Integrating PLM with Shop Floor Operations:

Validating As-Built to As-Designed

Integrating PLM with Shop Floor Operations:

Validating As-Built to As-Designed

Dick SlanskySenior Analyst

ARC Advisory Groupdslansky@arcweb.com

2© ARC Advisory Group

Evolution of the Design/Build Process

90s

Integration of Production Process Design and Shop Floor Operations

80s 2000 2008…..

3D

Digital Mockup

Digital Manufacturing

3D User Experience

2D

Tech

nolo

gic

al A

dvan

ce

Design, Simulation, & Validation of Manufacturing Processes

3© ARC Advisory Group

Today’s PLM: Holistic Approach to Product & Process

• Product, Processes, & Resources have become “Virtualized”: 3D Experience from Concept to Customer

• PLM Scope has expanded: Design/Build has become Design/Simulate/Validate/Automate/Build

• PLM Solution Sets Interface with most Enterprise Business Solutions: ERP, SCM, EAM

• Digital Manufacturing Solutions Extend Virtual Manufacturing Processes to the Factory Floor

• Integration of PLM with Operations Mgmt Validates the As-Built to the As-Designed

• Validation of As-Built Product Closes Loop between the Virtual Build and the Physical Build

4© ARC Advisory Group

3D CAD

Product Data Mgmt (PDM)

Project/Program Mgmt

Parts Fabrication (CAM)

Product Test (CAE)

Mfg Process Mgmt (MPM)

Knowledge-Based Engr. (KBE)

Digital Manufacturing

2D CAD

Service/Support/Content Mgmt

0% 10% 20% 30% 40% 50% 60% 70%

What PLM Solutions Companies are UsingWhat PLM Solutions Companies are Using

Growing Adoption Rate

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Mfg Process Definition/Creation

Process Planning

Production Mgmt/Shop Floor Execution

Workcell/Production Line Simulation & Validation

Automation & Controls Simulation & Validation

0% 20% 40% 60% 80%

Not ImportantSomewhat ImportantImportantEssential to MPM/Digital Mfg

What is the Importance of Digital Mfg & Shop Floor Operations Requirements?

6© ARC Advisory Group

Manufacturing Planning• Define High-Level Manufacturing Processes• Process Planning (Assembly & Installation) • Define Work Instructions & Work Flow

Detailed Process Design & Analysis• Detailed Resource Modeling & Simulation• Process Definition and Validation• 3-D Factory Layout • Equipment, Tool & Fixture Simulation• Ergonomic Simulation

Validation & Virtual Commissioning• Control Logic Simulation & Validation• Kinematic (Robotic) Simulation & Validation• Quality Assurance/Process Improvement Validation• Sensor/Metrology Placement Validation• Virtual Commissioning & Validation of Automation Systems• Knowing that the Production System Works Prior to

Launch: Priceless.

Digital Manufacturing Covers the Entire Build ProcessDigital Manufacturing Covers the Entire Build Process

3D

3D

7© ARC Advisory Group

Digital Manufacturing Enables Product & Process ValidationDigital Manufacturing Enables Product & Process Validation

• Product Design (CAD) tools are used to define “What" is to be built

• Manufacturing Process Design tools are used to define “How" it is to be built

• Integration of Product & Process Design directly supports concepts such as Concurrent Engineering & Mfg Process Validation

Digital Manufacturing facilitates the Holistic view of Product and Process Design as integral components of the overall product life cycle

8© ARC Advisory Group

Integration of PLM and Shop Floor Operations Enables Validation of the As-Built Product

Managing the Manufacturing Process

Integration of Product Design with Mfg Processes (Digital Mfg) Enables Production Management & Shop Floor Execution to be Integrated with the PLM Solution Set

Manufacturing Process Design coupled with Digital Mfg Simulation Integrates the Definitions of the Product, Processes, Factory, and Resources into a Comprehensive and Consistent Manufacturing Solution

Manufacturers want a more direct and horizontal integration between their PLM/PDM design/build environment and their shop floor operations. PDM Integration with ERP is not bi-directional

9© ARC Advisory Group

Shop Floor Systems Should be an Extension of PLM Shop Floor Systems Should be an Extension of PLM

Manufacturing Processes

Product Lifecycle Processes

Create Processes

PlanProcesses

Simulate & Validate Processes

ExecuteProcesses

Digital Manufacturing Solutions + MES

As – Built RecordsEngineering DesignValidate

Design Simulate Automate BuildValidate

10© ARC Advisory Group

Tailored Work Package• Process Configuration

• Work Instructions

• Work Flow Routing

• Operations Scheduling

• Shop Floor Requirements• WIP Tracking

• Process Control

• Quality Assurance

• Labor/Parts/Tooling

PLM Integrated with Shop Floor ExecutionPLM Integrated with Shop Floor Execution

PLM

Process Creation

Product Design

• E-BOM

• M-BOM

• Bill of Process

• Product Config.

Maintenance & Support

“As Designed” Product Data

Production Mgmt

Shop Floor Execution

(MES)

“As Built” Records

“As Designed” Process Data

ERP

11© ARC Advisory Group

Closing the As-Built to As-Designed LoopClosing the As-Built to As-Designed Loop

FEEDBACK LOOP: Operations Mgmt/PDM Integration

Product & Process Reqmts: As-

DesignedSimulation Analysis Validation Execution

(Build)Knowledge:

As-Built Records

Manufacturers Want to Know they are Building the Product they Designed

12© ARC Advisory Group

CAD

Product Design

Process Models,3D Simulations, Work Order

Instructions

Process Execution

Shop Floor Execution (MES)

Quality Assurance

Unit Data & Work History

Data Vault

3D ModelsE-BOM Process

Modeling

Digital Manufacturing/MPM

Process Simulation & Validation

Process Planning

InventoryMgmt

Work OrdersRelease & Status

Financials

Invoicing Shipping

Labor Reporting

ReceivingParts Purchasing

ERP

Production Scheduling

Work Order Release

Work Order Status

Material / Parts

Job Sign On/Off

Digital Mfg + Shop Floor Execution = Validation of As-Built to As-Designed Digital Mfg + Shop Floor Execution = Validation of As-Built to As-Designed

Closing the Loop From As-Built Records To As-Designed

Master Routings, M-BOM

E-BOM

PDM

Product Data Management

Collaborative

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What are Manufacturers Using for OM/MES Today and Plan to Use in the Future

In-house developed custom solutions

Vertical Industry Solutions from OM/MES application providers

OM/MES solutions from Automation provider

OM/MES solution from ERP provider

OM/MES solutions from PLM provider

OM/MES solutions from Supply Chain Mgmt provider

0% 20% 40% 60% 80% 100%

Current

Future

14© ARC Advisory Group

At What Stage are Manufacturers with PLM-OM/MES Integration

Operations/Inspection Records Interface with some Engr/Business Systems

Operations/Inspection records do not Interface with any Engr/Business Systems

Have some limited connection between Work History (Operation/Inspection) records and PLM/PDM

Have basically closed the loop between As-Built and As-Designed

Have an accessible Data Repository for Operations/Inspection (As-Built) records

0% 10% 20% 30% 40% 50%

Best Practice

15© ARC Advisory Group

Work Flow Routing

Work Order (WIP) Tracking

Quality Assurance Mgmt

Operations & Inspection Records

Production Data Acquisition

Product Tracking & Tracing

Tooling Mgmt

0% 10% 20% 30% 40% 50% 60% 70% 80%

Future

Currently

What Shop Floor Operations Interface with your Engineering/PLM Solutions?

16© ARC Advisory Group

What Business & Engineering Systems do your Operations & Inspection Records Interface with?

ERP

PDM (As-Designed Source)

Other (In-House Systems, etc.)

SCM

CRM

0% 10% 20% 30% 40% 50% 60%

Best Practice

17© ARC Advisory Group

Effective & Efficient Use of Digital Mfg & OM Tools: Guidelines for UsersEffective & Efficient Use of Digital Mfg & OM Tools: Guidelines for Users

Integrate Use of DM Tools into the Manufacturing Design Process• Set and Implement guidelines for application of DM technology• Provide DM training for Mfg Engineering Discipline & Resources

Emphasize Re-use & Commonality • Re-use dependent on a strategy of Common Process design

Reuse of Virtual Processes is a Key Enabler Establish a Library of virtual production systems & equipment

• Use modular approach for efficient use of Virtual Simulation Establish basic Virtual Production Equipment building blocks Build Virtual Production Systems with Common Virtual Equipment

Integrate DM Tools with Shop Floor Operations• Virtual Models Developed & Maintained by multiple engineering

disciplines (Product, Manufacturing, Tooling, Controls)• Use Latest Production Process Data for Virtual Simulations

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Thank You.Thank You.For more information, contact the author at

dslansky@arcweb.com or visit our web pages atwww.arcweb.com