A novel approach for product lifecycle management of mechatronic equipment in SME

1. Investigação e Desenvolvimento Tecnológico | Transferência e Valorização de Tecnologia | Formação Avançada
Consultoria | Pré-incubação de empresas de base tecnológica
Daproduçãodeconhecimentoàinovaçãodebasecientífica
PLM4all
T7.1 – Promoção e Divulgação de Resultados
Marco 20
Anexo 21
2015-06-30

2. FAIM 2015
23-26 June ∙ University of Wolverhampton
Flexible Automation & Intelligent Manufacturing
25th International Conference ∙ Wolverhampton ∙ UK
PLM4all
A novel approach for product lifecycle management of
mechatronic equipment in SME
António Correia Alves (INESC TEC)

3. FAIM 2015
23-26 June ∙ University of Wolverhampton
Table of Contents
1. Introduction
2. PLM4all Approach and Concept
3. Conclusions

4. FAIM 2015
23-26 June ∙ University of Wolverhampton
1. Introduction
Mechatronic Equipment Lifecycle
• With the advent of the
“information age”, the
sophistication of mechatronic
equipment has increased
exponentially.
• Full life cycle management of
mechatronic equipment has
become very complex:
– large amount of components and
systems involved
– high number of agents that
interact with the product.
Mechatronics is a multidisciplinary
field of engineering that includes a
combination of mechanical
engineering, electrical engineering,
telecommunications engineering,
control engineering and computer
engineering
en.wikipedia.org
Euler diagram for Mechatronics
Rensselaer Polytechnic Institute, MIT

5. FAIM 2015
23-26 June ∙ University of Wolverhampton
1. Introduction
Mechatronic Equipment Lifecycle
Mechatronics is a multidisciplinary
field of engineering that includes a
combination of mechanical
engineering, electrical engineering,
telecommunications engineering,
control engineering and computer
engineering
en.wikipedia.org
Euler diagram for Mechatronics
Rensselaer Polytechnic Institute, MIT

6. FAIM 2015
23-26 June ∙ University of Wolverhampton
1. Introduction
PLM Evolution
Product lifecycle management, evolution of computing applications
H. Cao and P. Folan

7. FAIM 2015
23-26 June ∙ University of Wolverhampton
1. Introduction
PLM Utilization Obstacles in SME
• PLM implementation is not generalised and
not always lead to the expected results:
– PLM solutions tend to have a very high total cost
ownership , which is difficult for SMEs to support.
– They require very thorough processes structuring
and information organization.
– Are complex to use and demand for high degree
of expertise.

8. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Characterization
• The PLM4all solution encompasses a range of methodologies
and an IT platform dedicated to product lifecycle
management:
– The methodologies cover all the fundamental phases of product life
cycle – Ideation, Design and Development, Manufacturing,
Maintenance, Retrofitting and End of Life – and embrace a lean
thinking approach focused on the critical needs of SMEs articulated
with a reduced cost mind-set.
– The IT platform includes modules for information management,
collaborative processes and activities management, interoperability
with CAD and ERP systems and knowledge management.

9. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Key Features
• Based on lean thinking principles, so that product interactions are
“value oriented” and with more emphasis in human capabilities.
• Methodological contents (recommendations, best practices) and
templates to support the implementation of the product’s life cycle
key phases;
• Adoption of neutral transfer connections for among CAD, ERP and
PDM systems;
• High simplification and flexibility;

10. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Product Lifecycle Reference Model
• Structured in phases, stages and activities:
Phases
Stages
Activities

11. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Product Lifecycle Reference Model
• Structured in phases, stages and activities:
Risk analysis’
templateTemplates
Phases
Stages
Activities
• Most critical activities are supported by
best practices templates

12. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Product Lifecycle Reference Model
PLM4all Product Lifecycle Reference Model
Ideation
Development
and Design
Manufacturing
Industrialization
Manufacturing
processes
studies
Specific means
of production
development
Installation of
man. means,
setup and tests
Pre-Series
production
Series
production
Maintenance Retrofitting End of Life
Phase
Stage
Activity
……
…

13. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PM4all Product Hierarchical Structure
Product
Hierarchical Tree
Family
Range
Model
Variant
Instance
Top level.
No Versions.
• Laser Cutting;
• Press Brakes;
• Shears.

14. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PM4all Product Hierarchical Structure
Product
Hierarchical Tree
Family
Range
Model
Variant
Instance
Top level.
No Versions.
Admits
Versions.
• Laser Cutting;
• Press Brakes;
• Shears.
• Press Brakes:
• GreenBender
• 13530
• 40
• 50
• 16030
• Bluebender
• PF Fast
• Bending cells

15. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PM4all Product Hierarchical Structure
Product
Hierarchical Tree
Family
Range
Model
Variant
Instance
Top level.
No Versions.
Admits
Versions.
Unique Product.
No Versions.
• Laser Cutting;
• Press Brakes;
• Shears.
• Press Brakes:
• GreenBender
• 13530
• 40
• 50
• 16030
• Bluebender
• PF Fast
• Bending cells
• Press Brake GreenBender 13530-40, SN 23654

16. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Product Functional Structure
System:
a group of devices forming a
network especially for
distributing something or
serving a common purpose
(merriam webster)
Product
Functional
Tree
System 1
System 2
• n systems
• Braking system
• Power trim system
• Control system
• …

17. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Product Assembly Structure
Product Assembly Tree
Module 1
Module 1.1
Module 1.1.n
Module 2
Module 2.1
Module 2.1.n
Module 4
Module 4.1
Module 7
Module 7.1

18. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Modules and Systems Association
Product Assembly Tree
Product
Functional
Tree
System 1
System 2
Module 1
Module 1.1
Module 1.1.n
Module 2
Module 2.1
Module 2.1.n
Module 4
Module 4.1
Module 7
Module 7.1

19. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Configuration Matrix
MODEL (Product)
Modules
M1 M2 M3 M4 M5 M6 M7 … Mn
Systems
S1
S2 x x
S3 x o
…
Sn A A
Module
Module
Coding: x – Required module
o – Optional module
A – Alternative module
n=2
n= no. of hierarchy levels

20. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all CAD – ERP Integration
• The conversion process is supported by the definition of business rules;
• Part search by attributes and formation and rearrangement of subsets
(BOM CAD);
• Filtering of “ghost” drawings used only for display purposes;
• Product tree generation from CAD subsets (BOM ERP);
• Construction and storage of CAD ERP mapping models;
Toolbox
Input Panel
M1
P
P
P
P
M1
P
P
M12
M11
P
P
Output Panel
Export
To
ERP
PLM4all
Product
Structure
DB
CAD
Model
STEP
AP233
Stub

21. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Configuration Matrix Fill In
How do we fill in the
Configuration Matrix?
 Manual data entry

22. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Configuration Matrix Fill In
How do we fill in the
Configuration Matrix?
 Manual data entry
OR
 DB import

23. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Lifecycle Activities’ Management

24. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Lifecycle Activities’ Management
• Structured activities
• Ad-hoc tasks
T T T

25. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Lifecycle Activities’ Management
• Structured activities in projects
• Ad-hoc tasks
• Projects
T T T

26. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Lifecycle Activities’ Management
• Structured activities in projects
• Ad-hoc tasks
• Projects
T T T

27. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Lifecycle Activities’ Management
• Structured activities in projects
• Ad-hoc tasks
• Projects
Development
and Design Manufacturing Maintenance Retrofitting End of Life
T T T

28. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
Product Lifecycle Overview
PHASE | STAGE
Ideation
Ideas manag.
Opport. manag.
Proposal develp.
Develop.& Design
Specification
Draft
Detail Proj.
Manufacturing
Industrialization
Pre-Series
Series Production
Maintenance
Corrective Maint.
< Jan Fev Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan >
Family: Press Brake; Range: GB; Model:13530; Variant: 40; Instance: SN:23654
Activity story
All details available

29. FAIM 2015
23-26 June ∙ University of Wolverhampton
2. PLM4all Approach and Concept
PLM4all Architecture
PLM4all PLATFORM
Ideation
Design &
Development
Manufacturing
Maintenanc
e
Retrofitting End of Life
DATA FLOWDATA FLOW
DATA FLOW
CAD SYSTEMS ERP SYSTEMS
DATA FLOW
stubs
TASKS – PROJECTS – OPERATIONS

30. FAIM 2015
23-26 June ∙ University of Wolverhampton
3. Conclusions
• The use of ICT in SMEs is critical as they bring a myriad of benefits in terms
of efficiency, effectiveness, growth, innovation and competitive
advantages.
• Despite the potential of ICTs, there is a low diffusion of structured ICTs in
SME since these solutions tend to require a high initial investment, skilled
staff, a coherent business strategy and training.
• Therefore, the need to develop low cost and user-friendly PLM tools that
are able to attend to SMEs operational demands is insurgent.
• PLM4all’s innovative characteristics, combined with the conciliation of low
possession cost software with ground features of a PLM platform, provide
PLM4all with an extremely high degree of flexibility, low cost and
facilitated utilization, being a highly suited solution for SMEs.

31. FAIM 2015
23-26 June ∙ University of Wolverhampton
4. Contacts and Acknowledgements
PLM4all consortium
António Correia Alves
INESC TEC (RTO)
(Technical Leader)
antonio.c.alves@inesctec.pt
www.inesctec.pt
This work was developed in the frame of the Co-Promotion Project 38834, from the Program of Incentives to
Technological Research & Development, supported by the Portuguese Innovation Agency (ANI), to whom the financial
support is to be acknowledged.
Team Members
Tiago Faro - ADIRA
(Project Leader – SME Pilot)
António Baptista – INEGI (RTO)
(Product Development Group)
José Faria – DREAMO
(ICT Company)