Sirris manufacturingday2011 digital-factory

ManufacturingDay 2011
Digital Factory introduces a new era for product development
marc.bollen@sirris.be

10-5-2011
© Sirris | www.sirris.be | info@sirris.be |
2
Product Development
The Goal
Bring the productsthatyourcustomers want to market at the right time and the lowestcost.
By The Way
on a limited budget
withlimited resources
withlimited time
and changingpriorities
on a daily basis

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#1
Start now and create
yourstrategic Digital Factory plan !

Rule #1: Start Now!
What are the strategicoptions?
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Breakthrough
Innovation
€
Additional room forimprovements
Incrementalimprovements
Room forimprovements
Do Nothing
2012
2013
2014
2015
2016
2017

1.1 Set Strategic Goals
Time To Market
First Time ThroughRate
CustomerSatisfaction
Product Performance
Efficiency
Flexibility
CostReduction
Margin
…
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1.2 Analyse CurrentProcesses

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'When we understand this slide, we'll have won the war.'
General Stanley McChrystal,
US and NATO force commander

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1.2 Analyse CurrentProcesses
ActiveVOS, Adeptia, Altova, Appian Corporation, Avolution, Axway, Bizagi, BOC AG Borland, Cordys, Corel, Embarcadero Technologies, HandySoft Corporation, IDS Scheer, ILOG, Interfacing Technologies, MEGA International, Microsoft, No Magic, Omni Group, Orbus software, Pegasystems, SAP AG, Software AG, Sun Microsystems, Sybase, Tibco Software, Troux Technologies, Visual Paradigm, yWorks, …

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Issue
1.3 DefineActions
Impact
Improvement
Action

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1.4 Prioritiseactions
Impact
Size = investment
ROI

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1.5 Action-types
X
X
Eliminate steps
Increase efficiency
Minimiseiteration-effects

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#2
Think Digital !

2.1 Digitiseyourprocesses
CAAD
CAD
CADD
CAE
CAM
CAPP
CAQ
CAR
CAS
CASE
CFD
CIM
EDA
FEA
KBE
MPM
MPP
PDM
PLM
Technologies
+

2.1 Technologies
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A photorealisticrendered picture createdwith POV-Ray 3.6. Glasses and ashtray are modelled with Rhinoceros 3D. Dicewith Cinema 4D

2.2 QuyOrthopedicMilling Services (1)
Original Process
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CreatePlaster-negative
AdjustPlaster-negative
Copymilling
AssessPatient-geometry
Long Lead Time
Average Quality
High Cost
Labour Intensive

2.2 QuyOrthopedicMilling Services (2)
DigitisedProcess
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X
X
AsessPatient-geometry
CreatePlaster-negative
Adjustplaster-negative
Copymilling
Create
CAM
Milling
Capture 3D data
Adjust
in CAD
CAM

2.3 Simulation of rainpenetration (1)
Original Process
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Physical
Prototype
Testing
Certification
Design Data
OK?

New Process
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Simulation
Testing
Certification
Design Data
OK?
OK?

No straight forward model to apply all the physics
(rain droplets, wind driven motion in fluid domain, droplet accumulation and motion over the wall boundaries)
DPM (Discrete Particle Model) lacks modeling droplet-accumulation. Therefore, trial tests were done with Eularian Mixing Model which is capable of modeling water accumulation and motion on the louver walls
Initial results were in poor agreement with the experimental study. Changing the droplet size improved accuracy. 30 days of simulation time were required to do droplet size optimization. Initial results indicate that modeling with 150micron droplet size is in better agreement with the experimental results.
In 2008 simulation was more expensivethanphysical testing. Now (2011) it is cheaper
Increaseyourknowledge and prepare for setbacks

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#3
Topmanagement has to support the improvementprocess !

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Room filledwithpeoplewho care.

3.1 Manage the project
Allocate resources (PM)
Plan learning (and setback) curve
Monitor KPI
Adjustimplementationspeed
Feedback results to stakeholders
Plan secondimprovement project
Take 1 step at a time
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#4
Modularise, Configure,
Automate !

Customer
Archive
InternalSales
Search forsimilar offers
Offerte
ERP
Calculation Software
BOM and routing
Manusla input
Engineering
Workpreparation
Sales
3.1 TypicalSales Proces: Offer (1)
Offer
Source: Sofon
Information Transfer
Knowledge at individuals

Customer
Archive
InternalSales
Modified Offer
Gewijzigde Offerte
ERP
BOM and routing
Manusla input
Engineering
Workpreparation
3.1 Typical Proces: Modified Offer (2)
Sales
Offer
Offerte
Source: Sofon
Information Transfer
Knowledge at individuals

Customer
Archive
Order
Modified Offer
Orderconfirmation
Delay
ERP
Planning / Production
3.1 TypicalSales Proces: Order (3)
Sales
InternalSales
Offer
Modified Offer
Offer
Source: Sofon
BOM and routing
Engineering
Workpreparation

3.2 Manuals (1)
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Provide CAD-linkages.

3.3 Modularity, standardisation
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Actions
Productportfolio (5)
Conceptual Design (8)
Systemdesign ( 20)
Detaildesign (100)
Leadtimedecreases 50%

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#5
Collaborate !

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5.1 InternalCollaboration (1)
PDM
CMS
Local
Documentserver
Content Management System
Intranet
…
Collaboration Platform
Communities

Atos Origin sets out its ambition to be a zero email company within three years (07/02/2011)
By 2013, more than half of all new content will be the result of updates of existing information
Online social networking is now more popular than email and search
Middle managers spend more than 25% of their time searching for information
2010 : Corporate users receive 200 mails per day, 18% of which is spam
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Why search whenyoucanaskyournetwork?

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My smmrholswr CWOT. B4, we usd 2 go 2 NY 2C my bro, his GF & thr 3 :-@ kds FTF.
2003, nn, 12 yearsold.
Now 20 years and starting in yourcompany!

5.2 ExternalCollaboration (1)
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Suppliers
Consumers
Manufacturer
Channels
Raw
Material
Component
Suppliers
Retailers
Resellers
Direct
HQ
Individual
Businesses
Supplier
Distributors
Contract
Manufacturers
Factories
Plant
Warehouses
Source: Microsoft
Service
Design / R&D

5.2 Externalcollaboration (2)
Data exchange : JT, STEP, 3DPDF, …
SME’swillbepressured to collaboratewithLarge Enterprises
LE provides portals foroffering and collaborative design
Largercompanies (Vestas, Airbus) centralise all engineerson a project base.
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5.3 Benchmark (1)
Source: CIMData 2011

5.4. Audit
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Conclusions (1): 5 Golden Rules
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#1
Start now and make a plan !
#2
Think Digital !
#3
Manage !
#4
Think Modular !
#5
Collaborate !

Conclusions (2): Sowhat?
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Savingstool design
Communication
and collaboration
Reduction Design Changes
Time to Market
Project efficiency
Timesavings
production planning
20
40
60
80
% improvement

Questions
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Sirris manufacturingday2011 digital-factory

by Sirris

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