Presentation to The Last Frontier: Eliminating the Manufacturing Bottleneck presentation to SME...

The Last Frontier:

Eliminatingthe

Manufacturing Bottleneckpresentation topresentation to

SME Automation Rendez-vousConference 2009

October 20, 2009OpenAire Inc. Logicap Engineering

Outline

1. OpenAire Background

2. The Manufacturing Bottleneck

3. Lean Stage 1: Automated Design

4. Results of Organizational Transformation

5. Lean Stage 2: Automated Welding

Company Overview

Founded in 1992

Marketing custom glass-aluminum retractable roof buildings globally

Recognized the manufacturing bottleneck in Year 2000

Began implementing Lean engineering

OpenAire Background

Water Parks

Resorts & Water Parks

OpenAire Background

Curved Retractable Roof Systems

OpenAire Background

Pre-Lean Practices

Sales Quotes relied on past experience Visuals generated by Engineering

Design 2D electronic drafting Manual material take-off

Manufacturing Frequent engineering changes 1,000s of hours of manual welding per building

OpenAire Background

Custom Manufacturing Process Flow

Time

Sales ProductionOrder Entry Purchasing

Applications Engineering

Design Engineering

Manufacturing Engineering

The Manufacturing Bottleneck

= critical path limiter

Bottleneck Functions

Applications Engineering Preliminary Bill of Materials & Process Plan Quote drawing and costing

Design Engineering Detailed Bill of Materials Fabrication & assembly drawings

Manufacturing Engineering Process Plan CNC programs


Why is Engineering a Bottleneck?

Most routine engineering work is delivered through time-consuming,

error-prone manual processes.

Bottleneck Consequences

Delay Sales prospects impatient for pricing Unpredictable delivery schedules

Error Engineers must remember 3D relationships

between components in different 2D drawings

Cost Engineering resources are expended in routine,

repetitive work Design errors usually result in shop floor waste


Preparation for Automated Design

Formalized design process as a series of inputs and validations

Wrote design rule algorithms

Created 3D parametric solid CAD template models

Installed multiuser web-based knowledge engine

Lean Stage 1: Automated Design

Automated Design Environment


Web-basedKnowledge

Engine

Web-basedKnowledge

Engine

SQL Database

SQL Database

AuthoringTools

AuthoringTools

InterfaceInterface

Output Generators

Output Generators

CAD Templates

CAD Templates

ERPLink

ERPLink

Automated Design Functionality

1. Submit inputs defining the building and its features

2. Review ‘working line’ pictorials

3. Generate CAD assemblies

4. Generate B.o.M. & drawing layouts


… then use interactive CAD to tweak the 3D assembly and annotate drawings.

Project HistoryGeneral Building Layout


Structural Layout


Truss Configuration


Truss Group & Bracing Layout

Face Configuration


Main Back Side(Gable, dimensions in inches)

Working Lines Review


FrontBack

Right

Left

Detailed CAD Digital Prototype

Typical Building

110’ x 100’ x 32’

Design Review

Truss Group

Column Truss

Retractable Slider


Curtain Wall Corner Detail

Web Browser 3D Model

Visualization &Installation Guide


Assembly Structure with P/Ns

Atomic Bill of Materials


Bill of Materials -- Salinas SME Project

Item Qty Part Number Description Material Length Cut Width Thickness1 16 630~EH05640~016 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 02 104 630~EH05640~017 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 03 16 630~EH05640~018 Brace Tube x H1.5 x W1.5 x T0.188 x L16.971 Aluminum 6063-T6 16.97056 0 04 20 630~EH05810~008 Brace Tube x H2 x W2 x T0.188 x L20.651 Aluminum 6063-T6 20.65149 0 05 20 630~EH05810~009 Brace Tube x H2 x W2 x T0.188 x L21.583 Aluminum 6063-T6 21.58253 0 06 20 630~EH05810~007 Brace Tube x H2 x W2 x T0.188 x L22.576 Aluminum 6063-T6 22.57587 0 07 20 630~EH05810~013 Brace Tube x H2 x W2 x T0.188 x L24 Aluminum 6063-T6 24 0 08 20 630~EH05810~006 Brace Tube x H2 x W2 x T0.188 x L25.072 Aluminum 6063-T6 25.07173 0 09 20 630~EH05810~010 Brace Tube x H2 x W2 x T0.188 x L25.157 Aluminum 6063-T6 25.15671 0 010 20 630~EH05810~005 Brace Tube x H2 x W2 x T0.188 x L27.805 Aluminum 6063-T6 27.8047 0 011 20 630~EH05810~004 Brace Tube x H2 x W2 x T0.188 x L30.797 Aluminum 6063-T6 30.79729 0 012 20 630~EH05810~003 Brace Tube x H2 x W2 x T0.188 x L34.074 Aluminum 6063-T6 34.07419 0 013 20 630~EH05810~002 Brace Tube x H2 x W2 x T0.188 x L37.662 Aluminum 6063-T6 37.66238 0 014 320 630~EH05810~011 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 015 20 630~EH05810~012 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 016 20 630~EH05810~014 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 017 20 630~EH05810~015 Brace Tube x H2 x W2 x T0.188 x L38.61 Aluminum 6063-T6 38.61011 0 018 20 630~TBD~001 Brace Tube x H4 x W4 x T0.5 x L36.018 Aluminum 6063-T6 36.01787 0 019 28 630~844987~002 Center Mullion Cap x L307.94 Aluminum 6063-T6 307.94018 0 020 28 630~844987~003 Center Mullion Cap x L313.86 Aluminum 6063-T6 313.86 0 021 8 630~844987~001 Center Mullion Cap x L626.065 Aluminum 6063-T6 626.06518 0 022 28 630~844986~002 Center Mullion x L308.128 Aluminum 6063-T6 308.12768 0 023 28 630~844986~003 Center Mullion x L316 Aluminum 6063-T6 316 0 024 8 630~844986~001 Center Mullion x L626.253 Aluminum 6063-T6 626.25268 0 025 20 630~p- CBG~001 Column Base Gusset x T0.25 x W6 x L14.04 Aluminum 6061-T6 14.04002 6 0.2526 20 630~p- CF~001 Column Foot Plate x T0.5 x W14 x L20 Aluminum 6061-T6 20 14 0.527 10 630~896139~003 Curtain Wall 3- 5/8" x L130.27 Aluminum 6063-T6 130.2705 0 028 99 630~896139~009 Curtain Wall 3- 5/8" x L135.938 Aluminum 6063-T6 135.9375 0 029 2 630~896139~005 Curtain Wall 3- 5/8" x L138.15 Aluminum 6063-T6 138.1505 0 030 2 630~896139~030 Curtain Wall 3- 5/8" x L138.15 Aluminum 6063-T6 138.1505 0 031 35 630~896139~032 Curtain Wall 3- 5/8" x L14.749 Aluminum 6063-T6 14.749 0 032 1 630~896139~001 Curtain Wall 3- 5/8" x L14.782 Aluminum 6063-T6 14.78159 0 033 1 630~896139~028 Curtain Wall 3- 5/8" x L14.782 Aluminum 6063-T6 14.78159 0 034 6 630~896139~011 Curtain Wall 3- 5/8" x L144.124 Aluminum 6063-T6 144.12404 0 035 6 630~896139~023 Curtain Wall 3- 5/8" x L144.124 Aluminum 6063-T6 144.12404 0 036 13 630~896139~006 Curtain Wall 3- 5/8" x L19.499 Aluminum 6063-T6 19.499 0 037 18 630~896139~037 Curtain Wall 3- 5/8" x L26.59 Aluminum 6063-T6 26.59001 0 038 1 630~896139~002 Curtain Wall 3- 5/8" x L29.541 Aluminum 6063-T6 29.54082 0 039 1 630~896139~029 Curtain Wall 3- 5/8" x L29.541 Aluminum 6063-T6 29.54082 0 040 2 630~896139~015 Curtain Wall 3- 5/8" x L34.022 Aluminum 6063-T6 34.02226 0 0

Accurate Drawings

Applications Engineering, time Preliminary building designs and costs

generated automatically on demand

Manufacturing Engineering, n/c The next Lean target, Stage 2

Design Engineering, time Detailed Bill of Materials and accurate shop

drawing layouts extracted automatically from the 3D CAD building prototype

Impact on Manufacturing Bottleneck

Results of Organizational Transformation

Positive Trends


Customer Service

Product Quality

Profitability

Growth

Costs

Quoting Improved customer response Reduced demand for engineering resources

Design for production Estimated 50% time savings in engineering Custom truss designs replicated digitally

Manufacturing New confidence in engineering drawings

Measurable Improvement


Ready for the Next Lean StagePast Investigations

A prerequisite for eliminating thefinal manufacturing bottleneck is

custom truss designsare replicated digitally.

Robotic weld programming Too time-consuming using truss designs

developed by 2D electronic drafting processes

Weld fixturing Precision positioning of long, extruded sections

is difficult so ‘ideal-path’ weld motions must be corrected for component warpage

Cost justification Existing robotic approaches could not compete

with current manual methods

Lean Stage 2: Automated Welding

New Developments

Robotic weld programming now feasible because … Automated design generates 3D geometry

suited to automated weld path extraction Fixturing demands are relaxed with tip-touch

system correction of CAD-to-actual weld path

Cost justification Will depend on price/performance of proposed

system relative to current manual methods


Digital Weld Path Extraction


Deviation of Actual from Digital


Weld path corrected by tip-

touch system

Path variability due to fixturing

limitations

Next Steps

Review welding machine builders Need system to fixture components for large,

variable size trusses quickly and accurately

Generate CNC code from 3D model Need algorithms to extract weld paths and tip

angles from relevant geometry faces

Cost justification Final decision to proceed with Lean Stage 2

dependent on projected savings


IN SUMMARY

The custom manufacturing bottleneck:

Is caused by routine manual engineering

Can be eliminated through design automation

Must be eliminated before welding automation is cost-justifiable

THANK YOU

Contact

Mark AlbertineOpenAire Inc.2360B Cornwall RoadOakville, Ontario Canada L6J 7T9Tel. (905) 901-8535Email [email protected]

Gord HobbsLogicap Engineering Corp.

#9 - 140 McGovern DriveCambridge, Ontario

Canada N3H 4R7Tel. (519) 489-7222

Email [email protected]

Presentation to The Last Frontier: Eliminating the Manufacturing Bottleneck presentation to SME...

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