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Transcript of Virtual Factory Amitom Without Swf
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Virtual Factory
Presented By Amitom
Medi-Caps
Indore
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Problem StatementVirtual Factory Program As the industry moves to a model with production being
outsourced at an increasing rate, rapid product introductionand cost efficiencies promised by the outsourcing modeldepends on quickly linking the OEMs information systemswith those of their suppliers.
However, most companies are still struggling to achieveeffective inte ration of desi n and roduction functions
within their own enterprises, a difficult task even whenmanufacturing is a captive activity. Such problems are amplified for the foundry/EMS provider,
which must be able to accept designs produced by a varietyof systems and return both product and formattedinformation back to their OEM customers.
The inefficiencies (costs and product delays) in the currentoutsource model will ultimately be passed on to thecustomer until they can be resolved through an effectiveeManufacturing environment.
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Defining Virtual Factory
A virtual factory is defined as anintegrated simulation model of majorsubsystems in a factory that considers thefactory as a whole and provides an
advanced decision support capability MODELING A VIRTUAL FACTORY:
Three modeling principles:-
Model the factory before building Simulate before producing
Anticipate and solve before they occur
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MODELING USING QUEST:
Queuing Discrete Event Simulation Tool
Simulating manufacturing processes for ensuring cost-effective process design
Identifying and understanding process problems and inevaluating proposals for changes to processes
Models directly emulate real-world system behaviorsthrough the distributed logics
Behaviors can be customized using Simulation ControlLanguage(SCL)
Automatic data collection and tabulation for simulationruns can be captured using Batch ControlLanguage(BCL)
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LANGUAGE USED:
Virtual Reality Modeling Language (VRML)
Created by Silicon Graphics, Inc. Standard 3-D format for the distribution of virtual
worlds on the Internet
VRML is the 3D analog to HTML
VRML codes are simple, reusable and compatible withJava
Using a VRML viewer, it is possible to navigate freelythrough the scene
VRML applications can have interactive behaviors thatallow user to influence the virtual environment
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VIRTUAL FACTORY SOFTWARE:
One of the software available for virtual factory is VR-Fact.VR-Fact is interactive virtual factory development softwaredeveloped as a part of a research to explore theapplications of Virtual Environments (VE) in the area ofmanufacturing automation. VR-Fact creates digital mock-up of real factory shop floor. Designers can drag and placemodular machines in the factory to study issues such as
p ant ayout, c uster ormat on an part ow ana ys s. orthe design of this shop floor the user can interactivelychoose the machines which are required to manufacture aset of parts. Furthermore, the VR walk through environmentprovides a unique tool for studying physical aspects ofmachine placements. Mathematical algorithms are used for
generating independent manufacturing cells. This approachsimultaneously identifies part families and machine groupsand is particularly useful for large and sparse matrices.
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DESIGNING A VIRTUALFACTORY:
The virtual factory is a mock-up of a real factory floor
It supports the analysis and design of the logistics ofmaterial movement, process flow and controlassociated with manufacturing
Ideas/proposed changes can be modeled, analyzed and
recon gure on e compu er e ore ey are u Models provide simulation, 3D visualization andanimation of machine operations to understandcomplex behaviors
Ensuring efficiency, saving money, human capital and
avoiding errors
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DIFFERENT LEVELS OF VIRTUALFACTORY:
TOP LEVEL: The top level is the factory implementationwith machines, transportation,control and schedulingmodels.
INTERMEDIATE LEVEL: The intermediate level is themachine level implementation where each machine can becontrolled and loaded with parts and appropriate codes. Insuch a model it will be ossible to "touch" the machines
control "knobs" and see actual functionality. MICRO LEVEL: the VR-Factory will integrate processsimulations such as metal chip formation with givendefinition of tool geometry, simulation of chatter, tool wearetc.
This step will also foster design for manufacturability analysisand design evaluation for a given assembly ormanufacturing process.
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Some Visual Scenes from SiemensIntrntl.
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UNDERSTANDING THE STRUCTUREOF VIRTUAL FACTORY:
Two approaches: -
a) Downward
b) Lateral
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Description
(a) Downward:-It is initiated by a large vertically integratedcompany seeking to reduce costs associated with fixedasset and to maintain focus on key operations.Outsourcingbreaks down thecompany's vertical structure. A company that successfullyoutsource becomes economically slimmer and moreado tive. It develo s lon term relationshi with the
supplier.(b) Lateral:- In small specialized enterprises firms that is inthe interest of seeking strategic alliances, form partnershipsalong a value added chain(e.g., suppliers, manufacturersand distributors). Without acquiring the ownershipheadache, the core firms of such network can increase
profit and reduce risks. Each such core firm can benefit bymodeling the adaptively and responsiveness of a small,specialized company and the large scale economies of alarge and integrated firm.
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VIRTUAL FACTORY ADVANTAGES:
Improved decision-making throughout the complete
life cycle of businesses, facilities and products Can be applied to improve
Facility sizing
Equipment layout
Material handling equipment requirements Group technology
Manufacturing design
Production scheduling
Just in time / lean manufacturing design andanalysis
BPR, TOC and strategic planning
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VIRTUAL FACTORY ADVANTAGES:
Improved operations efficiency, throughput,
flexibility and profitability of the operationsmodeled
Streamline lead times
Decrease capital investment, inventories, andrisks associated with change
Can be used to analyze/perform time studies,human accessibility/ergonomics/safety,process
optimization and verification To face the future with confidence
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VIRTUAL FACTORY ADVANTAGES FORSTUDENTS:
Helps engineering and business students to grasp
factory dynamics that are difficult to teach in lecturesand impossible to experiment in real factories
Allows students to work in groups to build factories,forecast demand for products, plan production,
,
and setting scheduling rules for workstations
Helps students to build a robust operatingprocedure to keep the system running smoothly
Students can program and configure the machinemodel in order to minimize the cycle time.
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CHALLENGES:
The challenges facing virtual factoryare inexperienced users, security,expense control, and the level of
successful virtual factory.
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Program ObjectivesVirtual Factory Program
Standardize and automate the common
business processes of contract manufacturingprocess to significantly reduce the cost andlead-time to change manufacturing capacity
an oca on. Ensure the quality of the outsourced product.
Provide visibility into the virtualmanufacturing environment.
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Standardize and automate the common
business processes of contract manufacturingprocess to significantly reduce the cost andlead-time to change manufacturing capacity
an oca on. Ensure the quality of the outsourced product.
Provide visibility into the virtualmanufacturing environment.
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What is Virtual Factory?Virtual Factory Program
Virtual Factory is a set of extensions tothe core Order Management processscenario framework to facilitate the
information needed to support all orpart of the outsourcing of the design
and manufacturing of a product
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Process Scenario
Order Mgmt
Virtual Factory DemandCreation
Design Forecast
ProductDataMgmt
2C Factory
CapacityPlanning7B + 4A
CollaborativeDesign2D
Order
Payment
LogisticsDesign
Transfer
7A
or r er
&WIP Mgmt7B
Direct Ship& 3rd PartyFulfillment2B, 3C, 4C
ProductGenealogy& Quality
7C
VirtualManufacturing
ConsignedMaterials
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Alignment Across BoardsVirtual Factory Program
Semiconduct
or
Manufacturin
g
Electronic
Components
Information
Technology
Boards
BoardSpecific
Priorities
Virtual Factory Milestone Programs
SpecificMilestone
Programs
with cross board
Validation teams
Resulting in cross
Supply Chain
Virtual Factory PIPsCommon Virtual Factory PIPs
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Virtual Factory Process ModelFactory WO & WIP
Work Order and WIP
Mgmt - Enables theexchange
manufacturinginstructions that are
DemandCreation
Design Forecast
pecu ar o a wor
order. Also providesinformation about
Work In Progress. WIPPIPs have been
engineered andvalidated, WO PIPs
have not been definedyet.
Order
ManufacturePayment
Logistics
Work Order&WIP Mgmt
7B
VirtualManufacturing
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Virtual FactoryWO & WIP ChoreographyO
EM
/OEM
Su
7BxNotify of Forecast Reply
Supplier,Foundry,
Subcontractor,Contract
Manufacturer
7Bx
Manufa
cturer
plier
7B1
Request Work In Progress
Request Work In Progress Response
7B2
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Virtual Factory Process ModelFactory Capacity Planning
Factory Capacity Planning -
Enables the exchange of thecontract manufacturersmanufacturing capability andcapacity information. It is
DemandCreation
Design Forecast
FactoryCapacityPlanning7B + 4A
use o commun ca e e
output equivalency units ofmeasure, equivalencyfactors, and availabilitytimes. A suite of 4A and 7B
PIPs have already beenengineered.
Order
ManufacturePayment
Logistics
VirtualManufacturing
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Virtual Factory Process ModelProduct Data Management
Product Data Management -Enables the exchange BillOf Materials, ApprovedSuppliers List, EngineeringChange Request,En ineerin Chan e
DemandCreation
ProductDataMgmt
2C
Approval, EngineeringChange Orders,Engineering ChangeImplementationinformation between
supply chain partners. Thissuite of 2A and 2C PIPshave already beenengineered.
Order
ManufacturePayment
Logistics
Design Forecast
VirtualManufacturing
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Virtual Factory Process ModelDesign Transfer
Design Transfer-
Enables the transferof engineeringdesign information to
DemandCreation
Design Forecast
.
Defines howmanufacturingdesign information isexchanged. No PIPsexist today in thisarea.
Or er
ManufacturePayment
Logistics
DesignTransfer
7A
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Virtual Factory Process ModelProduct Genealogy & Quality
Product Genealogy &
Quality - Enables theexchange manufacturingproduct and processinformation to support
Order
Demand
Creation
Design Forecast
,
management andwarranty entitlement. NoPIPs exist today in thisarea however NEMI/IPChas defined standards for
this area that we canleverage.
ManufacturePayment
Logistics
Product
Genealogy& Quality7C
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Virtual Factory Process ModelDirect Ship & 3PL
Direct Ship & 3PL -
Enables theexchange Logisticsinformation to the
DemandCreation
Design Forecast
direct ship to endcustomers directlyfrom the subcontractmanufacturer or
from a 3rd partylogistics provider.
Or er
ManufacturePayment
Logistics
Direct Ship& 3rd PartyFulfillment2B, 3C, 4C
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Virtual Factory Process ModelConsigned Materials
Consigned Materials -
Enables the trackingof consignedmaterials through the
DemandCreation
Design Forecast
virtual manufacturingprocess.Order
ManufacturePayment
LogisticsConsignedMaterials