INSTITUTO TECNOLÓGICO Y DE ESTUDIOS SUPERIORES DE MONTERREY

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INSTITUTO TECNOLÓGICO Y DE ESTUDIOS SUPERIORES DE MONTERREY

C A M P U S M O N T E R R E Y

G R A D U A T E P R O G R A M IN ARCHITECTURE A N D ENGINEERING AREAS

T H E S I S

M A S T E R O F S C I E N C E IN M A N U F A C T U R I N G S Y S T E M S

COLLABORATIVE FLEXIBLE M A N U F A C T U R I N G S Y S T E M D E V E L O P M E N T SUPPORTED BY P L M T O O L S

BY

K A R E N M. FUENTES LARA,

TECNOLÓGICO DE MONTERREY

MONTERREY, N.L., MAY 2008

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I N S T I T U T O T E C N O L Ó G I C O Y D E ESTUDIOS S U P E R I O R E S D E M O N T E R R E Y C A M P U S M O N T E R R E Y

G R A D U A T E P R O G R A M IN A R C H I T E C T U R E A N D E N G I N E E R I N G A R E A S

T H E S I S

M A S T E R OF S C I E N C E IN M A N U F A C T U R I N G S Y S T E M S

Collaborative Flexible Manufacturing System Development Supported by PLM Tools

by

Karen M . Fuentes Lara

TECNOLÓGICO DE MONTERREY

Monterrey, N.L., May 2008

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©Karen M. Fuentes Lara, 2008.

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Collaborative Flexible Manufacturing System Development Supported by PLM

Tools

by

Karen M. Fuentes Lara T h e s i s

Submitted to the Graduate Program in Architecture and Engineering Areas

at the

Instituto Tecnológico y de Estudios Superiores de Monterrey, Campus Monterrey

in partial fulfillment of the requirements for the

degree

^of

Master of Science

in

Manufacturing Systems

Instituto Tecnológico y de Estudios Superiores de Monterrey

Campus Monterrey

Monterrey, N.L., May 2008

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ix

Abstract

The main purpose of this thesis is to develop a model for Flexible Manufacturing System development that supports collaborative engineering and concurrent activities in order to achieve efficiency in the development process. The model is supported by PLM concepts that provides the structure to achieve the concurrency and collaborative work.

The thesis attempt to propose a solution to the high degree of sequencing on activities and the engineering disciplines involved on the FMS development. Typically, the FMS development starts with the mechanical design, followed by the physical implementation and later the control design and implementation. As an example, for the control engineering area, few activities can be made before the FMS is physically available. The result of this kind of work is a project with a large duration and a high degree of uncertainly on its deadline.

Is a key issue to reduce the deadline uncertainly and increase the efficiency of the FMS development project. To fulfill that, is required to prioritize and arrange the old practices and convert it into a processes well defined and supported by known frameworks, as is PLM approach. This change will bring additional benefits such as an innovating organization, and efficient and effective work teams, which have an effect on the cost and time consuming.

In order to minimize the problem, has been proposed a model which contextualizes the facilities development within the product lifecycle, facilitating the concurrent work and supported by PLM tools. Because the model is based on a collaborative environment, are considered standards processes modeling languages, such as IdefO and BPMN diagrams, in order to specify the inputs, outputs, resources and directives that controls every stage of the lifecycle. Each of the lifecycle stage has its own process diagram that defines clearly the concurrency of the engineering areas. At the same time, is defined the tools that supports the activities accomplishment.

Finally, the results and conclusion are exposed. These are grouped by five major's issues: the facilities development model, the collaboration and concurrency, the innovation, the PLM tools application and the activities integration. For the facilities model is analyzed the contribution that the model has, the benefits obtained with the concurrent activities, the enhancing of innovations and it consequences in the FMS development, the identification of the appropriated PLM tools, and the additional benefits achieved with the integration of the information.

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X

Acknowledgments

I would like to express my gratitude to my thesis advisor, M.C. Ricardo Jiménez, whose expertise, understanding, and patience, added considerably to my graduate experience through all these years. I would like to thank the other members of my committee, co-advisor Ph.D. David Guerra and examiner M.C. Edgar Ramon for the assistance they provided at all levels of the research project.

I must also recognize the valuable contributions of a great work team that have been working on PLM project, especially to Ing. Jorge Avila, Ing. Gabriela Barba, and Ing. Mauricio Hincapié. Special tanks to Lic. Claudia Ruiz de Esparza by its aid with the images generation for latex.

I must also acknowledge to Ing. Fernando Contreras from Dassault Systemes Mexico, and Ing. Tomás Vargas from Enterprise Engineering Solutions, by the support received in PLM software solutions developed by Dassault Systemes.

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List of Figures

1.1 Historical development of mechatronic system [Isermann 03] 2

1.2 Companies hit target [Jackson 06] 3

1.3 FMS typical workflow 4

2.1 The form partition of BOM in PLM system [Cui 06] 7 2.2 Digital manufacturing as a component of PLM [Cui 06] 10 2.3 General process chain of product development [Dankwort 04] 11 3.1 Reference model for the integrated environments [Lundgren 01] 17 3.2 Organization of the VIR-ENG research program [Moore 03] 18 3.3 The VIR-ENG manufacturing machine system model [Moore 03]. . . . 19 3.4 Control logic component system model [Moore 03] 20 3.5 The VIR ENG interrelationships between workpackages [Lundgren 01]. 20 3.6 Workflow within MMDE and DCSE [Lundgren 01] 21 3.7 Product lifecycle modeling framework [Zhang 06] 22

3.8 Requirements analysis model [Zhang 06] 22

3.9 Conceptual design model [Zhang 06] 23

3.10 Detailed design model [Zhang 06] 24

3.11 Manufacturing model[Zhang 06] 24

3.12 Services model [Zhang 06] 25

4.1 Product development lifecycle 26

4.2 Facility development lifecycle 27

4.3 IdefO diagrams summary 28

4.4 [A-0] Diagram: Product development context 30

4.5 [AO] Diagram: Product development lifecycle 36

4.6 [A20] diagram: Facilities development lifecycle 39

4.7 P-21 Process diagram: Process-level design 48

4.8 P-22 Process diagram: Conceptual design 49

4.9 P-23 Process diagram: Detailed design 50

4.10 P-24 Process diagram: Physical integration 52

4.11 P-25 Process diagram: Logical integration 53

4.12 P-26 Process diagram: Implementation 54

5.1 Process-level design task groups carried out by PLM Tools 57

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List of Figures xiv

5.2 CAD Specification 58

5.3 FMS virtual conceptualization 58

5.4 FMS virtual optimization 59

5.5 Conceptual design sequencing task 60

5.6 Sequence definition with state charts 60

5.7 Detailed design task groups carried out by PLM Tools 61

5.8 CNC offline simulation and programming 62

5.9 Mechanical device subassembly 63

5.10 FMS virtual subassemblies 63

5.11 FMS virtual mechanical integration 64

5.12 FMS engineering analysis 64

5.13 Robot offline programming 65

5.14 Logic control programming 66

5.15 Electrical Design 66

5.16 Physical integration task supported by PLM Tools 67

5.17 PDM supporting engineering changes 67

5.18 Physical Assembly 68

5.19 Logical Integration tasks supported by PLM Tools 69

5.20 Product Data Management support 69

5.21 Flexible Manufacturing System installed 70

6.1 MHS Reconfiguration 72

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Chapter 1 Introduction

1.1 Background

In order to eater the market demands is really evident the efforts that companies do to improves its own competitiveness by mean of increasing the product quality, minimize the time response to market changes, etc. In the other hand, the trends in many industries is an increasing importance to include embedded software and electronics component into mechanical products to make them work efficiently. These products are from aircraft to home appliances. These competitive improvement opportunities are driving the tendency toward mechatronie development: indeed, mechatronic innovations in the past are today commodities. Figure 1.1 summarizes the development, from the beginning with purely mechanical systems to mechatronic systems in the 1980s [Isermann 03].

This tendency really force to companies to renew or improve its internal production processes. Manufacturing automation is an alternative to achieve this goal by mean of Flexible Manufacturing Systems (FMS) implementations. An FMS may be considerate as a mechatronic manufacturing system since it is integrated by electrical, mechanical and control/software subsystems [Jackson 06]. In this way, the mechatronic concept is impacting not. only in products, but in the own productive process. In fact, today mechatronic systems are producing mechatronic products to the market.

At ITESM Campus Monterrey, Flexible Manufacturing Didactic Systems (FMDS) are fully developed by the Automation Group. The main purpose is to implement engineering mechatronics laboratories with the appropriate educative technology.

FMDS are composed principally by industrial robots, CNC machines, AS/RS and material handling equipments. The experience shows that the design and development stages are the mayor project's challenges. The inclusion of new automation technology, customer requirements considerations, optimizations and mechanical improvements impacts on the FMDS development process. Consequently, never a new FMDS is identical to the last one. Additionally, accordingly CimData, the mayor impediment that face the development of mechatronics products are organizational in nature

1

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Chapter 1. Introduction 2

Pure mechanical system

DC motor 1870 A C motor 1889

steam engine 1860 0 0 dynamos 1870 circular pumps 1860 combustion engine 1880 mech. typewriter Mechanical systems with

electrical drives 1 9 2 0

Relays, solenoids Hydraulic, pneumatic, electric amplifiers Pl-controllers 1930 Mechanical sysfcyn with automatic

control 1 9 3 5

Transistor 1948 Tryristor 1955 Mechanical system with

• electronic (analog) control

• sequential control 1 9 5 5 Digital computer 1955 Process computer 1959 Real-time software 1966 Micro computer 1971 Digital decentralized automation 1975 Mechanical system with

• digital continuous control

• sigital sequential control 1 9 7 5 Micro controller 1978 Personal computer 1980 Process/field bus system New actuators, sensors Integration of components

tool machines pumps el. typewriter

Steam turbines aircraft Electronic controlled lifts

Machine tools Industrial robots Industrial plants disk drives

Mechatronic systems

• integration: mechanics and electronics hardware

• software determines functions

• new design tools for simultaneous engineering

• synergetic effects

mobile robots magnetic bearings CIM automotive control (ABS, ESP)

increasing electrical drives

increasing automatic control

increasing automation with process computers and miniaturisation

increasing integration of processes and microcomputers

Figure 1.1: Historical development of mechatronic system [Isermarm 03].

[CIMdata 04].

Over the last several years, Product Lifecycle Management (PLM) has emerged as common term used to describe the creation, management and use of the product and plant related information and processes throughout the entire lifecycle and across the extended enterprise. Today, is well known that world-class companies are including PLM and collaborative work to develop complex product like air-crafts and automobiles improving in this way its design and product development processes. In fact, AberdeenGroup's research shows that getting engineering disciplines to work together is a formidable problem. As expected, companies in the different performance categories show marked differences with best in class hitting all five marks at an 84%

or better average, see figure 1.2. Additionally, AberdeenGroup found that the best in class¹ performers averaged margins of 29% overall compared to 9% for the other survey respondents. This should come as no surprise because companies that hit revenue, product cost, and development cost target rougthly 90%) of the time are more likely to be profitable [Jackson 06].

At most companies, structures generally are organized by different disciplines

1

Based on aggregate scores incorporating all five metrics, those companies in the top 20% achieved

"best in class" status; those in the middle 50% were "average"; and those in the bottom 30% were

"laggard"

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Chapter 1. Introduction

3

O B I C

• Avg O Laggard

R e v e n u e target Product cost Product

target development

cost target

launch dates Quality target

Figure 1.2: Companies hit target [Jackson 06]

working and operating in isolation from each other, and passing project information from one group to another in serial way. Disciplines works in silos with their own individual design processes and non-integrated information system tools. As a result, engineers downstream have little opportunity to provide valuable input early in the cycle, and design deficiencies often are not uncovered until late in the process when changes are costly and timing consuming [Miller 06]. According that, one of the main challenges of the present work is to develop a model that allows the design ans efficient work process under one collaborative program. Based on PLM experiences of other industries, PLM strategies and its tools must provide the bases to implement this approach on Flexible Manufacturing Didactics Systems (FMDS).

1.2 Problem Definition

The Flexible Manufacturing Didactic Systems (FMDS) developed by ITESM are made in collaboration with tree main teams. Accordingly to a typical mechatronics organizational areas[Guerra 06] and the professional experience of the author, the teams involved in the mechatronics development are Mechanical Engineering. Con- trol/Electrical Engineering, and Physical Assembly Engineering. The first one is in charge of mechanical design, being the starting point of entire development process.

Assembly area starts its job when the mayor number of commercial and designed parts were received and classified in storage inventory. That implies from one to two month of assembly engineering idle time, considering mechanical design time consuming, acquisitions and supplier's delays, etc. Control/Electrical team takes place only when FMDS is completely assembled, so the larges times delays seem to be obvious. Although Control/Electrical team can deploy limited activities before physical FMDS are assembly (such as HMI screens preparations, robot preparations for programming, etc.), the physical FMDS is required to optimize and testing the entire control software and programming.

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Chapter 1. Introduction ⁴

The figure 1.3 illustrate the lifecycle of the FMDS development. All stages are highly sequential. As a consequence, the FMDS workflow is a slow process, the information documented in project lifecycle is poor and communication channels are constricted.

Figure 1.3: FMS typical workflow

The negative impacts on projects are critical. These include important delays at launching time, a deficient documentation of engineering, a large amount of reworking and corrections, and the poor innovation capacity of the entire organization.

All derived from a lack of internal processes and communications channels that coordinates the deferents areas, and the lack of tools that facilitate the collaborative and concurrent work. Evidently, all this factors impacts finally on project cost and time.

1.3 Objective

The main objective of this thesis is to establish a model that, under a collaborative approach, defines, integrates and coordinates the multidisciplinary activities of engineering involved in the development of Flexible Manufacturing Systems (FMS), supported by Product Lifecycle Management (PLM) tools, in order to enhance the efficiency on FMS projects developments.

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Chapter 1. Introduction 5

Inside the main objective, the FMS development model specifically must to:

• Describe clearly the context within the facilities development is settled into the product development

• Define a collaborative and concurrent activities flow

• Support the innovation for the facilities development process

• Identify the specific PLM tools that supports the facilities development process

• Propose a software platform that integrates the engineering areas involved in facilities development

1.4 Scope of Research

The present: research will be focused on construct a model accordingly to the strategies and tools of the PLM philosophy applicable to Flexible Manufacturing Systems development, and its working areas, such as process, mechanical, electrical, control and physical installation. The integration toward the customer services such as sales, maintain, support, dispose, etc. are excluded as well as the suppliers relationship.

As it. includes a collaborative approach and the PLM framework, the concurrent development of the Flexible Manufacturing Systems must to be considerated inside the scope. An important PLM component is virtual or digital manufacturing, that is used in this model as the main PLM Tool. Therefore, the definition of the PLM tools that are useful to this model must be defined. As the main interest is the concurrent development, the project time is an important issue that is considerated as a metric in the results.

It is inside the scope to evaluate and define the Product Data Management benefits and its role on collaborative work, but is not considering in this research the Knowledge Management and its impacts over the FMS development lifecycle.

Not only engineering aspects make possible to build a FMS. Other areas supports the engineering development as is acquisition area. It is responsible for acquiring all commercial parts of the FMS and maintains a link with suppliers. Is not considering in this research to include economical aspect, and its integration with the PLM strategies is proposed for further researches.

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Chapter 2 Literature Review

2.1 Product Lifecycle Management

PLM is a new activity for manufacturing companies that opens up new business opportunities [Clements 03] [Ulrich 04]. As an holistic business activity, it. addresses many component such as products, organizational structure, working methods, processes, people, information structures and information systems. This new activity is just the product managing throughout its entire lifecycle from its imagination to disposal [Stark 06] [Ulrich 04].

Exist many references for PLM definition. Considering more than five definitions.

Michael Grieves define PLM as an integrated, information-driven approach comprised of people, processes/practices, and technology to all aspects of a product's life, from its design through manufacture, deployment and maintenance-culminating in the product's removal from service and final disposal. By trading product information from wasted time, energy, and material across the entire organization and, into the supply chain, PLM drives the next, generation of lean i/imfcmg [Grieves 05].

2.1.1 Integration in PLM Systems

In the system integration, PLM can manage the related product data with speed and efficiency, control the alteration process of data, then send, pass, share the needed data above all [Guerra 05]. Given the data system based on the web is actually cooperation between departments in the different places, which involves the management in the distributed data stock and the passing for the vast data. In this way, product lifecycle plat based on the web is constructed, the related data on the newest design and manufacture on every node can be knot weeded by web. On the basis of constructing web PDM system is applied. It allow individual to co-exploit, construct and manage the whole lifecycle thought the Internet technology, on the other hand, the design, manufacture, sale, after service and customer can be linked to the whole knowledge-net. The integration of PLM system includes the integration of

6

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Chapter 2. Literature Review 7

product data, process integration and application integration [Cui 06].

The integration of data

PLM defines and manages the different product data, and builds automatically the integration on the basis of relation [Mostefai 04]. The data integration provides the shared data to every applied system in company by the shift from a data source to the other. Given the data is organized and managed by BOM, is adopted to realize the data integration in PLM system.

In PLM, BOM is a data management of every phase, such as: product design, craft, manufacture, plan, stock, and sale. BOM is the basal data to workout the plan form manufacture and stock. The PLM system includes: product plau-BOM, design-BOM, craft-BOM, stock-BOM, manufacture-BOM, finance-BOM, customer-BOM, and after serviee-BOM, see figure 2.1.

s y

¹

. ' p r o d u c t p l a n \ i

vrmi

BOM / l a c

. ' a f t e r s e r v i c e d

I ^{BOM •/} CAL) 1 1

^{l o t s}

ilt+

ⁱ

stock

BOM manufacture) BOM

Figure 2.1: T h e f o r m p a r t i t i o n o f B O M i n P L M s y s t e m [ C u i 0 6 ] .

Product plan-BOM mainly conforms the product-plan phase, makes sure the quantity of product, the beginning time, the finish time and the resource distribution.

Design-BOM expresses the assemble relation between the parts and their structures

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by the sheet, at the same time, in also reflect the design structure and the design property of the material, Craft-BOM divides the craft work, arranges the part processes, and design the procedure on the basis of design-BOM. It includes structure tree, design information, part document, procedure tree, procedure plan cards and other documents. Stock-BOM is mainly and structural chart related with the data of outsourcing. It includes the related data of quantity, material, producing area and material lifecycle, physical and chemical property, etc. Manufacture-BOM adds the rough and the material ration from the procedure, normal time-ration needed, regulated craft-line, etc. It is the major basement, the input information for the MRP operation. Finance-BOM mainly embodies the relation between the part and cost and expresses the relation of current cost and ultimate cost. Customer-BOM reflects the ultimate structure of product, it includes the prediction about the realization of every function and the satisfaction to customer after using the product. Finally, after service-BOM is a data chart facing the technology and service.

The integration of process

Process integration realizes the exchange in every system, shares resources and cooperation in every system. It integrates organically those single system in the process of the wholly company operation. The process integration includes item process, workflow, alteration of design engineering and technology management, etc.

Process integration includes three steps: process modeling, process execution and interrelated process management.

Process modeling The process modeling describes the actual process from different views, which includes:

• Functional aspect: what is realized by defining a process

• Action aspect: how to perform by describing a process assignment

• Organizing/resource aspect: Who to perform this assignment

• informal aspect: which information is produced and used

Process execution The process execution servers for the formation of process plan operation, so to sustain personnel to complete the process plan. The system must be allowed to output the description for every process.

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Process management In the integration of process, there is some interrelated process management, such as notifying work information, browsing the interrelated operation data and interlinking the interrelated functional operation.

The integration of the applications

Software systems such as CAD, CAPP, CAE, CAM, etc. solves some actual problem in the process design, manufacture, etc. Some management software, like ERP, is applied extensively in the companies which deals with some problems of stock management.

However, these systems are independent, their data cannot be integrated. As a result, this software work like information isolated island. In PLM, integration between PLM and CAX, ERP is realized through the PDM system.As a result, the product data of every application system is integrated, which is the basis for realizing the optimized management of product in PLM.

2.1.2 Digital Manufacturing

Digital manufacturing is an approach involving people, process/practice, and technology that uses PLM information to plan, engineer, and build the first instance of a product;

rump that product up for volume production; and produce, monitor, and capture for other aspects of the lifecycle the remaining instances of thai product's production using the minimum amount of resources possible[Grieves 05].

Digital manufacturing is an integral component of PLM [Guerra-Zubiaga 06b][Guerra-Zubiaga 06c]. Maximum integration of product design, manufacturing engineering, and production operation is achieved ans effective use of information is established up and down the supply chain. cPDrn (Collaborative Product Data Management) capabilities for collaboration, change management, document management, workflow management, process management, resource management, and version and product variation management can be implemented and integrated with Digital Manufacturing to create a highly effective enterprise-wide product lifecycle solution. Digital Manufacturing's domain of support within the overall digital product lifecycle is depicted in figure (2.2) [CIMdata 06].

Digital Manufacturing enables increased and improved communication and collaboration, both of which are essential to effective product design. The software supports both internal and external collaboration. Internal collaboration allows engineers to visualize the effects product design decisions have on the manufacturing process.

By using digital models as a rich specifications, forms can better communicate with their suppliers. Reviewing accurate visual representations of the desired parts makes communication more; effective ans speeds problem resolution [CIMdata 02].

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C o n c e p t u a l D e s i g n

D e s i g n

E n g i n e e r i n g .+ M a n u f a c t u r i n g E n g i n e e r i n g

D i s p o s a l &

R e c y c l i n g After-Sales S e r v i c e

T e s t &

S a l e s & *•. Q u a l i t y Distribution '•

S i m u l a t i o n

& V a l i d a t i o n

M a n u f a c t u r i n g O p e r a t i o n s *'

Domain of Digital Manufacturing

Figure 2.2: Digital manufacturing as a component of PLM [Cui 06].

2.1.3 PLM Components and Tools

One of the challenges of PLM is to identify the system components that are most relevant to the activities on which a company wants to focus its efforts [Stark 06]

[Brown 06]. A large number of techniques are available to supports deferents aspects of engineering and management, such as Computer Aided Design (CAD), Computer Aided Engineering (CAE), Computer Aided Industrial Design (CAID), Computer Aided Manufacturing (CAM), Computer Aided Production Engineering (CAPE), Computer Aided Process Planing (CAPP), Computer Aided Software Engineering (CASE), Computer Integrated Manufacturing (CIM), Digital Mock-UP (DMU), Electronic Data Interchange (EDI), Knowledge Management (KM), Knowledge Based Systems (KBS), Manufacturing Process Management (MPM), Rapid Prototyping (RP), Simulation, Technical Document Management (TDM), Virtual Reality (VR), Virtual Engineering (VE), and Virtual Prototyping (VP). For mechatronics product development the main software tools are CAD, CAE, CAM, CASE, CIM, DMU, EDI, KSB, Simulation and VE [Guerra-Zubiaga 07].

In figure 2.3 a process applying PLM components and tool is exposed. It start with an idea, requirements and specifications for the product and ends with the serial production, customer after sales service, recycling, scrapping and disposal.

In order to avoid unnecessary loops the engineer has to have knowledge of the surrounding process steps as well as the kind and quality of data, respectively information, they produce or require. The knowledge about the previous process steps is to maintain the design intend, the knowledge about the following process steps is to guarantee their feasibility. In addition to this economical aspect the quality of the product describing information has to be taken into account [Dankwort 04].

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The modern product creation process proceeds more and more as a virtual product generation process. Keeping in mind that the processes are characterized by Simultaneous Engineering (performing different process steps at the same time) and Concurrent Engineering (developing neighboring components in parallel), it is obvious, that an enormous amount of data produced has to be handled by an efficient product data management system (PDM). Two facts increase the complexity of the situation:

- For different tasks within one or various process steps sometimes quite different CAX-systcms have to be used with quite different data models.

- In modern industry a network of suppliers is involved, often working with different systems or different versions of the same system.

Therefore not only CAx data exchange with data conversion is a key task for successful development and production processes but also the complete supplier integration.

Raquirerwrtt

Specification j I Concept' I Design!

OAD'CAE.' OAF.' C A C D GAAD

Preliminary

Development Engineering Design

GAD' CA F' OACTt

! Component;

& Assembly', I Prololypiny;

CAn/CNC i

, - < • • v J Product A

>- Idas V

C A D Computer Aided Design C A M Computer Aided Manufacturing C A E Computer Aided Engineering .Simulation C A P Computer Aided process p;an,iing CAT Computer Aided Testing CIM Computer Integrated Manufacturing C A G D Computer Aided Geometric Design CAS Computer Aided Styling CAAO Computer Aided Aesthetic Design

CAID Computer Aaded

lndi^EtT.*al

Design

C A C D Computer Aided Conceptual Das g«

C A S E Computer Anted Sott.vare Engineering CAPL Computer Aided Plant Layout C N C Computer Numeric Controlled F E A Finite Element Analysis P D M Product Data Management PLM Product Lifecycle Management

/ Market ^ ^

\ ^ R e q u i r e m e n t ^

Masloimodoi

Product Prototyping' Manufacturing

Planning Workshop Facility Engnew no Design

CAD/ CAE

W . T. Manufacturing I Production / Quality Assurance

• c

Customer ^\

Figure 2.3: General process chain of product development [Dankwort 04].

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2.2 Flexible Manufacturing Systems

The widest definition of Manufacturing Systems refers to a group of people, facilities and services needed to produce a product or a range of products[Bogdan 06][Guerra-Zubiaga 06a]. Nowadays, the old fixed hardware sequential assembly lines with dedicated workstations are toward to Flexible Manufac- turing Systems (FMS). A FMS is a re-programmable manufacturing systems capable of producing a variety of products automatically. The flexibility can be achieved in several ways [Bogdan 06] [Chryssolouris 06]:

• Machine Flexibility: Ease of making changes required to produce a given set of parts types

• Process Flexibility: Ability to produce a given set of part types in different ways

• Product Flexibility: Ability to change over to produce new products economically and quickly

• Routing Flexibility: Ability to handle breakdowns and continue producing a given set of part types

• Volume Flexibility: Ability to operate profitably at different production volumes

• Expansion Flexibility: Ability to expand the system easily and in a modular fashion

• Operation Flexibility: Ability to interchange ordering of several operations for each part type

• Production Flexibility: Universe of part types that the manufacturing system can produce

A FMS has the complete knowledge for transforming raw parts into finished parts by means of a process cycle which defines all the technological information (assembly programs robot, G codes for CNC machines, velocities, tools, manufacturing processes, etc) for each productpvlatta 05]. In order to carry out the process cycle, FMS are composed by the follow basic components [Askin 93]:

• CNC Machines: Performs operations on the raw parts. All the operations and movement of these machines are locally controlled by a computer (for example, milling, lathes, drill preses, grinders, laser/plasma/water jet cutting machines, etc)

• Load/Unload Stations: Execute the operations of clamping raw parts onto pallets before entering into systems, and removing finished parts after their process cycle has been completed by machines of the system.

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• Part handling sub-system: is the set of devices that move parts through the system. Different mechanical devices are adopted in reality: automated guides vehicles, carriers, conveyors, AS/RS, etc.

• Tool handling sub-system: Is the set of devices that move tools through the system.

Robots applications are part of the last group. Generally, industrial robots are prepared with and end effector to accomplish different manufacturing tasks [van Amerongen 00]. In fact, International Federation of Robotics [IFR 05],[Barrientos 97] classify industrial robotics applications as handling, weld- ing, material applications, mechanized, assembly, packaging/palletizing, measuring/inspection/quality control, material handling, research/teaching, and others.

Commonly, is required additional tasks to accomplish the entire manufacturing process. These complementary tasks assuring quality or specific products specification.

For example, visual inspection cameras and measuring machines assure the product quality. To be part of an FMS, these devices must to be integrated physical and logically to the FMS control[Askin 93].

Additionally, to integrate in a flexible manner the FMS components, some supporting devices are needed. These devices are classified as follow:

• Pallets: are the physical interfaces between the systems components and the pieces.

• Tools: Perform the cutting operations on raw parts. Since tools are expensive resources their numbers is limited and as a consequence they are moved through the system when requested by machines

• Part buffer: is the place where parts wait for the availability of systems resources (machines, carriers, load/unload station)

• Tool buffer: Is the place where tools can be stored when they are not used

• Computer based supervisory controller: to monitoring the status of jobs and directing part routing and machining jobs selections.

The process cycle generally start with the production recipe elaboration. This recipe contain the characteristics, quantities and productions sequencing of the products that will be manufactured in a FMS. The Automated Storage and Retrieval System (AS/RS) dispatch the raw material to the system by means of pallets that are loaded with the parts. The parts will be blocked on each load/unload stations according to the recipe defined at starting and are managed by a supervisor which decides the path each pallet has to follow to complete the process cycle of all its

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Chapter 2. Literature R,eview 14

pieces. Pieces must visit at least one machine. If machines are busy, pallets wait in the central buffer. After the pallet has been blocked in the working position and the tolls necessary for the operation are available to the machine, the processing operations can be executed. After the completions of the process cycle, the finished parts are moved through the part handling sub-system to the load/unload station where the parts are unloaded and the empty pallet can be used again [Bradley 00].

2.3 Collaborative Product Development

The collaborative Product Development (cPD) begins the first phase of the products lifecycle in which product development is driven along the; customer driven development line: a customer specifies to a greater o lesser degree the requirements, functionality, geometry, specifications, and characteristics of the products [Danesi 06]

The collaboration between customer and product developer around a common understanding of product requirements is the first approach of collaboration in the product lifecycle [Molina 02]. Michael Grieves ([Grieves 05]) define cPD as on approach to capturing, organizing, coordinating, and /or controlling all aspects of product development information, including functional requirements, geometry, specifications, characteristics, and manufacturing processes in order to provide a common, shared view as product requirements are translated into a tangible product and to create a repository of product information to be used throughout the product lifecycle. Some aspects of cPD that organization are focusing in order to use PLM to drive their product development are [Grieves 05]:

• Mapping requirements to specifications The mos useful function of cPD is the performing the development and mapping the product requirements to its specifications.

• Part, numbering: Is the key issue in abstracting product information and simplifies the handling of the information.

• Engineering vaulting: is the initial PLM project. Identifying and consolidating all the engineering specifications and characteristics in one repository is a great benefit.

• Product reuse: Supported bu engineering vaulting, the reuse of the product can be made.

• Start and smart parts: These are PLM mechanism to create an asset of the organization by capturing the forms and rules used in components of the organization's products. Start parts are prototypical forms of the building blocks that are used to create new products.

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• Engineering change management: is the administration of engineering changes doing in the manufacturing stage or the customer.

• Collaboration rooms: It visually presents the product simultaneously to all par- ticipants. It contains a project board that list the development steps, status, and step responsibility, and that it captures the changes to the product ads the development progress

• Bill of material and process consistency: PLM has the potential for providing a consistent and cohesive view across these different functional areas, the end result is that all areas' are working with the most current and accurate information not only about how the product is designed, but also how it is manufactured, sourced, and costed.

• Digital mock-up: The mock-up and prototypes allowed product designers and engineers to gather around a virtual/real object. The digital mock-up reduce the requirements for building physical mocks-ups with the resulting of saving time, energy, and material and better functionality

• Design for environments: DFe has two objectives, the fist one is to deal with the disposal and recycling in the design process. The second objective is to examine the manufacturing process for producing the product and substitute methods, power sources, chemicals, and solvents that are environmentally unfriendly with ones that are less so

• Virtual testing and validation: Organizations can use information about structure and composition to use computers to simulate conditions under which the product is tested

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Chapter 3 Reference Frameworks

3.1 Virtual Engineering Project

VTR-ENG is a project created to integrate the design, simulation and distributed control in order to build agile manufacturing machines systems, devised and implemented in the European Commission Framework IV ESPRIT research project: Integrated Design, Simulation and Distributed Control of Agile Module Manufacturing Machine System. This project seeks to integrate the functional requirements from different user level and perspectives and in this way to close the gap between the machine system design environment ans the control system design environment, to develop a mapping between the virtual world and the real world and to build the links between the design environments and the run-time environments.

3.1.1 Reference Model for the Integrated Environments

Three perspectives are identified to encapsulate the major constituents of the philosophy adopted for the VIR-ENG project (as is depicted in figure 3.1), namely the design viewhhe simulation view and the control view [Lundgren 01].

• The control perspective encapsulates the functional levels within a manufacturing machine, namely the control system, and machine system,

• The simulation perspective encapsulates the virtual perspective of the design and run-time processes of both the modular machine design environment and the distributed control system environment.

• The design perspective encapsulates the design and run-time attributes of devel- oping manufacturing machine systems.

VIR-ENG consist of two highly integrated environments, namely Modular Machine Design Environment (MMDE) and Distributed Control System Environment (DCSE)

16

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Chapter 3. Reference Frameworks

17

Control Perspective

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Figure 3.1: Reference model for the integrated environments [Lundgren 01].

(illustrated in figure 3.2).

The input to the VIR-ENG environments can be viewed as the machine systems specification requirements, while the end product from these environments would be the distributed run-time machine system (DRMS).

An Information Infrastructure (IIS) based on the component object-based computing environment provides all the pipes and plumbing for the information integration within the VIR-ENG environment.

Among these work-packages, MMDE and DCSE are the major environments, which support different facets and activities in the machine system life cycle. While MMDE provides the tools to support all facets of the design process using graphical simulation, DCSE is designed to provide an integrated environment to facilitate distributed control system design and its operation. Uniquely, DCSE is partitioned into three main elements, namely, the Control System Design Environment (CSDE), the Component Design Environment (CDE) and the Distributed run-time Environ- ment (DRE). MMDE and DCSE are highly integrated, whereby the physical layout, kinematics, mechanical constraints and sensing scheme of the virtual machine system designed and validated in MMDE are transferred to DCSE as the blueprint for the further development and deployment of the control systems. The control logic created in MMDE, which is used to drive the simulation, is also transferred to DCSE for developing the machine and application code of the real machine systems.

Furthermore, run-time data, once available from the real machine system, is gathered from DCSE and can be used to validate and calibrate the virtual model developed in MMDE. This serves as the feedback in the machine design process. In

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Chapter 3. Reference Frameworks 18

order to facilitate the seamless integration between MMDE and DCSE, the underlying Infrastructure and Integration Services (IIS) is needed to provide the services for these two environments to exchange design models, information and data [Adolfsson 02].

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3.1.2 Manufacturing Machine System Model (MMSM)

MMSM is composed by four layers: at the lowest level is Device Component which refers to actuators, motors, valves, sensors, etc. The next level is Composite Component that is comprised by elementary subsystems like linear actuators, motion systems, RFID systems, etc. The third layers is the Modular Machine, in which is observed work stations with a defined task inside the productive process, examples of this machines are assembly stations, CNC stations, etc. the top layer correspond to Machines Systems which can be defined as an integration of two o more Modular Machines. At bottom level the reusability is mayor and at the top level the machine is strongly dedicated to a specific manufacturing function or activity (see figure 3.3).

The MMSM work as a reference model to MMDE and DCSE subsystems (see figure 3.4). The purpose of the model is to ensure the integrity in analysis, design and

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Integration Platform

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implementation in building machines and their associated control system [Moore 03].

Device-level details are encapsulated within device components, which provide;

well-defined services and associated interfaces. The complex interrelationships between components are encapsulated into the control logic component (depicted in 3.4), in this way the hierarchical structure ensures that only the next lower level of services can be accessed [Lundgren 01],

As is illustrated in figure 3.5, there are two major workpackages (MMDE and DCSE) and a third component called Information Infrastructure (IIS). Particularly, DCSE module is composed by three modules: Control System Design Environment (CSDE), Component Design Environment (CDE) and Distributed Run-time Envi- ronment (DRE). The process flow start with an order received by MMDE. Then MMDE place the Control System Specifications to CSDE using virtual engineering and information tools to generate the specifications and send the information. CSDE, as a part of DCSE, generates the Control System Solutions from the Control System Specifications to be implemented in DRE. This last module require of MMDE the Virtual Machine, in which the entire machine system can be demonstrated.

CDE is feed directly by IIS to generate virtual and real components to CSDE and DRE. Finally, IIS obtains its resources from databases, Internet and objects standards.

The interrelationship also can be explained from engineer roll viewpoint (figure

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Chapter 3. Reference Frameworks

Figure 3.4: Control logic component system model [Moore 03].

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3.6). The design engineer is in charge of the machine designing, generate the specifications of the control system and analysis and simulations of the system. Those;

information is send to and received from the Data Base. Control engineer is able to fed the Data Base with Parametrize and design components, simulations and analysis results and the off line programming. Application engineer take this information and generate the real control systems and human machine interface application.

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This framework has a well structured FMS development approach, but in figure 3.6 is clearly depicted that the work is carried out sequentially.

3.2 Product Lifecycle Modeling Framework

Zhang et.al. divide the lifecycle of a product into five stages showed in the figure 3.7.

Requirement analysis captures and analyzes customer requirements, the conceptual design developed a conceptual product plan, the detailed design to design parts, assemblies and product structure, etc., manufacturing to produce the product and services to offer the technical support and maintenance to overhaul ans repair for products.

The integral flow of data are created and evolved along this life line. Each phase contributes to this flow and the BOMs become the standard data format for integration and data exchange. The data can be partially or totally derived from the common resources which affords single source of product data for knowledge reusing. The product evolution flow needs to be controlled by a workflow system, so the businesses can be triggered and performed automatically. It infrastructure is

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Workflow Control Product Evolution Phases

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the foundation that includes hardware, software and Internet technologies, underlying representation and computing languages and distributed objects and components.

3.2.1 Requirement Analysis

The model of requirement analysis assure to capture and understand customer needs effectively and subsequently transfer them to design specifications. Figure 3.8 present this approach.

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Figure 3.8: Requirements analysis model [Zhang

The first phase is to capture the requirement in order to transform them into information, features ans sketches. The second phase is the translation of the captured data into customer specifications which is organized by RBOM. the last phase is the management of the customer requirements to ensure that the product is the ex- act one customer needs and make agile responses to the customer requirement changes.

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3.2.2 Conceptual Design

Conceptual design transform the customer requirements to a systematic product developing specification. Figure 3.9 show a conceptual product structure constructed in the functional, technical and physical view. Further, the technical tasks of design, manufacturing and devices need to be specified according to conceptual product, structure. Finally, the cost, feasibilities and difficulties of these solutions should be evaluated for decision. The result at this stage is a conceptual BOM that contain the design specifications for downstream phases.

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Figure 3.9: Conceptual design model [Zhang 06].

3.2.3 Detailed Design

In the detailed design a product family architecture is presented in order to satisfy the last stage; demands (see figure 3.10). It is composed by modules which is a collection of components or parts closely integrated and form a physical building block. A platform is constructed by key modules and bears the key technologies, product line policies and market strategy of a product family. A generic product structure is responsible for organization of all the related data and files of a product family. Domains are special data views which cover each phase of product lifecycle. The knowledge base for each phase is unburdened to form the foundation and mechanism, and it can be reused and reconfigured to produce the new products along the lifecycle.

3.2.4 Manufacturing

In manufacturing stage, a physical product is gradually produced and assembled.

Three essential flows string all the activities and functions of this phase, including information, material and energy flow. A Product-Process-Plan-Resources model is presented in3.ll, which attempts to support concurrent development, manufacturing

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