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Digital Thread eBook - Final

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Digital Thread eBook - Final

  1. 1. ENABLING THE DIGITALTHREAD UnifyingDesign,ManufacturingandERP inaClosedLoopDigitalThread
  2. 2. TableofContents Introduction ManagingComplexitywiththe DigitalThread TheThreeOpportunities RealizingtheThreadwithProduct LifecycleExecution ClosingtheClosingtheLoopwithSolumina AboutiBASEt Notes 1 2 4 6 8 10 11
  3. 3. Manufacturingisinthemidstofanotherrevolutionanditisagain transformingtheindustryasweknowit.Todaytherevolutionisdigital, andaswithallrevolutions,thisonedidnotoccurovernight.Fromthe introductionofthePCtothefactoryfloorinthe1970stothe developmentandmaturationofcomputer-aideddesign,clear evolutionarystepsresultedinproductivityandefficiencygainsin manufacturing.1 AcriticalandconcurrentAcriticalandconcurrentevolutionwasalsooccurringwithindesignand engineering,wheretechnicaldocumentationevolvedfromblueprintsto two-dimensionaldrawingstothree-dimensionalmodels.Thishad dramaticeffectsacrossdesignengineeringfunctionsandcouldhave evenmoreimpactonthemanufacturingenterprise.TheModel-Based Definition(MBD)couldfacilitatedesigncommunicationacrossthe entireproductlifecycleandacrosstheorganizationfromdesignto productionandqualityassuproductionandqualityassurance. ThedigitalthreadwiththeModel-BasedDefinition(MBD)caneliminate theproblemsofcomplexityconsolidatingthe3DCADmodel, componentlist,revisionlevels,GeometricDimensionandTolerance (GD&T)interpretation,productdetailsandotherproductionand inspectionrequisiteinformationintoamodelinformationpackagethat issharedbeyondengineeringfunctions.2 Asthedevelopmentofdigitaltechnologiescontinuestoaccelerate, manufacturersarecontinuingtorethinktheirenterprisesintermsof howtobestleveragethoseadvancestoremaincompetitiveina progressivelynuanced,increasinglychallengingglobalmarketplace.Itis withinthismarketplacethatproductsandprocessesarechanging rapidlytomeetdemand,andwhereinnovationandqualityarenolonger themarkofanexceptionalcompetitor,butratheraprerequisiteto compete.Bringingustowherewearetodcompete.Bringingustowherewearetoday,andrevealingtheneedto enablethedigitalthreadofmanufacturingintoacomplete manufacturingModel-BasedEnterprise(MBE). 1 Introduction
  4. 4. Today’smanufacturers,especiallythoseinsectorssuchasaerospace, defense,medicaldevices,industrialequipment,andelectronics,are facedwiththechallengeofmanagingacomplexandoftenfar-flung supplynetwork.Anendproductmayhavehundredsofindividual componentsorassemblies,someofwhichthemanufacturermay produceandotherssourcedfromarangeofsuppliers(orsuppliers’ suppliers).Thisnetworkcanbecomeincrediblycomplextomanage,asa singledesignchangecanaffectthemanufacturingofmultiplesingledesignchangecanaffectthemanufacturingofmultiple components. Forexample,acompanymayhavearequirementtoproduceapartwith threemeasurementsthatareverified.Ifnothingchanges(i.e.,no engineeringchanges),theprocessissimple.Butwhenaproducthas multiplelayersthatarechanging(e.g.,dimensions,characteristics, supplier),associativityneedstobemaintainedamongengineering, manufacturing,inspectionandmaintenance—acrosstheentire enterprise—sothattheproductisproducedandverifiedtothecorrect engineeringlengineeringlevel.Tofacilitatethisprocessandbettermanage complexity,anincreasingnumberofmanufacturersarelookingtothe model-basedenterprisemodel. 2 ManagingComplexity withtheDigitalThread
  5. 5. TheNationalInstituteforStandardsdefinesaModel-BasedEnterprise thisway: Model-basedenterprisesutilizemodel-baseddefinition:thepModel-basedenterprisesutilizemodel-baseddefinition:thepracticeof using3-Dmodels(suchassolidmodels,3-DProductManufacturing Information(PMI),andassociatedmetadata)within3-DCADsoftwareto define(i.e.,providespecificationsfor)individualcomponentsandproduct assemblies.ThetypesofinformationincludedareGD&T,componentlevel materials,assemblylevelBillsofMaterials(BOM),engineering configurations,designintent,andsoon.Bycontrast,othermethodologies hahavehistoricallyrequiredaccompanyinguseof2-Dengineeringdrawings toprovidesuchdetails. Thecoretenetofamodel-basedenterpriseisthatdataiscreatedonce anddirectlyreusedbyalldataconsumers(i.e.,allfunctionalareas)in themanufacturingenterprise.Thisisthe“singlesourceofthetruth,”the digitalthread. Simplyput,thedigitalthreadrepresentsthesumofalldata(i.e.,model data,productstructuredata,metadata,effectualdata,andprocess definitiondataincludingsupportingequipmentandtools)digitallylinked toformasingle,contiguousdefinitionofallvalue‐addeddecisionsmade duringthedefinitionofaproduct,itsconfiguration,manufacturingand repairprocesses,logistics,andoperationalsupport.Foracomplex manufacturer,itprovidesasinglereferencepointfordesign,engineering, andmanufacturing,ensuringthandmanufacturing,ensuringtheyactinconcert.4 3 AModel-BasedEnterprise(MBE)isanorganizationthatapplies modelingandsimulationtechnologiestointegrateandmanageits technicalandbusinessprocessesrelatedtoproductionandproduct lifecyclesupport.Byusingproductandprocessmodelstodefine, execute,control,andmanageallenterpriseprocesses,andby applyingscience-basedsimulationandanalysistoolstooptimize processesateverystepoftheproductlife-cycle,itwillbepossible tosubstantiallytosubstantiallyreducethetimeandcostofproductdevelopment anddelivery.3
  6. 6. Throughouttheproductlifecycle,keyvalue-addedelementsaredefined andinsertedintoproductandprocessdefinitions.Anywherethisdatais definedtoolatecreatesacost,risk,andqualityimpact.Anywherethis dataiscopied,transcribed,orreinterpretedincreasesthepotentialrisk andqualityimpact.Consequently,ninetypercentoftheproductand processvalue-addeddataneedstobeaddedbeforetheendofthe prototypestage. RealizingadigitalthreadaffordsmanufacturerstheopportunitytoRealizingadigitalthreadaffordsmanufacturerstheopportunityto ensurequality,controlcosts,andmitigaterisk. Eachelementofamanufacturer’svaluestreamwheredatais reinvented,reinterpreted,ortranscribedintroducesanopportunity forproductorprocessdefects.Ifthedefectiscaughtinhouse,it nonethelesscoststimeandmoneytoaddress.Ifthedefectenters thedownstreamsupplychain,itsescapecompromisescorporate credibilityanddiminishestheprospectsforrepeatornewsales. Havingadigitalthreadinplacereducesthelikelihoodofsuch evevents. TheThreeOpportunities 4
  7. 7. TheThreeOpportunities Evenifcostandqualitywerenotanissue,aprogramcannotafford anyvariationthatwillaffectitsabilitytoreachandmaintaingoals. Mostprogramsnowhavepenaltyclausesthatmaybetriggeredby latedeliveries,escaperates,andavailabilityrates.Assuch, programsneedstabilityandlittleornoprocessvariability.By preservingandsustainingvalue-addedcontent,thedigitalthread supportsthisstability. Thedigitalthreadintroducesaframeworkwherevalue-added actionsareefficientandsustained.Workgetsdoneonce.Quality variancesareresolvedonce.Engineeringchangesareprocessed once.Considertheexampleofstep-by-stepvisualsforamajor defenseprogram: 5
  8. 8. EnterpriseResourcePlanning(ERP)andProductLifecycleManagement (PLM)havelongbeenconsideredthefundamentalenterprisesystemsin amodel-basedenterprise;butagenuinedigitalthreadcannotexist withoutaProductLifecycleExecution(PLE)platform. TTodevelop,describe,manage,andcommunicateinformationabouttheir productsfromconceptiontoend-of-life,manufacturersusePLM.PLM architectureisobject-orientedandstructuredaroundproducts, productrelationships,andconfigurationmanagementfunctions. TTomanageresourcesforproduction,manufacturersuseERP.ERP architectureistransaction-basedandorganizedaroundproduction resources.WhiletheERPsystemutilizesproductdataandprocess planscontainedinthePLMsystem,thearchitecturesofERPandPLM arefundamentallydifferent.Bothsystemsmustcontroltheirowndata andnotduplicateorimpedethefunctionsoftheother. PLMprPLMprovides“thewhat”:modeling,BOMmanagement,process planning,processsimulation,andengineeringchangemanagement.ERP provides“thewhen,where,andhowmuch”:scheduling,financials,and inventory.Buttohaveafullydevelopedmodel-basedenterprise—anda fullyfunctioningdigitalthread—manufacturersalsoneed“thehow.” That’swhatPLEprovidesthroughprocessexecution,processcontrol, qualityassurance,traceability,anddeviationhandling. 6 RealizingtheThread withProductLifecycle Execution(PLE)
  9. 9. Byenablingamanufacturertoexecuteonthedigitalthreadinrealtime, PLEprovidesorfacilitatesahostofbenefits,including: Historically,thebiggestpotentialbarriertorealizingthemodel-based enterpriseandthefullpotentialofthedigitalthreadhasbeenintegration oftheenterpriseapplications,5 butthisissomethingiBASEthasaddressed withitsSoluminaG8suite. 7 RealizingtheThread withProductLifecycle Execution(PLE)
  10. 10. SoluminaeasilyintegrateswithallpopularCAD,PLM,andERPsystems, inadditiontothirdpartyandlegacysystemsmanufacturersareusing today.Everyaspectofmanufacturing—fromautomatinganddigitizing interactiveworkinstructionsusing2-Dand3-DCADdrawingsand visualizationstoprovidingreal-timeupdatesanddatacollection—is synchronizedacrossmanufacturingoperationswithSolumina. 8 ENTERPRISEQUALITY MANAGEMENT MANUFACTURING EXECUTION SYSTEM MANUFACTURING INTELLIGENCE SUPPLIERQUALITY MANAGEMENT MAINTENANCE, REPAIR,& OVERHAUL MANUFACTURING OPERATIONS MANAGEMENT PRODUCT LIFECYCLE MANAGE- MENT ENTERPRISE RESOURCE PLANNING ClosingtheLoopwith Solumina
  11. 11. ByconnectingwithPLMandERP,Soluminaclosestheloopamongthe differentfunctionswithinthemanufacturingenterprise(i.e.,design, engineering,production,qualityandresourcemanagement),creatinga seamlessflowofdataamongsystemsheretoforeisolated,realizingthe potentialinherentinmanufacturingfromthedigitalthread. AsdataiscollectedinPLMAsdataiscollectedinPLM(e.g.,EBOM),itcanflowintoSoluminaasan MBOM.PlanningcaneitherbedoneinthePLMorSolumina.Changes madearefedbacktoengineering;or,ifresourcesaremodified, consumed,orchanged,theycanbefedbackintotheERP.The closed-loopenvironmentencompassestheapplicationstocompleteand ensuretheintegrityofthedigitalthread. SoluminaisbuiltspecificallytohandlethecomplSoluminaisbuiltspecificallytohandlethecomplexrequirementsin criticalsectorssuchasaerospaceanddefensemanufacturing.Managing productconfigurationsandchangemanagementacrosstheentirevalue chainandproductlifecycleiswherethesolutiondeliversexceptional valuetocomplexmanufacturers.Thesecapabilitiesallowcompaniesto efficientlymeetandexceedregulatorycompliance,time-to-market,and qualityrequirementsintoday’sdemandingglobalmarketplace. 9 ClosingtheLoopwith Solumina
  12. 12. HeadquarteredinFoothillRanch,California,iBASEtmakesdiscrete complexmanufacturingsimple.iBASEtsolutionsreplaceamyriadof disparateshopfloorandsupplychainsolutions–suchasmanualpaper andemailprocesses–withoneintegratedsuiteofsoftwaresystems thatsynchronizedataandfostercollaborationbetweeninternaland externalteams. FFromprocessandinspection,planningtotheshopfloorandsupply chainexecution,weprovideproven,out-of-the-boxsolutionsthat deliverreal-timeinformationandprocesscontrolthatsimplifies complexmanufacturing. iBASEt’sManufacturingEiBASEt’sManufacturingExecutionSystems(MES),Maintenance,Repair andOverhaul(MRO)andqualitymanagementsoftwaresystemsare givingourcustomersthepowertomonitoreveryaspectofproduction, qualityandcomplianceefficiency.Throughoutmanufacturing,supply chain,andmaintenance,repairandoverhaul,theiBASEtSoluminasuite ofapplicationsenablefullshopfloortotopfloormanufacturing visibility,consistentpractices,continuousproductandprocess imprimprovement,andeffectivecompliancewithprocessstandards includingISO9001,ISO13485,AS9100,andFDA’s21CFRPart11and Part820. TheiBASEtSoluminasoftwaresuitealsoenablesenterprise-level productlifecycleexecutiondeliversleanefficiency,improvedquality managementandcomplianceprocesses.Manyaerospaceanddefense (A&D)andmedicaldeviceindustry’slargestmanufacturersareusing theiBASEtSoluminasoftwaresuitetoenablecollaborationandquality assuranceacrossdiverse,globalsuppliernetworks.Streamliningand simplifyingcomplexmanufacturingstrategiestoenablefast time-to-martime-to-marketforneworimprovedproductwithhighlevelsofquality andcompliancearewhereiBASEtcustomersseethegreatestresults. Developedspecificallyforthemostchallenging,complex,discrete manufacturingenvironments,wehaveaproventrackrecordof deliveringglobalimplementationsacrossmultipletiersofthesupply chain. AboutiBASEt 10
  13. 13. 27442PortolaPkwySuite#300 FoothillRanch,CA92610 Phone:877.422.7381 Fax:949.598.2600 www.ibaset.com 11 ContactUs 1. Hartman,Brian;King,William;andNarayanan,Subu.“Digital Manufacturing:TheRevolutionWillBeVirtualized,”McKinsey& Company,August2015. 2. “ModelBasedDefinitionPromisesBigDividendsforQuality Assurance,”http://www.hexagonmetrology.us/applica tions/2011-09-16-14-41-07/310-model-based?tmpl=compo nent&type=raw 3. Frechette,SimonP.“ModelBasedEnterpriseforManufacturing,” ManufacturingSystemsIntegrationDivision,EngineeringLabo ratory,NationalInstituteofStandardsandTechnology,March 2010. 4. Packer,Michael.“HowtheDigitalThreadIsTransformingManu facturing,”http://www.aerodefevent.com/how-the-digi tal-thread-is-transforming-manufacturing/. 5. Ibid,Frechette. Notes

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