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IBM Software Group – Product Lifecycle Management
2
목 차
What is Digital Manufacturing?What is Digital Manufacturing?III
Design-to-Build Process with DELMIA Design-to-Build Process with DELMIA IIIIII
Process Engineer IntroductionProcess Engineer IntroductionIIIIIIIII
DELMIA Process Engineer Key BenefitsDELMIA Process Engineer Key BenefitsIVIVIV
IBM Software Group – Product Lifecycle Management
3
What is Digital Manufacturing?
Process planning
Factory Modeling
Visualization and Collaboration
Simulation of operations
Ergonomic and human factor analysis
“the Keyhole to the Future”
Digital Manufacturing is…
IBM Software Group – Product Lifecycle Management
4
INTELLECTUAL PROPERTYINTELLECTUAL PROPERTYINTELLECTUAL PROPERTY
VIRTUALTangible Assets
REAL OPERATIONSREAL OPERATIONSREAL OPERATIONS
Non Tangible Assets
PHYSICAL
Product & Process Knowledge Production
Courtesy Dassault Aviation- Falcon 7X
Bringing the two together
IBM Software Group – Product Lifecycle Management
5
Product Development
Process PlanningManufacturing Concept
Layout planning Standard Time Measurement
A Seamless End-to-End Workflow
RobotSimulation
Manufacturing SimulationQuality Control
Material FlowSimulationProduction
Planning
3D WorkInstructions
ControlEngineering
Process Planning
WorkstationLayout
Ergonomics
HUMAN
Resource Modeling
and Simulation
Process Planning
Production
Flow
Simulation
Process Detailing
And
Validation
Automation
Manufacturing
ExecutionProcess Detailing
And
Validation
IBM Software Group – Product Lifecycle Management
6
ProcessPlanning
Process Detailing & Validation
Resource Modeling & Simulation
Product EvaluationProcess & Resource PlanningTime MeasurementLayout PlanningLine BalancingCost Analysis
3D geometry based detailing Assembly SequencesFastener ManagementMachining OperationsFactory/Cell Layouts
Factory Flow SimulationsRobotic Work cell Setup and OLPNC MachiningVirtual Reality ScenariosErgonomic AnalysisControl Engineering
Three Distinct Domains for Digital Manufacturing
IBM Software Group – Product Lifecycle Management
7
목 차
What is Digital Manufacturing?What is Digital Manufacturing?III
Design-to-Build Process with DELMIA Design-to-Build Process with DELMIA IIIIII
Process Engineer IntroductionProcess Engineer IntroductionIIIIIIIII
DELMIA Process Engineer Key BenefitsDELMIA Process Engineer Key BenefitsIVIVIV
IBM Software Group – Product Lifecycle Management
8
OUT Tail Number MBOM & Tooling/Equipment/ Manpower Definition, Part/Equipment Ordering,
Work Scheduling, Textual Planning
ERP
INTa
il N
umbe
r EB
OM
D
efin
ition
•40%+ Higher Re-planning Cost•25%+ Higher Assembly Cost•25%+ More Assembly Errors & Rework
• Risks meeting commitments• Competition will make this model unsustainable• Limits future growth through hampering innovation
• Longer Time to Production / Market• Longer Cycle Times in Production
• Production Knowledge Undocumented• Intellectual Property Left Untapped
OUT Model-Based Definition: Features, Annotations, Tooling Definition
IND
esig
n R
equi
rem
ents
DESIGN
Design Engineers
Model Views
Textual Work Instructions
PRODUCTION
OUT Build Aircraft, Document As-Built Record
INB
uild
Pla
ns &
Wor
k In
stru
ctio
ns
MRP/MES
Manufacturing Engineers
Workers
MRP/MES
MBD Explosion(Model Views)
EBOM-MBOM Reconciliation
Design-to-Build Process in non-DELMIA Digital Manufacturing
IBM Software Group – Product Lifecycle Management
9
PRODUCTION
OUT Build Aircraft, Document As-Built Record
INB
uild
Pla
ns &
Wor
k In
stru
ctio
ns
MRP/MES
ERP
INTa
il N
umbe
r MB
OM
D
efin
ition
OUT Part / Equipment Ordering, Work Scheduling
Workers
Design Data Integration:Product Structure / Metadata / Configuration / Effectivity (ENOVIA)Intellectual Property (CATIA)
Shop Floor Integration: Assign Daily Work OrdersPart / Equipment / Worker Status
Shop Floor Integration:Model-Based Instructions per Work Order
ERP Integration:
Tail Number M
BOM
(including Standard
Parts re
ferenced in
CATIA design)
Routings
Tools & Equipment
OUT Model-Based Definition: Features, Annotations, Tooling Definition
IND
esig
n R
equi
rem
ents
DESIGN
Design Engineers Production Engineers
MANUFACTURING ENGINEERS
OU
TM
odel
-Bas
ed P
lann
ing
IN Model-Based Definition: As-Designed Requirements
ME Planners
Design-to-Build Process with DELMIA Digital Manufacturing
IBM Software Group – Product Lifecycle Management
10
목 차
What is Digital Manufacturing?What is Digital Manufacturing?III
Design-to-Build Process with DELMIA Design-to-Build Process with DELMIA IIIIII
Process Engineer IntroductionProcess Engineer IntroductionIIIIIIIII
DELMIA Process Engineer Key BenefitsDELMIA Process Engineer Key BenefitsIVIVIV
IBM Software Group – Product Lifecycle Management
11
PRODUCTEngineering HubEngineering Hub
((Product))
Manufacturing HubManufacturing Hub((Product, Process, , Resource))
Process EngineerProcess Engineer
Process Engineer Position in PLM
PRODUCT
RESOURCES
V5 DPMV5 DPM--AssemblyAssembly
V5 DELMIA HumanV5 DELMIA Human
QUESTQUEST
PROCESS
IBM Software Group – Product Lifecycle Management
12
Process Engineer에 의한 Digital Process Planning
=> 생산기술 전체 영역의 디지털 공정 및 생산계획 Solution => 가상생산의 PPR Hub
M-BOM 및 Option 관리
Process Planning
Resource Planning
Digital 환경에서 제품의 조립체계에 의한 공정계획 및 공수산정, 최종 생산설비 Layout 계획을 수행할 수 있는Digital Manufacturing Solution
Process Engineer®
생산 전제조건 정의 (Target, Shift Model, 투자비, 부자재, 생산계획조건 등…)
Process Engineer의 주 역할
자재계획 정의, 생산 Concept 및 3D Layout
M-BOM 정의 및 OPTION, 이력관리 인간공학적 작업자 계획 및 작업자 분석
작업 표준공수 산정 Cost 분석
공정계획, Work Plan, Process Flow 정의 제품, 공정, 자원 DB 관리
1
2
3
4
6
7
8
9
Line Balancing (Work Load 및 Automatic ) 공정도, 작업표준 및 문서 출력5 10
IBM Software Group – Product Lifecycle Management
13
Process Engineer Process Planning &
Resource management Product Data Management
P D M
3D CAD
설계 DMU CAE
2D CAD
제품설계지원 Solution 생산기술지원 Solution
자재 Layout 조립 DPA 검증
HUMAN
공장 물류흐름
Robot OLP, MCP, MCS 공정계획, 표준작업시간, 조립공법서, 작업편성표
선행제품검토, Concept Manufacturing에서 최종 Layout 설계에 이르기 까지관련 제품, 공정, 자원을 고려하여 쉽고, 빠르고, 정확하게, 경제성을 고려한 최적의 Process
Plan 을 수립할 수 있는 시스템 지원 필요합니다.
Why we need Process Engineer?
IBM Software Group – Product Lifecycle Management
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Process
Resource
Product
BOM 관리
조립프로세스
Layout
자원
제품
필요한 모든 Data와 시스템이상호 유기적으로 Link 되어 있지 않다.
시간, 노력, Data 손실
현재 생산기술과 제조에서 필요한 기술검토와 문서(공법서, 작업지시서)들은 매번 Engineer의 경험과수작업에 의해 Excel로 만들어지고 있습니다.!!
AS IS TO BE
PDM
SAP, Manual (Excel)..
AutoCAD /EXCEL..
CATIA..
CATIA..
Integrated Environment for Digital Process Planning
All in one
IBM Software Group – Product Lifecycle Management
15
Non-Integrated Environment for Process Planning
Project Premises Process Definition
Concept Layout
Line Balancing
Simulation
Ergonomics
Product Evaluation
Layout
Time Analyses
Product Viewer
123
IBM Software Group – Product Lifecycle Management
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Project Premises Process Definition
Concept Layout
Line Balancing
Simulation
Ergonomics
Product Evaluation
Layout
Time Analyses
Product Viewer
123
Integrated Environment for Process Planning
IBM Software Group – Product Lifecycle Management
17
IntegratedDatabase
Project Premises
Process Definition
Manufacturing Concept
Line BalancingTime Analyses
Simulation
Layout
Ergonomics
Product Evaluation
Systematic Process Planning
IBM Software Group – Product Lifecycle Management
18
Premises
Manufacturing Hub
Line Balancing
Product analyses
Process definition Process graph
Time analyses
EvaluationManufacturingConcept
LayoutErgonomicsSimulation
Quick access to up to date data
Quick documentationQuick analyses
DELMIA
Digital Process Planning in Process Engineer
IBM Software Group – Product Lifecycle Management
19
Engineering Engineering -- BOMBOM Manufacturing Manufacturing -- BOMBOMPProductroduct
Process PlanProcess Plan
PProcessrocess
RResourceesource3D 3D –– Layout PlanLayout Plan
Production PlanProduction Plan
2D 2D –– Manufacturing ConceptManufacturing Concept
Preliminary PlanPreliminary Plan
Concept M-BOM
Final M-BOM
Process Engineer의 전체 Work Flow
IBM Software Group – Product Lifecycle Management
20
Listviewlists up all objects which belong to selected parent object
Property dialogfor a selected object
Easily access/edit/view
– List views
– Object properties
– Process Graphs
– Time Analyses
– Product geometry (from PDM)
– Layout
– Line Balancing
Process Engineer User-Interface
IBM Software Group – Product Lifecycle Management
21
Planning Premises ( 전제조건 )새로운 Project 시작 시, 생산계획을 위한 경계조건(Boundary Condition) 정의
제품 생산계획 곡선
전제 조건의 속성 Data
– 생산일정별 생산계획
– 생산공장 Site 정보
– 교대조건(Shift Model)
– Cost 목표
– Cost 비율(Cost Rates)
– 혼류생산 비율
– Target Volume
– Target Cycle Time
– ...
IBM Software Group – Product Lifecycle Management
22
Product Evaluation ( 제품 검토 )
외부 시스템이나 소스로부터 E-BOM Import/Update
– E.g : From VPM or PDM or Excel File
M-BOM 생성
Product variants 관리
– By use of variant codes and mathematically logical expressions
IBM Software Group – Product Lifecycle Management
23
Process Tree 구조에서 Process 생성 및관리 (관련 부품과 Link)
다중의 상세 Level 단계를 가진 Process 계층 구조 정의
Process Graph에서 Process의 우선순위조건과 Process 순서 정의
Process에 제품과 설비의 쉬운 Link (Drag & Drop 사용)
Drag&drop parts directly on process
Model precedence constraints for processes
Process Definition ( 프로세스 정의 )
IBM Software Group – Product Lifecycle Management
24
Same DataManufacturing Hub is the
common data source(one common data model)
DELMIA V5 Interaction
IBM Software Group – Product Lifecycle Management
25
Time Analysis
빠르고 효과적인 표준시간 분석값 생성
– 사용 가능한 국제표준 시간분석방법 :
– MTM-I, MTM-II, Standard Data, UAS, MEK, WF, Office tasks, Visual Inspection,…
표준시간 Data Card를 사용한 신속하고 효과적인시간분석
사용자 정의 Data Card 생성
Process 시간을 계산하기 위한 사용자 정의함수(Formulas) 생성
정확성을 위한 Rules Check
유연한 검색 기능(Filtering)
IBM Software Group – Product Lifecycle Management
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Line Balancing
PROCESS ENGINEER에서 2가지의 line balancing module을 제공합니다.
– Work Load Balancing module
• 일반적 Line Balancing • 신속한 Process의 Balancing• Station/작업자 편성율(가동율) 최적화
– Automatic Line Balancing module
• 다양한 제약 구속조건 고려
• 혼류생산과 자재면적 Balancing
IBM Software Group – Product Lifecycle Management
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기간별 생산계획조건에 따른 생산 능력 검증
3D layout 생성
Simulate material flow
다른 시나리오 조건의Manufacturing Concept과 비교
사용자 작업표준서, 공정계획서 출력
목표 Cost 추적
From the Manufacturing Concept...
Traffic light evaluation of Occupancy levels
IBM Software Group – Product Lifecycle Management
28
Manufacturing Concept
Manufacturing Concept에 의한 직접적, 대략적 상세 3D Layout 생성
Line Balancing된 Resource Tree 구조와 Link
BOR(Bill of Resources) 자동 생성
공구, 지그, 설비들에 대한 공용 System Library 활용 다중 Layout에서 재사용
Library
Layout
Line Balancingresource structure
IBM Software Group – Product Lifecycle Management
29
3D 작업장에서의 정적 작업자에 의한 작업환경평가
– human models of different nationalities and size (5th, 5th,95th percentil)
– View reach ranges, field of vision
Assess workplace by using common check sheets and analysis methods
– NIOSH, REFA, DIN, EN, etc.
– Analysis & check sheets are stored with each workplace and can be accessed anytime
Ergonomic Evaluation
IBM Software Group – Product Lifecycle Management
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Reporting in Process EngineerProcess Engineer는 내장된 template editor를 이용하여 각 회사에서요구되어지는 문서 표준에 맞추어 프린트 기능을 제공
Work plans,Cost sheets,Station resource lists,…
– Combine any geometry and meta data from product, process and resource on a single template
– Print documents, or output to
• MS Office,• html, xml, pdf, etc.
IBM Software Group – Product Lifecycle Management
31
TargetCosting
ProcessGraph
Work Plan
Assembly SimulationPre-Planning
Bill of Resources
Integrated Process Modeling(Common Data Model)
MBOM
Task sequencing
Reconcile EBOM-MBOM, & Process Plans
Status reports
Cost Tracking
Capture and Reuse Best Practices
StandardTimes
Operations Balancing
Output Result
Summary Process Planning
IBM Software Group – Product Lifecycle Management
32
목 차
What is Digital Manufacturing?What is Digital Manufacturing?III
Design-to-Build Process with DELMIA Design-to-Build Process with DELMIA IIIIII
Process Engineer IntroductionProcess Engineer IntroductionIIIIIIIII
DELMIA Process Engineer Key BenefitsDELMIA Process Engineer Key BenefitsIVIVIV
IBM Software Group – Product Lifecycle Management
33
DELMIA Process Engineer Key Benefits
체계적 방법론에 의한 생산준비 계획업무의 Structure화
Planning Process안에 모든 기술요소의 통합화
선행단계에서 Process의 위험 및 Error요소의 검출
검증된 공정과 자원의 재 사용
다양하게 분산된 공정지식의 통합 사용
시나리오를 기반한 선행단계에서의 대안평가
체계적인 Cost Input 평가에 의한 최적 Solution의 실현
합리적이고 이해하기 쉬운 의사결정과 변경
중복업무의 감소
계획의 질과 신뢰성 증진
계획시간의 단축 (생산준비시간의 단축)
Process Planning, Detailing and Validating에 대한 연속되고 통합된 3D 환경 제공
Product Process Resource 정보를 공유하고 활용하는 Collaborative Workspace 제공