Digital Factory를위한 Bill of Process Production 정보와 …통계적품질관리 DPV & SPC •업지시서,공법서 •공정현황정보 •가동실적, 공정개선정보

Digital Factory를 위한 Bill of Process

검증과 Production 정보와 Integration2016년 12월 15일 박세종 상무 / PfD 팀

siemens.com/hm16© Siemens AG 2016

Unrestricted © Siemens AG 2016

09.07.2016Page 2 Siemens PLM Software

목차

Real FactoryVirtual Factory

1. Plant-Centric BOP

2. BOP Validation

3. BOP Output

4. BOP & MES

5. 사례

- Siemens Amberg

- ITP Aircraft Engine

- ZeMA (CPS)



Trend

- in Heavy Equipment

Emerging global demand

“John Deere expects 50% of their

revenue to come outside of the US by

2018.”

-- Business Week

Global Production

“From March 2011 to March 2012, John

Deere says, customers ordered more

than 7,800 different configurations of

the 8R.”

-- Business Week

Massive configuration possibilities



Trend

- Get digital proof of product & production success

Digital Product Model

Digital Twin with Collaborative MFG

To fulfill the needs

Digital Production Model

For autonomous

production, configure-to-

order and plant specific

driven



Trend

- Evolution of Synchronized Information

PLM에 생성된 BOM, 공정계획, 작업표준서 등의 BOP 정보는 MES, 생산 라인과 유기적으로 연동되어 유연한 생산 및 제품

변경에 따른 변경관리 프로세스를 지원합니다.

PLM

상품 기획 설계 개발

생산 계획

영업

마케팅

생산테스트

단종

서비스

ERP

MES

작업 계획/ 진척관리

공정/설비 관리

Parts / Assys / EBOM/MBOMVariant Conditions / BOP / Work Instruction

OrdersVariant RulesOrder BOMMat’l Consumes

TransactionsMaterial MovesCompletionsDates/OperatorEWI

MBOM, Routing

Process BOMEWI Sheets

Order Configuration

As-Built Result

Production Order Progress

Results

https://sales.industrysoftware.automation.siemens.com/ext/images/Acoustic_coupling_sm.jpg

https://sales.industrysoftware.automation.siemens.com/ext/images/Acoustic_coupling_sm.jpg



Trend

- Information Flow - Current State

Development Planning Manufacturing

Digital Factory Manufacturing Control

Product

Process

PlantWork Plan

Ind. Engineering

Based on Vehicle Modules




- Connected and Integrated Data

Requirements

Customer

Regulatory

Design

Build

Systems

Engineering

Function

Logical

Architecture

Verification

Simulation

Behaviour

Reliability

CAE

Manufacture

Support

Engineering

MCAD

ECAD

Software

PhysicalManufacturing

Assembly

MBOM

Process

As-tested

As-built

As-maintained

Benefit

디자인~생산: 요구 사항 추적

변경 관리 – 변경에 대한 모든 영향





공정 계획(BOP) 정보는 제품(자재), 공정, 공장 및 생산 리소스(치구, 공구 등)이 체계적으로 관리되어 공정 Structure에 관련정보를 Logical하게 연결함으로써 구성됩니다.

Cell A

Rev A

Rev B

Part A

Assy A

Rev A

Rev B

Op 1: Move part to machine

Op 2: Machining Milling

Act. 1: Assign Tool A

Act. 2: Assign Fix. A

Op 3: Machining Turning

Building A

Building B

Line A

Line B

Cell B

Op 4: Move part to inspection

Op 5: Ship part to line A

Robot 1

Gun 1

Mill 1

Part 1

Part 2Fixture library

Tool library

Tool A

Tool B

Product Process Plant

Resources

작업순서, 작업시간 정의 포함

Bill of Materials

Bill of Process





BOP 구조

E-BOM 구조Product

P1

P2

pa

pb..

..

pd

pcE/Item

comp

M-BOM 구조 ERP ; Super M-BOM 구조

동기화 구조

. BPN, 작업표준서

. Part, 공정, 작업표준서

. M-BOM구조

. BPN. E-BOM과 M-BOM구조 동기화

Interface

Product

P1

P2

pd

Body

Paint

Chasis

Trim

E/Item

사급

pa

Relationship

P3R 관리

Vehicle UnitAssy, Module

Plant

Line

Line

공정

공정

OP

OP

OP

OPPress

Welding

Assy

Paint 정합성

E-BOM, M-BOM, BOP 정합성고려된 Architecture

BOM Data 관리 Architecture

설계 변경 정확성과 효율성 고려된Architecture

Product

P1

P2

pa

pb..

..

pd

pcE/Item

comp차종별 구성 및 BP 적용 차량별 구성

2

1

3

2

1 1 1Pd.001 Pd.002

3

. ECO,BP,공정

E-BOM, M-BOM & BOP Data 정합성과 업무 효율성을 고려한 기능조직과 관련 프로세스가 필요합니다.




- Enterprise BOP

BOP B Plant 3BOP A Plant 3BOP A Plant 1

Product BOP - BProduct BOP - A

Std. Tooling Std. Processes

Generic ProductGeneric BOP

Product BProduct A

Level 1

Level 2

Level 3

Level 4The same product

in multiple plants

and/or Multiple

products in the

same plant

BOP A+B Plant 3

Plant 1 Plant 3

Global 환경 에서는 하나의 제품을 여러 곳의 공장에서 생산하는 경우가 일반화 되고 있어 Plant-Centric Process Planning 과관리가 필요 합니다.




- Enterprise BOP

Process

Plant C

Plant A

Plant B

Process

Process

Plant C

Plant B

Plant A

Part X

Part Release

지역별 제조 환경과 고객 요구 사항에 따른 Plant-Centric Process Planning이 필요 합니다.

Support product configurations and

variants - as business grows globally

Enable Re-Use in Product Families and

production standardization

Business Goal

Save time when propagating changes

on generic parts

Create Manufacturing BOM partly

automatically based on rules

Standard product skeletons to support

downstream production planning

process

Adapt product to local markets

http://images.google.com/imgres?imgurl=http://img341.imageshack.us/img341/6863/fordmfggx8.jpg&imgrefurl=http://kengkai.blogspot.com/2007/07/headquarter-of-automobile-manufacturers.html&usg=__4oj-_HesRAZgZDm8deevc2qIfVs=&h=440&w=680&sz=82&hl=en&start=20&tbnid=xUTFZC8PR6ZpiM:&tbnh=90&tbnw=139&prev=/images?q=manufacturing+plant&gbv=2&hl=en


http://images.google.com/imgres?imgurl=http://www.bipc.com.ph/images/photos/bar-manufacturing-plant.jpg&imgrefurl=http://www.bipc.com.ph/gallery.html&usg=__7DV7fxAbTbTkzwy2nnYvgryN6Zo=&h=361&w=600&sz=76&hl=en&start=5&tbnid=K_lqZpqoVkqMfM:&tbnh=81&tbnw=135&prev=/images?q=manufacturing+plant&gbv=2&hl=en


http://images.google.com/imgres?imgurl=http://www.krauscarpet.com/images/manufacturing_plant.gif&imgrefurl=http://www.krauscarpet.com/manufacturing.htm&usg=__bLaWpoA4_mrpuZqCVj9X0Lstbsw=&h=328&w=600&sz=161&hl=en&start=1&tbnid=6z9Tc0RV39EiyM:&tbnh=74&tbnw=135&prev=/images?q=manufacturing+plant&gbv=2&hl=en











- Enterprise BOP

표준 공법을 재 활용하여, 해당 공장 별 제조 환경 (부품 공급사, 설비 etc.) 을 반영한 Plant Specific BOP를 생성 관리 하며,공장별 공정계획, 작업표준서 등의 정보를 해당 공장의 MES와 유기적으로 연동되어 유연한 생산을 지원합니다

M-BOM for Plant A

M-BOM for Plant B

M-BOM for Plant C

Process

Plant C

Plant A

Plant B

Process

Process

Deliver production plans up to 40% faster

Plant specific production planning, with

process standardization and shared best-

practices

Business Goal

Integrate new sales options into

existing plant processes

Pool of best practices to support

standardization and re-use

Derive production and supply strategy

and adapt to local needs











2. BOP Validation

Manufacturing Process Management (디지털 생산 준비 시스템)

공장 계획 공정 계획 공정 검증 투자 관리금형/설비

설계 및 제작설비 설치 및

Tryout시험 가동

설계 PLM

2D/3D 도면, 형상

E-BOM, 속성

문서, 부품정보변경정보,…

자원관리

(ERP)

QIS

설비관리

(M-Ware)

생산관리

(MES)

금형자산관리

제품D

ata

인터페이스

Layout 및 공장내외물류계획,생산능력 검토

조립공차 분석

DPV : Dimensional Planning & ValidationSPC : Statistical Process Control

설비 가동률자재 재고 사전 검토

통계적 품질관리DPV & SPC

• 작업지시서,공법서

• 공정현황 정보

• 가동실적, 공정개선 정보

공정계획 / 공정편성 설비 및 치구 계획Resource배분(ST분석) 작업지시서,공법서

기본 3D 뷰잉문서관리 / 검색 송부 / 통지 Classification

Workflow BOM 관리 MS Office 연동도면 관리

Legacy

인터페이스

• Cost 정보

• Resource 정보

• Routing 정보

Process

Part

Resource

Plant공정기반정보관리

BOP



2. BOP Validation

BOP내 공정 별로 정의된 3D 제품, 설비, 조립순서를 기반으로 검증 시뮬레이션을 수행하고, 제품과 설비, 공구간 간섭,

작업자의 작업 성, 조립작업 시간 등을 검증합니다.

Process

Part

Resource


BOP

Digital Twin

Final assembly process Final/modular assembly simulation

Man-machine

operation analysis

Virtual manufacturing

Static process

prototype analysis

Robot simulation

SMT shop floor layout planning

Detailed design of work

station layout

Assembly line balance analysis

Beat / Bottleneck analysis

SMT production line layout

planning

Factory planning

Time evaluationLogistics analysis

Virtual verification of assembling



2. BOP Validation

BOP내 공정 별로 정의된 공장 Layout, 물류, CAPA,C/Time 등을 검증 합니다.

Process

Part

Resource


BOP

Digital Twin



2. BOP Validation

BOP내 공정 별로 정의된 리소스 자동화 설비, Robot의 가공, 용접 ,조립 작업 및 C/Time 등을 검증 합니다.

Robot Spot용접 작업 Operation

# 101 공정

Part1/A.000 내수 두께1 재질1 중량1, MIP

Part2/A.000 수출 두께2 재질2 중량2, VDR

용접점 001 결합 판넬 (Part1,Part2) ..

용접점 002 결합 판넬 (Part1,Part2) ..

Robot

Gun

이송 및 클램핑 Operation

Digital Twin



2. BOP Validation

BOP내 공정 별로 정의된 조립 라인의 Robot의 조립 작업 및 C/Time 등을 검증 합니다.

Robot 조립 작업 Operation

# 55 공정

Part1/A.000 내수 두께1 재질1 중량1, MIP

Part2/A.000 수출 두께2 재질2 중량2, VDR

Mfg 001 결합 판넬 (Part1,Part2) ..

Mfg 02 결합 판넬 (Part1,Part2) ..

Robot

Hand & Gripper

이송 및 클램핑 Operation

Digital Twin



2. BOP Validation

BOP에 정의된 공정, Line, Factory Level의 가상 시운전을 통하여 상세 작업을 검증 하고, Real Factory와 연계하여 생성된

로봇, PLC 프로그램을 전송, 생산 라인의 이슈 또는 문제 빠른 대응

공법 계획

Process

Part

Resource


BOP

Digital Twin



3. BOP Output

완성된 BOP로 부터 전자 공법서 및 작업 지시서 생성, 현장 전송과 생산 라인의 정보 즉각적인 Feedback

웹기반EWI 조회

3D PDF배포



3. BOP Output

검증 후 BOP Data에 Robot 및 PLC 프로그램을 저장하여 현장 생산 정보 시스템과 연계 관리 하며, 제품 사양 또는 공법

변경에 따른 업데이트를 자동화 합니다.

로봇프로그램

Real Factory

ETHERNET

FLOOR 라인

30 공정

10 공정

40 공정

FLR ASSY-COMPL

Robot 1

BIW 용접

1라인

Floor Panel1

용접점1

조립공법1

40 공정

창원공장

20 공정

Weldgun 1

Robot 2

Weldgun 2

Download

로봇프로그램생성

Upload

여러 공장별로봇 프로그램생성 관리

로봇프로그램

상세공정의로봇

및특정로봇프로

그램 선택가능



3. BOP Output

NC 검증 후 BOP Data에 머시닝 센터 Off Line NC 프로그램을 저장하여, 해당 공구 Tool 정보와 함께 현장 생산 정보

시스템과 연계 관리 하며, 제품 사양 또는 공법 변경에 따른 업데이트 작업을 자동화 합니다.

Teamcenter Shop Floor Connect for Teamcenter DNCFailoverDatabase

Shop Floor Connect Services

▨ Transparency ▨ Revision control▨ One logical database▨ Compliance▨ Security ▨ Closed loop



4. BOP & MES- PLM-MES-ERP

Teamcenter Manufacturing

Enterprise BOP

SIMATIC IT

Executable BOP

SIMATIC IT

Preactor APS




Avoid disturbances on mix-model production lines when applying process changes

Manage different plants from centralized place

ERP

MES양산 품질 추적 관리

실시간 생산 Data 수집

APS생산 일정 계획

Simulation

Shop FloorShop Floor

Integration

Digital Factory

Product A

Complete

프로젝트 관리

개발단계 품질 문제 관리

Process

Definition`

Engineering

Feedback

Part Program

& Instructions

Production

Feedback

Scheduled

OperationsProduction

Snapshot

Production

Performance

Order

List

Component

List

Component

Availability

Tool

Tool A

BOP

Master

Schedule

Digital Backbone for Enterprise Manufacturing System (Data & Process Management)

. .

. .




BOP에 저장된 BOM, 공정계획, 작업표준서 등의 정보는 MES, 생산 라인과 유기적으로 연동되어 유연한 생산 및 제품 변경에

따른 변경관리 프로세스를 지원합니다.



60,000+ customers worldwide each year

24 hour lead time for new orders

75% OEE plus 20% buffer for overcapacity

~1 Million monthly production of SIMATIC products

1200+ Teamcenter managed products shipped to

Siemens Amberg plant

Fast!

Flexible!

Efficient

~11 dpm means near perfect quality – every timeQuality!



MES Software (Simatic IT)

Customer

PCB-program-generator ERP

Product data management

Manufacturing Planning (BOP)

5. 사례 – Siemens AmbergPLM / MES Integration

Templates SMT SPI AOI ICT / FP

X-Ray THT Labels IFT Inspection

PLM Software

Supplier

Production order

Capacity

Inventory Mgmt.Process interlocking

Traceability

Serial number report

Test protocol

Relevant product data

information

Recipe

Intelligent

preprocessing

Material forecast

Automatic order

Delivery

BOM

Resource

Process







Enterprise Level

Management Level

Operator Level

Control Level

Field Level SIMATIC NETIndustrial

Communication

SIMATICControllers

SIMATIC IDENTIndustrial

Identification

SIMATIC Distributed I/O

SINAMICSDrive Systems

SIRIUSIndustrialControls

SINUMERIKCNC

SIMATICHMI

SIMOTIONMotion Control

TIA PORTALEngineering

Framework for

Automation Tasks

SIMATIC IT

Intelligence Suite

SIMATIC IT

Production Suite

SIMATIC IT

R&D Suite

PLMERP

MES

SCADA

SIMATIC WinCCSCADA System

TECNOMATIX

Digital

Manufacturing

TEAMCENTER

Collaborative

PDM

NX

Product

Development

Plant Cloud

Services

BOP

MES

Collaborative Operational Approach - Seamless Lifecycle Integration

Prg.




Program and Project management

Sales Manufacturing ExecutionProduct Engineering Manufacturing Planning

Customer RequestOffer

discussion/orderRequirements management

Conce

ptionDesign Serial Design Prototyping Ramp-up Execution

Manufacturing conception Process planning Manufacturing Tryout

Customer

requests/

forecast

Order

Management

EBOM

Technical

Material

Master

Qual. prdt.

Ideas with

requirements

and features

MCAD

ECAD

SW

Bill of

Material

Bill of

Resource

Order handling (eq:

availability capa,

material, releasing)

Production order management

Production Execution-S-ITPool of

product

ideas

Data Transfer-

via COMESA

Document Management

APQP( Audit, FMEA, Review, Quality Function Deployment, Deisgn of experiment)

ERP

Master

Material-

SAP-A2P

MBOM

definition

including

configuration

rules, NC prog

Project management

Production

tracking

Production

traceability and

data collection

Production

Performance

Analysis-line out.

Production

Definition

Management

Production Quality

and defect

management

Production

Dispatch

Production Data

Collection-QME

Production

Resource and

Gage

Management

+Access tool

MDE/ OEE- for

equipments utilization

APLAUS

Unicam

Stab

Doors

S-IT

Production order

prioritization and

creation

Scout

WSS

APLAUS

WSS

S-IT

KapMes

methods

PNBs

TFS

TFS

SCM-plan

methods



5. 사례 – Siemens AmbergPLM / MES Integration; Employees are integrated into the Digital Factory



Light Guide Video



SIT Manufacturing

Service APIs



5. 사례 – ITP (Aircraft Engine)

PLM / MES Integration

Every time you

are flying a

newer Airbus,

chances are

that the plane

was built with

the help of

SIMATIC IT(MES)

Aircraft structure

Mechanical part manufacturing (Zamudio)

Composite part Manufacturing and Assembly (Ajalvir)



5. 사례 – ITP (Aircraft Engine)

PLM / MES Integration

설계에서 생성된 CAD도면 과 Engineering BOM를 기반으로 생산 프로세스를 연결하여 BOP를 생성하고 SMATIC IT를

이용하여 MES와 연계 합니다.

ITP

(Industria de Turbo Propulsores)



5. 사례 – Rolls-Royce

BOP & Planning Shop Floor Operations



5. 사례 – ZeMA (CPS)

Cyber-physical assembly planning in Siemens Teamcenter

- Virtuality meets Reality




Three-pillar model of ZeMA is directed to the needs of education, application research and industrial problems



5. 사례 – ZeMA (CPS)Challenges for the assembly planning between product development and production



5. 사례 – ZeMA (CPS)Objective for assembly planning and operating of cyber-physical assembly system



5. 사례 – ZeMA (CPS)Approach to connect virtual and real world during planning




Using the data from the virtual planning by requesting assembly services from the assembly modules in reality




Identification of the configuration and update of the planning model




Summary

© Siemens AG 2016

25.-29. April 2016Seite 45 siemens.de/hm16

© Siemens AG 2016

25.-29. April 2016Seite 46 siemens.de/hm16

Digital Enterprise Software Suite –

Siemens’ answer to Industrie 4.0 requirements

TIASIMATIC / SINUMERIK

PLMTeamcenter / NX

MES/MOMSIMATIC IT / QSYS

12.12.2016 Dr. Jan Mrosik | Siemens AG | CEO Digital Factory DivisionPage 46

© Siemens AG 2016

AnalyticsMindsphere / Omneo

Documents

Digital Factory를위한 Bill of Process Production 정보와 …통계적품질관리 DPV & SPC •업지시서,공법서 •공정현황정보 •가동실적, 공정개선정보