Post on 05-Mar-2020
Presentation date: 2018 10 30
Presenter name: Corsin Buerer, Siemens Industry
Software
Room name: Estrel Hall C5+6
Presentation title: End to End Part Manufacturing
Your name/Company® PLM Europe 2018 – All rights reserved Your name/Company Page 1
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2017.MM.DDPage 2 Siemens PLM Software
End customer demand
for customized products
Global competitive
pressures from new, low
cost
providers.
Personalization is driving massive amounts of Customization
How industrial companies are getting closer to customers
SOURCE: 2016 Global Industry 4.0 Survey PricewaterhouseCoopers
TREND
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2017.MM.DDPage 3 Siemens PLM Software
“Of the companies surveyed, more differentiate themselves by
the level of product customization and their ability to meet
customer needs than anything else”
Driving Engineering to Order Differentiation and Profitability
Tech-Clarity, 2016
Companies will differentiate based on customization
IMPLICATIONS:
Companies must differentiate on
level of customization
Need to better sense and manage
customer requirements
Difficult to estimate and meet order
lead times for custom products
Reduced opportunity to reuse past
designs and manufacturing patterns
because of customer specific
demands
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2017.MM.DDPage 4 Siemens PLM Software
Digitalizing the entire value chain
is key to staying competitive in the future
IDEATION UTILIZATIONREALIZATION
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2017.MM.DDPage 5 Siemens PLM Software
Information Flow
Across the Entire Enterprise
ProductionProduct
engineering
Manufacturing
engineering
Operation Silos with Disconnected Systems
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2017.MM.DDPage 6 Siemens PLM Software
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Digitalized Part Manufacturing
Integrated
process planning
and management
Virtual verification
and production
optimization
Digitalized part
manufacturing
Manufacturing
operations
management
Integrated – Intelligent Interoperability – Closed-Loop
Product Quality
analysis
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2017.MM.DDPage 7 Siemens PLM Software
Integrating and digitalizing the entire value chain is key
ProductionPlanning
Tooling and
fixture design CAM
Part model
preparation DNC
Shop floor
program validation
SINUMERIK
CNC
Data and process management
CMM
programming
CMM inspection
execution
Tool
management
Shop floor
data access
Tool
libraries
Process
planning
Seamless Data and Process Management from part model to production
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2017.MM.DDPage 8 Siemens PLM Software
Managing Work Packages – CAM / CMM Data Management
PLM
Shopfloor
• PLM is used as a secure environment to manage the manufacturing files all in the context of a single work package,
providing version controlled managed data directly to NX CAM or the shopfloor.
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2017.MM.DDPage 9 Siemens PLM Software
Managing Manufacturing Processes
• The process of manufacturing a component requires a detailed definition of all steps, resources,
consumables and detailed execution steps required, this complete set of information is know as the
‘Technical Package’ and all products must have one.
• The individual steps or operations within the process which contain the explicit details regarding equipment
and resources for an individual step is known as a ‘Work Package’
Make Component 1
Process
Work Package 1
Work Package 2
Work Package 3
Op010- Goods
Inwards
Op020- Rough
Machine Side 1
Op030- Rough
Machine Side 2
Op040- Measure
Side 1 Work Package 4
Technical Package
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2017.MM.DDPage 10 Siemens PLM Software
Part Manufacturing Data Management
data & process management
manufacturing resources management
Tool Assemblies
Shopfloor
Machine tools Tool presetter StorageTool managementMachine tools Resources management
Manufacturing ResourcesDNC
MACHINIST
TOOL
SETTER TOOL
SETTER
• Access WI
• Down / upload NC Programs
• Load / unload Resources
• Access Ressource Library
• Manage storage
• Assemble / disassemble resources
Manufacturing
Resource
LibraryNX CAM TOOLING
AUTHOR
• Load / access vendor catalogs
• Define company wide resources
• Assemble resources
• Define feeds and speeds data
NC
PROGRAMMER
• Create machining setup
• Load resources from library
• Create WI and NC Programs
• Store NC workpackages
1
4 3
2
PROCESS
PLANNER
Part Planner
• Retrieve Parts for Planning
• Own overall Technical Package
• Distribute work to ME’s
• Release Process 2
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Component Bill Of Material (CBOM) Structure
Design Part
Cut Section (150)
Raw Material
(30*60 bar)
Raw Material
(15*120 bar)
Bent 90 deg, 250 dia
Profiled, Marked Part
Raw Material
(10*120 bar)
Stage Model
Welded Assembly2 Welded Assembly1
Profiled, Marked Part
Profiled,
balanced disc
Cut into 8 equal
section, Billet for
Machine ops….
X8
X1X1
Welded Assembly4 Welded Assembly3
X4X4
X8
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Component Bill Of Material (CBOM) Structure
• The CBOM Structure is your working structure which contains individual manufactured parts that
makes up your MBOM part assemblies. The CBOM level is a ‘placeholder’ which allows
manufacturing engineers to specify which raw materials are to be used.
This is the Engineering Part Number to be
manufactured an that has been designed by
the engineering organization.
Exists in ERP.
This is the Manufacturing Part only required
to assemble the different stages of the
machining process.
Does not exist in ERP.The different stages of the machining process,
including the raw material and the finished part.
Exists in ERP.
The BOP (route) defining all the
operations required. Each operation
define the geometry (stage), the tools
/ tooling and machines required.
Exists in ERP.
Mfg. Target
relation
Mfg. Workpiece
relation
Mfg. Target
relation
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2017.MM.DDPage 13 Siemens PLM Software
Synchronous Modeling and Geometry Linking to build C-BOM
Data Cleanup
• Incomplete or inconsistent translation
Model Optimization
• Remove or simplify features that require electrodes to
simplify and improve milling programs.
As-cast Blank Development
• Non-primitive blank modes are typically derived from the
finished part models.
Fixture Modeling
• Fixture development and modeling often fall to the NC
programming department
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2017.MM.DDPage 14 Siemens PLM Software
How does PMI impact Manufacturing?
• PMI (e.g. notes and dimension tolerances) drives the selection of the
necessary manufacturing process
• Milling, Drilling, Honing, Grinding, Heat treatment, …
• PMI (e.g. form tolerances) is used to determine the setup datum scheme
• PMI (e.g. dimension tolerances and surface finish) drives the selection of the
necessary operation and tools *
• PMI (e.g. position tolerances) is used to determine the correct machining
location
• Mid tolerance machining
• Minimum / Maximum material conditions
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2017.MM.DDPage 15 Siemens PLM Software
PMI Application Touch Points
PMI underpins all functions for model-based enterprise solutions
Feature/PMI underpins
all functions
Part Planning &
N/C
Manufacturing
Variation
Analysis
Assembly Process
Planning
CMM Inspection
Drawing
Production
Production Validation
Production Validation
Production Validation
SLM
SLM
SLM
DPV
Author
Key Characteristics &
Build strategy
Machining pgm &
stage part inspection
Machine-based
inspection
Inspection plan
management
Data collection
control points
Cross, up and down
domain analysis
Service
requirements
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2017.MM.DDPage 16 Siemens PLM Software
PMI Characteristics in Workflow
(Part-based PMI)
Workflow targeted at manual
inspections versus machine inspections
(calculated results)
Linear
Angular and radial dimensions
Upper and lower specification limits
Nominal values
Visual inspections (created on demand)
Import from selection & filtering
Single-frame, feature control frame
GD&T tolerances
Composite PMI display/management
1st line dimensional note
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2017.MM.DDPage 17 Siemens PLM Software
Using MENCMachining items the design and manufacturing lifecycles are separated allowing for
greater flexibility and change control.
/01 /02 /03 /04
Status Status Status WIP
NX CAD
/01 /02
Status WIP
NX CAM
Designer
Manufacturing
Engineer
Separate Lifecycles – During development
Different Access Control rules can be applied to both lifecycles
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2017.MM.DDPage 18 Siemens PLM Software
Part Manufacturing Data Management
- Work Package Content
Work Package 1
Work Package 2
Work Package 3
Work Package 4
Technical Package
Operation Steps
Process
Work Package 4
NC Program & Macro
Sequence Flow
Manufacturing Documents
& Work Instructions
Manufacturing data capture
details
Standards, Engineering &
Quality Documents
Required Equipment
Information
Required Resources
(Tooling etc.)
Quality Data
NC Programmer completes task with all assiciated data synchromnized to PLM
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2017.MM.DDPage 19 Siemens PLM Software
Integrated Planning
• Create a common process plan for part
manufacturing operations, typically casting,
machining, heat treatment, finishing,
inspection….
• Associate part data, resource (tooling, fixtures)
and plant data (machines, work cells) within
process definition
• Create and classify process/operation templates
for later re-call, re-use
• Dynamically generate work instructions
• Bi-directional integration with NX CAM
NC Programmer details assigned manufacturing operations
unrestricted © Siemens AG 2018
2017.MM.DDPage 20 Siemens PLM Software
Part Material
Handling
Machine
Fixtures
Raw Material
Integrated Manufacturing Resource Library
Cutting Tools
NC Programmer assigns to manufacturing operations
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2017.MM.DDPage 21 Siemens PLM Software
NX Work Instruction Authoring
Capabilities
• Add Work Instructions to new or existing
machining operations
• Create Work Instruction operations with only
documentation
• Publishing within NX Manufacturing
Customer Benefits
Define Work Instructions as the NC program is
created saving time
No new workflows to learn
NC Programmer creates associative Operator Work Instrcutions
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2017.MM.DDPage 22 Siemens PLM Software
Shop Floor Connectivity
data & process management
manufacturing resources management
Tool Assemblies
Shopfloor
Machine tools Tool presetter StorageTool management
tools management
tools live data
DNC
tool statistics
tool management
and planning
low stock notification
resource planning
standard tool
presetter interface
Machine tools
connect multiple
CNC controllers
DNC
Resources management
fixtures, tool components
data
load-/unload dialogs
1
ProductionPlanning
Manufacturing Resources
Connect Shop Floor Operators to PLM
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2017.MM.DDPage 23 Siemens PLM Software
Machines Tool assemblies with constantly up-to-
date data from the CNC ( remaining live
time, tool offset data, …. )
Stock location Administration of tool assemblies and
components
Organization of storages
Assignment of resource data to
appropriate location
Tool demand planning
Tool life time only with tool type request
Consideration of already existing tools
with selection of potential storage areas
Technical data and drawings Components data and assembly drawings
Shop Floor Integrate Resource Management
Physical Tool Management
Online access to tool data loaded to machine tools, storages, and presetters
Life data
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2017.MM.DDPage 24 Siemens PLM Software
Shop Floor Connect
DNC (NC Program Management)
• Shop Floor Connect for Teamcenter
• Easy to use displays for shop floor
• Web browser technology – any device
• Secure log-on to Teamcenter
• Data stays in Teamcenter
• Direct machine connection for DNC
Tooling and
fixture designCAM
Part model
preparation
CMM inspection
execution
Tool
management
CNC
Quality
Inspector
Machine Tool
Operator
Tool
Manager
Data & process management Shop Floor Connect for Teamcenter
PLM integrated DNC solution
unrestricted © Siemens AG 2018
2017.MM.DDPage 25 Siemens PLM Software
Integrating and digitalizing the entire value chain is key to staying
competitive in the future
ProductionPlanning
Tooling and
fixture design CAM
Part model
preparation DNC
Shop floor
program validation
SINUMERIK
CNC
Data and process management
CMM
programming
CMM inspection
execution
Tool
management
Shop floor
data access
Tool
libraries
Process
planning
Seamless Data and Process Management from part model to production
unrestricted © Siemens AG 2018
2017.MM.DDPage 26 Siemens PLM Software
Product Design and Product
Engineers engineers are primarily
focused on defining products from
technical perspective and solving
problems related to CAX files
management and their relationships with
As Designed Structure (Engineering
BOM with functional view)
Process Engineers are mainly focused
on transforming Product Design to
Manufacturing Process evolving the E-
BOM in AsProduced Structure
(Manufacturing BOM with process
manufacturing approach ) according to
Operations (E-BOP) and the related the
resources (BOR).
ERP
Resource Planners are primarily
focused on the definition / enhancement
of business processes. A planner
manages the M-BOM to satisfy Logistic
and Commercial requirements (material
flow, inventory control, part purchasing,
customer order tracking, finance
accounting ..)
MOM Production supervisors and team
leaders manages the workload and local
resources availability and ensure
technicians and machines are in the
best conditions to run production.
CAX
PLM
Closed Loop Manufacturing
Orchestrating the Shop Floor
Teamcenter
collaboration backbone
Closed Loop
Manufacturing
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2017.MM.DDPage 27 Siemens PLM Software
Shop Floor Orchestration
Managed tasks
Teamcenter Simatic IT APS Shop Floor Integrate
BOP authoring
• Product 3D, resources, attachments,data collection forms
• Execution data validation
Processengineer
1
Productionmanager
Production preparation
• Complementary engineering
• Production order creation
2
Scheduler
Production order scheduling
• Verify and release sequence3
Machine operator
Operation work booking
• Start and stop production operation
• Operation details
5
Machine Operator /DNC Machine
Trigger (Shop Floor Connect) DNC machine activity
• Send correct Part Program to the machine
• Tool tracking
6
Access EWI and data collection
• Technical documentation, videos
• Data collection form
Machine Operator
7
Non-conformity declaration
• Defect catalog, defect severityMachine Operator
8
Non-conformity escalation
• Instant messaging
• Deviation analysis (as-built) and reaction
Production manager
9
Issue management
• Deviation analysis(process engineering and as-built)
• Change
Processengineer
10
Tool Setter
Production resource preparation
• Analyzes amount of required tools
• Manages Inventory and assemble tools
• Verify and release sequence
4
SIMATIC IT UA DM
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2017.MM.DDPage 28 Siemens PLM Software
1 2 3 4 5
Provide the best sequence of operations
according to plant resources and constraints
Prepare Manufacturing Resources ahead to
avoid machine downtime
+
+
Physically connect to Shop Floor Devices to
download latest Programs and Resources
Continuous quality improvement enabled by
the analysis of shop floor as-built data
+
+
Execute production