Welcome to this presentation on Getting Started in Product Lifecycle Management, essentials for excellence in industrial machinery assembly manufacturing.
Let’s take a look at the Industrial Machinery segment and some of the challenges that your organization may face.
Complexity (Increasing automation:/product configuration):
Machines need to be smarter: the amount of software content is increasing in machines, especially with the advent of the Internet of Things…e.g. production machines need to be able to communicate with other production machines, and the products they are producing, so mass customization customer demand can be met.
Product configurations: End customer demand for customized products drives OEM demand for customized machines
Environment and safety: Regulatory pressures driving many aspects of machine design – one such regulation is the Eco-design for energy efficiency – an EMEA based regulation demanding that machines be energy efficient.
Low profit margins: Largely driven by global, competitive pressures from low cost providers: margins are already critically low in Industrial machinery…and exacerbated by competitive pressures!
Services: manufacturers of goods in every industry expect their machinery providers to be full services partners…and machinery producers realize this presents a large profitability opportunity…to help offset the low margins that exist in the industry.
Industry 4.0=manufacturing with decentralized, autonomous machines that communicate with one another and the products they are manufacturing, so they can optimize production.
…which means, and increased amount of software content within machines! Let’s take a look at a statistic from VDMA, the German Machine Tool Association, on the rate of software content increase in industrial machines…
Due to this complexity, the top challenge is for machine builders to product quality, high performing machines that meet unique customer needs. And to do so quickly, so they can get paid quickly and increase margins.
You can see here a graphic from the German Machine Tool Association on the ever-increasing amount of software code within an industrial machine.
Let’s take the modern manufacturing machine, and you can see how complex it is to develop:
From sensors, to mechanical design, to motion control, to system design, there are many diverse requirements that the modern machine builder must have at their fingertips while there are designing, simulating, and ultimately commissioning the machine.
I talked about the increase in the amount of software content in machines, and machines getting “smarter”…this is what I mean by this.
The only system that can manage this complexity is PLM (ERP can’t, office tools can’t)…and the only PLM system that can truly manage the lifecycle of machine design, development, and commissioning, is Siemens PLM
The possible solution to these challenges of more functionality in the machine, and higher risk of performance and quality defects is a platform that enables global, virtual assembly and validation that at the same time is flexible enough to meet the unique configuration needs of machine builders that serve many different industries.
Let us now have a look at the essentials for excellence in assembly manufacturing that you can take advantage of to help you make things right.
Note to Presenter: You can decide for yourself if this first part is necessary:
While companies are faced with the challenge of turning more ideas into successful products, today’s environment means that they have to meet this challenge in a world that is increasingly more complex; much more so than ever before. This complexity derives from the fact that companies need to achieve successful innovation while meeting the more demanding requirements for speed, globalization, sustainability and optimization.
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In order for manufacturers to meet these requirements, address the implications of their industry’s trends and realize the possibilities, they must be able to manage this increased complexity. The complexity is evidenced in every part of their business, from product and manufacturing engineering to production to the partner and supplier ecosystem.
With Tecnomatix, the world’s most widely used Digital Manufacturing solution (according to CIMdata), you can sharpen your edge with next-generation manufacturing technology and bridge the gaps that exist between product engineering, manufacturing engineering, and production through the use of Product Lifecycle Management (PLM). This solution enables excellence in assembly manufacturing through the following essentials :
Right synchronization across product engineering, manufacturing engineering, and production through a single source of manufacturing knowledge served on a best-in-class product lifecycle management platform (PLM for Manufacturing);
Right ingenuity to create leaner, more efficient processes through better planning;
Right insight into the real-world performance of plans through simulation;
Right control of quality and production operations through better change management and issue tracking.
What Manufacturing Planning solutions does Tecnomatix offer and what do they mean for our customers?
Tecnomatix Manufacturing planning solutions allow manufacturers to leverage a single source of product and process information across their enterprise for current and future product programs, helping to cultivate the right ingenuity to create leaner, more efficient processes.
This means that they are better able to account for product to process to resource (equipment and labor) completeness, are able to quickly identify the impact of changes on the process plan (model), both from within the design function and from within the later manufacturing engineering or production phases, are able to capture and re-use best and/or proven practices on each new program, and are able to provide high visibility to variations and configurations across different plants, programs, and products, including time-based effectivity.
Ultimately, they are in a position to leverage this single source of product and process information or “truth” across their enterprise for current and future product programs, resulting in effective collaborative product and process development.
Successful manufacturing planning is best achieved through the use of technology and functionality that can deliver solutions such as:
Process planning, accountability and management
Electronic work instruction (EWI) development
Layouts and facilities design and management
Dimensional Quality planning and management
We will now have a closer look at the capabilities of these planning solutions.
Process
Define optimized and balanced process plans linked to product data
Tecnomatix Process Design and Management tools allow you to associate and reconcile multiple configurations of product bills of material (BOMs) and bills of process (BOPs). You can also validate manufacturing planning decisions by using advanced visualization and analytical tools.
Work Instructions
Create detailed 3D work instructions that stay up-to-date
Tecnomatix Manufacturing Work Instructions offer a comprehensive suite of 2D/3D work instruction authoring and viewing applications to help you improve communication of assembly instructions to the shop floor by providing 3D views and up-to-date process steps.
Layouts
Achieve faster design of more efficient production facilities and lines
Tecnomatix Factory Design and Optimization tools allow you to design your assembly lines, equipment and tool requirements in a 3D environment. Optimize your factory space and maximize capital resource utilization by digitally configuring your factory layouts.
Dimensional Quality
Incorporate manufacturing analysis into designs
Tecnomatix Dimensional Quality tools can help mitigate this risk that dimensional variation can have on profitability through excessive tooling, labor and metrology costs, by reducing the need for costly prototypes and allowing you to analyze variation before design release.
We will now have a look at a short video to demonstrate an example of the use of Tecnomatix tools for manufacturing planning.
IM_Planning_Accountability.mp4
<Video Script>
This task is being performed by the manufacturing planner whom has to determine if the manufacturing bill of material is aligned with the engineering bill of material and contains the same components. Within Teamcenter Manufacturing Process Planner (MPP) the planner opens the new brake assembly top down, which is easily accomplished through the visual interface.
The top left window displays the Engineering BOM (EBOM) where the new subassembly is selected and highlighted green in the top middle graphics window.
The Manufacturing BOM (MBOM) is shown in the bottom left window where the old subassembly is selected and highlighted in green in the middle bottom window. The right part of the screen is showing the accountability window. The planner activates the accountability check comparing the EBOM with the MBOM.
BOM Comparison differences are shown in the top right windows by highlighting the part numbers in red. These exist in the EBOM, but not in the MBOM. Graphical BOM Compare provides a more detailed, visual assessment regarding actual design changes in the top left window. The parts that are missing in the MBOM are highlighted red in the assembly tree.
The manufacturing planner copies the left-hand subassembly components first. The graphics window shows the copied geometry in the bottom middle window. The next step would be to copy the right-hand subassembly components from the EBOM into the MBOM. The color of the BOM lines show the status of the material lists.
Once again, the accountability check is performed, after the planner has executed the engineering change. All lines are highlighted green indicating that both bills of material are aligned. The right accountability window is empty because there is no longer any nonconformance.
What Manufacturing Simulation solutions does Tecnomatix offer and what do they mean for our customers?
Tecnomatix Manufacturing Simulation solutions allow for verification of the methods and resources being defined and selected during manufacturing planning, whereby a significant number of changes only found in production have already been overcome while they are easier and less costly to fix, helping to gain the right insight into real-world performance of plans.
Through the use of simulation, it is possible to try variations of the manufacturing process, with a high degree of accuracy, in order to determine which will provide the best results. These engineering studies and what-if analyses are carried out very quickly, easily and at low cost during pre-production development phases, thereby reducing the need for physical tryouts and ensuring that any required physical tryouts can be executed faster. The resulting process plan (model) can easily be shared with others using visual displays that show the exact operations, resource layout, and their use, resulting in proven right-first-time manufacturing plans.
Successful manufacturing simulation is best achieved through the use of technology and functionality that can deliver solutions such as:
Assembly simulation and feasibility analysis
Robotics and automation simulation and analysis
Logistics and throughput simulation and analysis
Human factors and ergonomics simulation and analysis
We will now have a closer look at the capabilities of these simulation solutions.
Assembly
Confirm design for assembly
Tecnomatix Assembly Simulation and Validation tools allow you to simulate assembly sequences, human tasks, and machine interactions to optimize assembly processes before the start of production.
Robotics
Reduce programming time and optimize cycle time
Tecnomatix Robotics Simulation and Programming tools allow you to develop and simulate manufacturing processes for robotic applications, including tooling and peripherals. You can also construct studies based on event-driven simulation capabilities and offline programming for automated systems.
Logistics
Optimize system performance for material flow and throughput
Tecnomatix Logistics and Material Flow Simulation allows for the analysis and visualization of production throughput and performance using discrete event simulation. This allows you to quickly check for bottlenecks, validate transported materials, and view resource utilization over time for multiple process alternatives.
Human
Ensure worker safety, validate workspaces and maximize efficiency
Tecnomatix Human Simulation and Ergonomics tools use advanced scaling for accurate human simulation and some of the most sophisticated human factors and ergonomics analysis capabilities available, allowing you to build safer and more ergonomic human operations.
We will now have a look at a short video to demonstrate an example of the use of Tecnomatix tools for manufacturing simulation.
Machinery_Simulation_Human.mp4
<Video Script>
In Digital Pre Assembly, tests can be defined by the process planner within Teamcenter Manufacturing Process Planner (MPP). In this case, a check for posture conditions.
The process planner activates the test in Process Simulate. This task can be performed by an ergonomics engineer. This goal is to create the optimal assembly sequence for the operation while avoiding collision during assembly using the ergonomics functionality within Process Simulate.
The bottom window (sequence editor) sequentially shows all movements needed to assemble the components. The virtual human is locating the part with the left hand and places the two fasteners. For these movements, the system will check if the forces due to the weight of the components will be ergonomically acceptable.
To speed up the analysis the ergonomics engineer can select what should be checked; i.e., forces for different body parts.
In addition to the visual reporting of the condition, in this case a RULA code directly above the virtual human, a report is created. The chart shows a peak at the left which represent the forces put upon the left shoulder of the operator.
The test results are captured in Teamcenter MPP where the planner finds out which tests passed and which failed and where the appropriate corrective action can be captured.
What Manufacturing Production solutions does Tecnomatix offer and what do they mean for our customers?
Tecnomatix Manufacturing Production solutions ensure faster response to installation, implementation, quality and production issues, driving higher launch confidence and quality into the process for existing programs in alternate production facilities and for future programs, helping to maintain the right control of quality and production operations.
Identification and correction of quality and production issues prior to and in support of launch and in the early stages of production, and monitoring of production performance by program and/or plant allows for shortened product program times and ultimately leads to the successful execution and support of predictive launches and continuous improvement.
Successful manufacturing production is best achieved through the use of technology and functionality that can deliver solutions such as:
Issue Tracking and CAPA for corrective and preventive action
Virtual Commissioning for better coordination between mechanical and electrical engineering prior to launch
Shop Floor synchronization of process steps and resources to production operations
Build Quality for aggregation and analysis of collected quality inspection data
We will now have a closer look at the capabilities of these production solutions.
Issue Tracking
Correct at the source, prevent at the source
Tecnomatix Issue Tracking and Management tools allow you to capture issues, solve root causes faster and continuously improve your preventive measures with closed-loop processes, supporting you in achieving the ultimate goal of preventing non-conformances.
Virtual Commissioning
Validate system behavior before launch
Tecnomatix Virtual Commissioning tools allow you to promote early and effective collaboration between your simulation and control engineers. You can digitally validate both mechanical and electrical system components, including the programmable logic controller (PLC) programs that drive them.
Shop Floor
Synchronize execution steps and resources to worker operations
Tecnomatix Shop Floor Integration tools enable product lifecycle management (PLM) to manufacturing execution system (MES) integration, closing the gap between product design, manufacturing engineering and production. A two-way integration allows you to deliver proper work instructions, capture errors and validate successful execution of work plans.
Build Quality
Solve launch and start-up issues faster
Tecnomatix Build Quality tools allow you to optimize the throughput of inspection equipment and automate manual processes for data collection, translation and reporting. You can then consolidate the results so that your quality teams spend time solving problems instead of chasing data.
We will now have a look at a short video to demonstrate an example of the use of Tecnomatix tools for manufacturing production.
Machinery_Assy_Manufacturing_Order_Execution.wmv
<Video Script>
Using filters, the operator browses the order to work on; SIMATIC IT shows the operations to be executed and lists them in the correct execution order; the operator selects the first operation and, by pressing the start button, declares he/she has started working on that operation and his/her labor time is now tracked in background.
The first operation is a simple operation without any steps inside and does not require any materials or tools to be consumed nor any work instructions to be read nor data to be collected; in this case the operator can perform his/her job and then simply declare the completion of the operation; at this time, SIMATIC IT stops tracking labor time.
The operator can now move on to the next operation; like done before he/she has to start the operation execution and this time he/she is asked to specify the machine he/she is working with. This operation requires materials to be consumed; the operator accesses the operation details, declares the used serial number and completes the different steps inside the operation.
The third operation contains electronic work instructions to be browsed and read; the operator accesses the operation details and sees all of the EWIs available in different formats.
Make it right with Tecnomatix through essentials for excellence in assembly manufacturing:
The right synchronization across product engineering, manufacturing engineering, and production through a single source of manufacturing knowledge served on a best-in-class product lifecycle management platform;
The right ingenuity for the creation of leaner, more efficient processes while achieving collaborative product and process development (through better planning);
The right insight for the assessment of real-world performance of right-first-time manufacturing plans (through simulation);
The right control of quality and production operations for predictive launches and continuous improvement (through better change management and issue tracking).
Some of our customers are already receiving some of this significant value.
Burkhardt and Weber: “Product lifecycle management reduces cycle times in development and production, increases in-house efficiency and fosters innovation. PLM helps us gain a better position in the global marketplace." Andreas Mittermüller, CEO
Hyundai, Heavy Industries: “…The system is very easy to use and convenient for our designers. In addition, product data is totally reliable…" Ahn Chi Sung, Section Chief
Bihler: "Anyone without access to Teamcenter is poorly informed." Hermann Schwarzenbach
CIO
Siemens has been selling manufacturing solutions to the <industry> market for over 165 years; our PLM software solutions, such as Tecnomatix, continue that heritage by enabling your organization to bridge the historical gaps between design, engineering, and manufacturing. Being able to connect product design to virtual assembly of that product, and share your bill of process across engineering and manufacturing ensures planning efficiency and strong collaboration, resulting in a higher performing, higher quality product.
How can Tecnomatix help? With assembly manufacturing, we have seen most companies start by addressing the following manufacturing challenges:
Creation of leaner, more efficient processes (planning efficiency)
Assessment of real-world performance of manufacturing plans (simulation and virtual build)
Better control of quality and production operations (lifecycle quality)
Synchronization across engineering, manufacturing, and production (PLM for Manufacturing)
In short, Tecnomatix from Siemens PLM supports assembly excellence for industrial machinery companies in all three major product development areas:
1. Planning
2. Simulation
3. Production
Thank you for attending this presentation on Getting Started in Product Lifecycle Management, essentials for excellence in industrial machinery assembly manufacturing.
Getting Started in Product Lifecycle Management, essentials for excellence in industrial machinery assembly manufacturing.
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Agenda
• About Us (partner details)
• Market Challenges and Trends
• Essentials for Excellence in
Assembly Manufacturing
• Planning
• Simulation
• Production
• Success with Siemens and
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