapid Product Innovation: Improving Processes for Production System Design Implementation and Design, Implementation, Operations ARC's Greg Gorbach Rapid Product Innovation Presentation @ ARC Industry Forum 2010 in Orlando, FL. 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. 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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ARC's Greg Gorbach Rapid Product Innovation Presentation @ ARC Industry Forum 2010
- 1. Rapid Product Innovation: Improving Processes for Production System Design Implementation and Operations Rapid Product Innovation: Improving Processes for Production System Design Implementation and OperationsDesign, Implementation, and OperationsDesign, Implementation, and Operations Digital Manufacturing and Collaborative Digital AutomationCollaborative 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 Today’s Business Environment Makes Innovation and Responsiveness A Necessity A Turbulent Marketplace: Global Competition Impact on Production: • Re-tool for new productsGlobal Competition Customers have many alternatives Price pressure More products and variations needed p • Rapid Introduction of New Production Processes • More Automation • More Plant Software • Re tool to Reduce Energy &More product info: Traceability, Pedigree, Carbon footprint, etc. Consistently high quality is critical Fast turnaround • Re-tool to Reduce Energy & Emissions • Re-Tool for Green Packaging • Re-tool for more flexibility Complex delivery terms and schedule Green Increasing Costs EnergyEnergy Natural resources Regulatory Pressure Growing Climate Change Pressure 2 © ARC Advisory Group Other Environmental/Safety
- 3. Today’s Product/Process Innovation BottleneckToday’s Product/Process Innovation Bottleneck Product Lifecycle For certain manufacturing segments (especially discrete and portions DESIGN BUILD OPERATE Physical Production 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 d i /i l t ti hi h i t d d l d tdesign/implementation process, which introduces delays and cost Once in operation, virtual reference models, if available, could aid in performance monitoring, process optimization, problem diagnosis, operator training, and continuous improvement 3 © ARC Advisory Group
- 4. Limitations in Today’s Digital Manufacturing and Automation Tools Limitations in Today’s Digital Manufacturing and Automation Tools Physics-Based Component Models Product Mechanical Design Component 3D Solid Models Design Modeling/Simulation Typically, many different design and modeling environments are ModelsDesign Models Physics-Based Equipment Models Mfg Systems Process Design Queuing/ Network Models Mfg Systems Mechanical Design Equipment 3D Solid Models g used. They often don’t integrate well. Limited tools have been available for designing and Chemical Process Model Product Electrical Design Product Electrical Simulation Design Models Energy & Emissions Model available for designing and simulating the implementation of control systems and devices, and the behaviors of the control systems as they interact with Mfg Systems Electrical Design Equipment Electrical Models es g S u at o Inspection & Test Systems Design Inspection & Test Systems Models systems as they interact with the electromechanical systems Control Engineers need to be able to collaborate and interact with other manufacturing Mfg Systems Controls, Logic Design Controls & Logic Models Mfg Systems Software Design HMI & MES Software Models I/O Emulation with other manufacturing engineers and their models and systems 4 © ARC Advisory Group Models/Simulations Can Improve Design, Build, and Operate Phases
- 5. Digital ManufacturingDigital Manufacturing 5 © ARC Advisory Group
- 6. Developing Production Systems Requires Parallel Engineering Activities Developing Production Systems Requires Parallel Engineering Activities PRODUCTION PROCESSES • Equipment Layout • Queuing/Throughput Industrial Engineering • Queuing/Throughput Models • Human Factors Models • etc. El t i lMechanical Engineering GEOMETRY AUTOMATION SYSTEMS Production System Electrical & Controls Mechanical Design • Mfg Equipment Design • Mfg Equipment 3D Model(s) • Electrical & Wiring Design • Electrical & Wiring Models • Controllers & Control Devices • Controller & Control Device Models • Control Code t y Virtual, Science- • etc. BEHAVIORS • Core Manufacturing Process Models • Equipment Modeling • Kinematics • Simulated Work Environments Virtual, Science Based Modeling & Simulation 6 © ARC Advisory Group Simulated Work Environments • etc.
- 7. Digital Manufacturing: Modeling and Simulating Geometry, Processes, Behavior, and Automation Digital Manufacturing: Modeling and Simulating Geometry, Processes, Behavior, and Automation Digital Manufacturing & Production PRODUCTION PROCESSES • Equipment Layout • Queuing/Throughput Models • Human Factors Models • etc. Industrial Engineering Mechanical Design Electrical & Controls Digital Digital PROCESS Models Collaborative GEOMETRY • Mfg Equipment Design • Mfg Equipment 3D Model(s) AUTOMATION SYSTEMS • Electrical & Wiring Design • Electrical & Wiring Models • Controllers & Control Devices C ll & C l i Production System GEOMETRY (3D) Digital BEHAVIOR Models Digital Automation • Controller & Control Device Models • Control Code • etc. BEHAVIORS • Core Manufacturing Process Models Virtual, Science- Based Modeling & Simulation Models Management & Integration • Project Management • Data Management • Portfolio Management • Connectivity 7 © ARC Advisory Group Models • Equipment Modeling • Kinematics • Simulated Work Environments • etc. • etc.
- 8. Digital Manufacturing: Model-Based Development of Production Systems Digital Manufacturing: Model-Based Development of Production Systems Product Lifecycle DESIGN BUILD OPERATE Physical Production System Concept & Design Validation and Validation and Problem-SolvingValidation and Optimization Problem-Solving through Start-up System Design Models & Simulation Production System Digital Mfg RobotConveyor CAD, etc RobotConveyor Simulation Environment RobotConveyor Mfg USE & REFINE Virtual Models DEVELOP & USE Virtual Models Environment Physical Production Cell 8 © ARC Advisory Group Typical DM Scope
- 9. Manufacturers Need Better Tools for Digital Manufacturing and CDA Manufacturers Need Better Tools for Digital Manufacturing and CDA Production Systems • Assembly Lines C• Conveyors • Work Cells • Safety Systems • Packaging Lines • Batch Vessels • Power Plants Collaborative Digital Automation • etc. • All with Mechatronics: • Electrical Systems & Wiring • Controllers, Sensors & Control Devices • Plant Software, etc. 9 © ARC Advisory Group
- 10. Collaborative Digital Manufacturing (CDA)Collaborative Digital Manufacturing (CDA) 10 © ARC Advisory Group
- 11. What is Collaborative Digital Automation?What is Collaborative Digital Automation? The application of digital tools, simulation, and virtualization to the process of developing, CDA p p g, implementing, and operating production systems Especially involving the interaction of control devices and systems with the electromechanical componentsa d sys e s e e ec o ec a ca co po e s that constitute the production system Design Virtual Simulation Physical System 11 © ARC Advisory Group Design Virtual Simulation Physical System
- 12. Collaborative Digital Automation (CDA) in the Design – Build Phases Collaborative Digital Automation (CDA) in the Design – Build Phases DESIGN Software Design IMPLEMENT Software System Manufacturing Process, System, & Components Build, Test, & Deploy Physical System VALIDATE Software System Process, Interference, Kinematics, Controls, etc. n Execution Visibility Controls Interface Control Logic MES EMI Execution Visibility HMI Controls Interface Controller Control Logic MES EMI Execution Visibility HMI Controls Interface Virtual Controller Control Logic ign calInstallation CDA I/O BlockSensor Drive Electrical Design I/O BlockSensor Drive Electrical System I/O BlockSensor Drive Electrical Model OptimizeDesi alidatePhysic CDA Safety MCCHOA Mechanical Design Safety MCCHOA Mechanical System Safety MCCHOA Mechanical & Environmental Model Validate&O missioning:Va RobotConveyor RobotConveyor CAD, RobotConveyor Environmental Model Simulation VirtualComm 14 © ARC Advisory Group Production Cell Design Physical Production Cell CAD, etc Virtual Production Cell Simulation Environment V
- 13. Collaborative Digital Automation (CDA) is an immature but rapidly developing space Collaborative Digital Automation (CDA) is an immature but rapidly developing space Collaborative Digital A i Processes Geometry Software & Human Interfaces Live Production Systems Collaborative Digital A t ti Electrical & Wiring Model Execution Logic Automation Virtual Simulation Systems Automation Other Systems Electrical & Wiring Model Control Devices Models I/O Emulation Control System Design Execution Logic MES/CPM Configuration Virtual Commissioning Connectivity to:Control System Design Control Logic Controller Code C ll l i Connectivity to: • Process Models • Geometry Models • Simulations Controller Emulation HMI Configuration • Mgmt & Integration etc. Standards Libraries Tools 15 © ARC Advisory Group Standards, Libraries, Tools, Interoperability, etc. Are Needed
- 14. Virtual Production SystemsVirtual Production Systems 16 © ARC Advisory Group
- 15. Virtual Production System Extend Digital Mfg to Operations Virtual Production System Extend Digital Mfg to Operations Physical Production Virtual Production Design System Production System Execution & Visibility S/W Interface Systems Interface • Performance Deviations • Optimization • Diagnose Problems • Operator Training • Maintenance Activity Modeling • etc • Process Improvements • Problem Resolution • Alternate Designs • etc Metrology Quality Inspection Signoffs Product Data Faults Throughput Shift Data CAPA Process Data Metrology Quality Inspection Signoffs Product Data Faults Throughput Shift Data CAPA Process Data Signoffs Etc. CAPA Etc. Maintenance Cycle Count Etc. Asset Data Supplier Quality Inventory Levels Rejections NCR Material Data Signoffs Etc. CAPA Etc. Maintenance Cycle Count Etc. Asset Data Supplier Quality Inventory Levels Rejections NCR Material Data 17 © ARC Advisory Group NCR Etc. Actual Manufacturing Results & As-Built NCR Etc. Virtual Results (As- Designed & Simulated)
- 16. DM, CDA, and VPS Model-Based Development & Operation of Production Systems DM, CDA, and VPS Model-Based Development & Operation of Production Systems Product Lifecycle Production System Simulation Enables DESIGN BUILD OPERATE Physical Production System Concept & Design Validation and Validation and Problem-Solving Continuous Improvement Virtual Production Validation and Optimization Problem-Solving through Start-up USE & EXTEND Production System Digital Manufacturing (DM) USE & REFINEDEVELOP & USE USE & EXTEND Virtual Models • Steady State Design D i Si l ti • Virtual Commissioning Di P bl • Performance Deviations O ti i ti Virtual ModelsVirtual Models Collaborative Digital Automation (CDA) Digital Manufacturing and CDA 18 © ARC Advisory Group • Dynamic Simulation • Design Optimization • etc • Diagnose Problems • Process/System Validation • Operator Training • etc • Optimization • Diagnose Problems • Operator Training • Maintenance Activity Modeling • etc
- 17. Issues Faced by UsersIssues Faced by Users There are lots of different pieces involved, it’s hard to know how to proceedp 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?use eque y What will we encounter when we start down this road? What don’t we know? Integration and InteroperabilityIntegration and Interoperability What are the costs? What are the benefits? Etc. 19 © ARC Advisory Group
- 18. Issues Faced by SuppliersIssues Faced by Suppliers How to persuade manufacturers to try CDA apps • Seems complicated risky and costly• Seems complicated, risky, and costly • Who drives buying decision? How do I justify creating device models and solution t ?components? • 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. 20 © ARC Advisory Group
- 19. Summary: Key PointsSummary: Key Points Digital Manufacturing is becoming more important in creating competitive advantageg p g ARC advocates extending Digital Manufacturing to the Operating phase (Virtual Production System) Collaborative Digital Automation (CDA) unlocks theCollaborative Digital Automation (CDA) unlocks the true potential of Digital Manufacturing Digital Manufacturing & Production Digital PROCESS Models & Production Digital GEOMETRY (3D) Digital BEHAVIOR Collaborative Digital Automation CDA 21 © ARC Advisory Group BEHAVIOR Models
- 20. Digital Manufacturing With CDA Helps Create Competitive Advantage Digital Manufacturing With CDA Helps Create Competitive Advantage Enterprise Products Enterprise Products Equipment Processes Engineering Operations Digital Digital Mfg Automation Collaborative Solutions for Digital 22 © ARC Advisory Group Collaborative Solutions for Digital Automation are Beginning to Emerge
- 21. Thank YouThank You For more information, contact the author at ggorbach@arcweb.com or visit our web pages at www arcweb com 23 © ARC Advisory Group www.arcweb.com