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Technologies Enabling - Agile Manufacturing *nf--.

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DEC 9 9 2995 Q S T I

Macro Planner Requirements Guide

VERSION 1.0 28 March 1995

PRODUCT VIRTUAL DESIGN &

ENTERPRISE CONCURRENCY mNUFAcTUPING

INTEGRATION

MANUFACTUR- INTEUIGENT

8 CONTROL PROCESSING ING PLANNING CLOSED-LOOP

TEAM Program Office P.0.Box 2009 Oak Ridge, TN 37831-8068 Phone (61 5) 574-1 884 Fax (61 5) 576-4663

E-Mail: TEAM@ORNL.GOV

DISCLAIMER This roport HIU prepared as an W n t of work s p a n o d bv n robncy of thr Unitad Stam Government. Neither the United States Govrmmrrrt nor any m f , nor any of their employees, nukes any mrranty, e x p a n or implied, or atwines m y legal liability or rerponribility for the accuracy, c o m p l e t a ~ , or usefulna of any information, BpParatur, product. or process disclosed, or reprrrmts that i ts use would not infringe privately owned rights. Reference hemin to any spocific cornmerehi product, process, or service by trade name, trademark, mmuf.ctunr, or othttrwirs, doas not necwsarily constitute or imply its e n d o m rscomn#n&tion, or favoring by the United States Govrmment or any wncy thoreof. The vi- and opinions of authors expressed hemin do not necsEclrily m or roflrct of the United States Government or any agency thereof.

I

d '

Table of Contents

TEAM MACRO PLANNER REQUIREMENTS GUIDE ................................................................... 2

5 1.1 Id~chte#pyofplarming ............................................................................................................................................. 5 1.2 Emlu;ue produa Definition ~mpleteness ........................................................................................................................ 3 1.3 RetrievalofHistoricalMamrfacMing plans ....................................................................................................................... 6

1 . PERFORM MANUFA-MG ANALYSB

1.4 ldentify Best Similar proctua .............................................................................................................................................. 6

8

2.1.1 Nominal Femres Recognition ..................................................................................................................................... 8

9 2.1.3. Tolmce AnatySi s. ...................................................................................................................................................... 2.2 Mam~facturing Plan Optimimion ..................................................................................................................................... 10

2 PARTPROCFS UNDERSTANDING 2.1 Id&fy F m & To1 gances ........................................................................................................................................... 8

2.1.2.RawMaterialSelectim ............................................................................................................................................... 9

2.1.4. Detailed Feature CreationlAssociation ...................................................................................................................... 10

3 . PROCESS SELECTTON AND ORDERING (&TS/TO-BE DESIGNS) -.-- . 12 3.1 Develop Resource Base .................................................................................................................................................... 12

3.1.1 In-proceSS F a m e Selection ...................................................................................................................................... 13

3.1.3 CandidateSpNnmg ..................................................................................................................................................... 13 3.1.4 Tool Selection .............................................................................................................................................. 13 3.1.5 Machime Tool Representation ..................................................................................................................................... 14 3.1.6 Potentiai Machine candidates For Each ...................................................................................................... 14

3.2 G e n W Routing .............................................................................................................................................................. 14

3.3 M W B i i l Of- ................................................................................................................................................. 16

3.1.2F~AndprocesSMapping .................................................................................................................................... 13

3.1.7 preferred Machines Associated With E a d ~ operation ............................................................................................... 14 3.1.8 Plarming ........................................................................................................................................................... 14

3.2.1 ~ ~ ~ G f t ~ u p t ~ R o ~ m ......................................................................................................... 15

4 . PLANPERFORMANCE ANALYSTS. 18

4.2 Evaluate- g Plan Performance ...................................................................................................................... 18 4.3 uentify Altematzv es .......................................................................................................................................................... 18 4.4 Assign Grade ..................................................................................................................................................................... 19 4.5. Establish Marrufachrring Plan Business Methods ............................................................................................................ 19

4.5.1 EvafuateRtquirementsForMfgPlanBusinessMethod ........................................................................................... 20 4.5.2 rnentifvAf€eaedMfgPhBusbesMe&od ........................................................................................................... 20 4.5.3 Maate Mfg PIan Business Method ........................................................................................................................ 20 4.5.4 GmeaaE operation .................................................................................................................................................... 21 4-55 Evafuate Use mMfg Plan Business Method ............................................................................................................ 22

. 4.1 ~ ~ m P h E v d W h l ~ ................................................................................................................ 18

5 . PROCESS DOCUMENTATION AND CONFIGURATION CONTROl.----- 23 5.1 Ed- Com.mmls .......................................................................................................................................................... 23

5.3 A&veMan&&&gPhn ............................................................................................................................................. 24 j.2 m e Affeded Me Plans ........................................................................................................................ 23

.

Appendix A. Glossllrg of Terms. 25

Appendix B. PubiicrtiOns-.... 27

1 .... . _ _ -. .. . .

~

TEAM Macro Planner Requirements Guide

ICLP

g2-1 tmwo Shop Floor

Control

L

Automated lnteradlve generic Metrdogy - NC Programs

-Work Instructions - Fixture Design

MPC Interactions

Figure I

Process Planning Interactions . . ... .:: .. . :... , : .......... :::: ....: ::... ......::: ..: ::..: i..... .::::::..::::::

Figure 2

I. PERFORM WUFACTUWNG ANALYSIS

1.1 Identifjl Category of Planning

l.1.b - Rebieve manufacbrrng -fora qeciikd planing category.

1.l.c - oisphy menu d p(smb’rg csdegaies to seledfran when retrieving by, OT Lpctatins the pbrrina aegay.

1.2 Evaluate Product Definition Completeness

13 Rebieval of Historical Manufacturing Plans

1.3.C - ACE@ -&fined GT dsssificatiar schemes.

1.3.f -Aaxpt mitiple CAD based 3-D sdid models tiwough a STEP based inkface.

1.4 Identifj. Best Similar Product

7

2 PART/PROCESS UNDERSTANDNG

2.1 Identifj. Features & Tolerances

21.1 Nominal Features RecogniriOn

21.2 RawMaisialselection

2.1.2a - Rovide chdced nominal raw material stodc - bar, sheet, vendormsttng, &.

2.1.3. T o l e m n c e A W

Requirements:

2.2 Manufacturing Plan Optimization

3. PROCESS SELEcTlON AND ORDEWNG (AS-/S/TO-BE DESIGNS)

3.1 Develop Resource Base

3.1.1 In-procesS Feature M e d o n

3.1.2 F e n ? And Process Mapping

3.1.3 Lhduhks ' Pnrning

3.1.4 Machine Tool Sekdon

3.1.5 Machine Tool Repmemation

3.1.6 PotentialMachim cbndidates FmEach O p d n

3.1.8Set-Up PIandng

3.2 Generate Routing

3 3 Generate ,M Of Material I

Thispocess icWiies a needfora bid of matwid, cmatas poducts needed as canpnmk in a bill d material, andcreates a Bill d IT&&. This indodes Mtbfykg dl the corrponerds used in the till as wJl as sssigins an iderrtifierto the MI. Ttis procass dso asaiabs a bill d ~ M t h a p m c k c t ~ .

3.3.a - Entersi@e-hd BOMs that on be athckd at a pruhct- . The atlding d a BOM at a p t u b t m h operatiol'l iscdleda BOM jtmbn.

3.3.c- IdWfyan item asa bt orbnrwtory itsm in the BOM 0.e. qmblyper).

4.1 Cmate Manufacturing Pian Evaluation Criteria

4.2 Evaluate Manufacturing Plan Performance

4 3 IdentifjlAlternatives

4.4 AssignGrade

4.4.c - ReccrdexkfnaJ inRuenceswtjch inp#ted the plan grad9.

4.5 Establish Manufacturing Plan Business Methods

4.5.a - DEhne elementsd the mmfadmg . planas-

4.5.1 Evaluate Requimnents Far Mfg plan Wries Mahod

4.5.1 b - Record request fora standad

4.5.2 I&&!! Affktd Mfg plan &sines Method

4.52.c - Dehrmine wtrat &le d s&nrtard is needed

4.5.3 Genelute Mfgl%m Business MeiW

4.5.3.1 Generate Mt9 plan strrdard Route

4.5.3.3. Gen Stanr)ad ManufaGhnna ResarceEvents

e -

m

5. PROCESS DOcUMENTATlON AND CONUGURATlON CON7ROL

5.1 Evaluate Comments

5.2 Determine Affected Manufaciunng Plans

53 Archive Manufacturing PIan

actMty A single process within a process plan (as. a drilling acbvity, a sew actiVity) Application Protocd (AP) An application Rotocol (AP) is a amstmint &set of STEP intended to define the information requirement of one specific damain (e.g., 'configuration Control Design of Mectranical Piece parts or '2D O M @ ) . STEP is so all inclusive that no YBndOT is aqmcted to imp(emeclt all of STEP. The use of APs coordnates these partial STEP inplementatiorts.

BREP (Boundary REpmaentabon ) Wid Model Aconpletedefinition of the gecnnebyand tapdogy of a solid The definition is in tmof faces, edgesandvertices, wtrjcb have associated Waces, anves andpoints. dass A set of objecbthatshzrea common shuchae and a cornmoll behauior. The temrs dass and type are usually (but not always) i-e; a dass isa digMtydffererrtconcept thztn a type, in that it emphasizes the inportance of hierarchies 0fdasses.A daas-bothdataandmethods. Computuited Numerical Control (CNC) A cunputerthat controls a machine tool.

convex hull A volume endc6ad by a set of faceswhich meet mat COIIVBX angles.. design feature Aregionofapart(e.g. a dot, MI pocket) that is a basic el emerrtin the design ofthe shape of a part orusedcapture some design intent design for manufadurability The process of designing a product with manufacbing considerations in mind. feature The make, stnrchrre, fm, or artward appearance of a poCtian ofa part Holes, slots, pockets, shaftsmexemplesoffeatures. featun-bilsed solid modeling A complete Mnition of the shape of a part using featwas as basic buildng ti&. feature recognition A technque used in manufactun'ng plaming systems to identify and exbactfeatuesfmm a part model by examining the seometry and topology ofthe solid form feature (see Feature above). Imf Wai Applicafhn Protocol (UW) An Application Rotocol deW(0ped and used by industry witfiout f o m l rpproval by the STEP community. knowiedge baed system Sanetimes refecred to as an aped system. In artificial intelligence, a system that processas information pertailling to a partiadarapplication and perfoms functions in a manner similar to that ofa human who is expeA in that field; a knowledge based system can solve problemsbydram'ng inferern;asfrom a collection of infumah that is based on human expiem ~ ~ e m s t h e ~ h a s ~ ~ ~ machine code Code that is used to reprasent the instructions in an instruction set In this domain, machine code refers to the code wedtorepresent NC msctdne tool instrUCtim in 811 NC part program; or CMM instructions in a CMM partprogram. NC machinecode is usually represented Using the EM standard Vaiiable Block Fomrat

mufaduring feature A basic element ofa part which resutts fm dsfinct menufactun 'ng processing. manufaduring plan A pxss plan repesenting set of qmmtkms, bill of material, instnrctions and information needed to manufactureapartAmwfachm 'ng plan for machining indudes high level o p e d k d plans, settp plans, cutting plans, and NC

NC process plan Apxssplan representing instnrCtionsand information needed to oorrplete an NC part progrem. An NC process plan indudes low level qemlbnd plans, sew plans, and cutting plmswithin the scope of a sin@ NC part prosam requast

NC pat program Adofinstructions (machine code) that controls a numwicdfymbdled machine t d . The NC partprogram is the final instruction set that is usedto control the NC machine tool.

NC program Synonymarswith NC part program (See NC part program) ob@ An object is an instanceof a dass, containing thedabinterface inplementation. An object hasstab, behwior, and identity. ThestruchaeandbehaMrafsimilarcdjtxtsaredefinedintheircommondass. Thetennsinstanceandobjectamint~.

processplans.

objectdented programming A methodof programming in Mich programs am organii?ed as cooperative collections of objects, each of wMh reprasentsan instance of some type, and whose types are all mtmbrs of a hiemhy of types unitedvia 0th than inheritancemWmdips. In such programs, t y p e s m ~ l y v i e v r e d as static, whereasabjectstypically havea much more dynamic nature.

solid modtl A solidmodel is a corrputerrepresentation of a physical object with the property W any point in space can be classified as either inside the abject, outside the object, won the bocardaryof the objed Asolid model is useful because it has sufficient information to allw aubmbon ' . Somesimpleexanplesamvolume,centerofmass,andmomentsofinertia. Thesepiupat~escan easilybecaladatedautomaticallywithasolidmodel.

STEP ( S T M for the Exchmge of Product model data) ihe emerging International Standarcfs OrganimtiOn (ISO) standard for exchangeofalldataaboutprodudSTEPistheinfomrainameforIS010303.

tolerance feature Atype of feature usedtoattach tolerance information to a d i d rodel. topology The zbslmct connectivify and trimming of geometry. In the context of solid modeling, toPo(0gy

Vorond DIagnm AVoronoi diagram ofa set of points P in a plane and is a partrtiOn of the plane ash that each region of the partition represents a locus of poi ntsthatare d m t o one member Os P than to any other member. Voconoi diagrams am usedfor conputingoffsetaaves,fi~e(ementmeshing,anddosestdstancebetweenobjects.

A

Alps: A Language for procesS SpatkaWn, 8yran A Catron and Steven Ray, lntemafiond Joumd computer Inkgrated Manufactwing, 1991, Vd 4, No. 2,1051 13.

procesS Planning & Deployment form Inkgated Product Development Environment A Wh& Paper, D. Emerson, T. Freund, D. Grant, C. sadc

AModular Process Planning System AfchiWtum, Steven Ray, Factory Automakn System Division, Nand ImfMe of Standards and Technology, Roceeding ofthe 1989 IIE Integrated Systems Conference, November 1989.

N B S AMRF procesS Planning Systm-System Architecture, Peter F. Brown and Steven R Ray, NlSTlR 88-3828, M&I 1989.

procesS Planning, Peter E Brown and Steven Ray, Production Managefnent System Group, AMRF, Nadional Institute of Standards.

muter Aided ptocess Planning: the s k k d h a t survey, Leo AHing and Hongchao Zhang, Instjtuk of Manufacturing Engineering, Technical Univmity of Denmark, CIM-I, Inc. , ReportM-91-PPP-05, Sept 1991.

Usingthe ALPS Process Plan Model, Steven Ray, United States D e p a r b n e n t o f C , Nationd Institubof Standards andTechnology, Manufacturing Engineering Library, 1992

A Nation4 Testbed for procesS Planning Research, Steven R. Ray and Allison Barnard Feeney, U.S. Depabmntof Cormerce, TechnologyAdmirWa8on, Nationd Institube of Standards and Technology, Manufactun'ng Engineering Labmbry, Factory Automation Systems Division, April 1993, NlSTlR 5169.

A Conceptud Model for procesS Planning, P. M. Ferreira, S. C-Y. Lu and X Zhu, Depzhentof MechanM and Industrid Engineering, UniverSrty of Illinois at Urbana C h q a i g n , CAMI, Inc. Report R-N-pp-01, Aprii 1990.

Qeckabon for a Manufaduring Planning Enabling Platform, P. M. Ferreira, S. GY. Lu, V. Hetern, X Zhu and M. LuCenti, Depalmentof M a n i d and Industrid Engineering University ofllinok at UrbanaChanpaign, CAM4, Inc. Report R-92-PPP/ANcIQAp-ol, Mmh 1 992

Pmceedings ofthe 1993 I n d m Process Planning Workshap, Steven R. Ray, Editor, US. Depatmentof Camem, Nationd Institube of Standards and Tech-, ManufMuing Engineen'ng Labo&ry* Factory Automtbn System Div., NlSTlR 5284, Wber 1993.

Enlerprise Engineering Techndogies Requirements, CTA lncgxxated September 1994.

Funclional (Shape, Material. etc.) and

b

~~ ~~

POEC generates conceptual design

~ ~~

Macro planner requests detailed cost. time. and quelity estimates for an operahon from

the appropriate micro planner.

~~

Macro planner produces conceptual plan and determines preliminary time. cost, and quality estimates.

design and plan

--

be detail planned

NO

Macro planner confirms when required resources are available

Macro planner communicates RFQ to POEClcustomer

Conceptual P roduct l Process Design

Detailed Product/ Process Design

Oh, well! Customer places order Better luck next time! through PDEC

YES

PDEC provides order entry

Macro planner retrieves planlrouting, queries SFC to assure availability of resources, and locks the resources

instructions, etc. for a particular operation

I Micro planner generates requested information I

Are there more operations for which information needs to be created

Macro planner conveys order and manufacturing script

to Shop Floor Control

I Chips hit the floor! I

Manufacturing E ng ineerin g

and Execu tio n

M 4

Mike K& JefFLindbetg MakLuce Jan P e W n David prawel

STEPTOOlS lAMS NlST CTA Spacial TEchndogies

Steve Ray Phd Rosen KeithScherbafth

NET CTA IAMS

Steve Ray Phd Rosen KeithScherbafth

NET CTA IAMS

Distribution:

Automation and Robotics Research Institute John Mills

CAMAX Bruce Winegarden

Concurrent Technoloqies Cornoration Jim Cook

Consortium for Advanced Mfa., International Ron Boykin

Sandia National Laboratory Mike Griesmeyer Paul McKey

Step Tools, lnc. Mike Kutcher

Universitv of Southern California Ari Requicha

CTA, Inc. Phil Rosen

DOE Headquarters Ted Vojnovich

- Ford P. Arramowitz

Huqhes Missile Svstems Company Gordon Hunter

Institute for Advanced Manufactuflnq Sciences Jeff Lindberg

Institute for Manufactuflnq Automation Research Ron Dick

lntelliqent Svstems Technoloqv. Inc. Adad Madni

Lawrence Livermore National Laboratory Ken Hernandez Douglas Sweeney

Martin Marietta Enerw Svstems R. E. Hewgley, Jr. E. J. Klages A. K Lee/DOE-OSTI, 9731, MS-8175 (2) Y-12 Central Files, 9711-5, MS-8169

Pratt and Whitnev Derek Grant

Ravtheon Mitch Heller