Presentation date: 2018 10 30 Presenter name: Corsin ......• PMI (e.g. form tolerances) is used to...

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

unrestricted © Siemens AG 2018

2017.MM.DD 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



“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



Digitalizing the entire value chain

is key to staying competitive in the future

IDEATION UTILIZATIONREALIZATION



Information Flow

Across the Entire Enterprise

ProductionProduct

engineering

Manufacturing

engineering

Operation Silos with Disconnected Systems



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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



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



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.



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



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



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



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



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



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



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



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



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



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



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



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



Part Material

Handling

Machine

Fixtures

Raw Material

Integrated Manufacturing Resource Library

Cutting Tools

NC Programmer assigns to manufacturing operations



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



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



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



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



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



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



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



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

Thanks for being part

of the [email protected]

Presentation date: 2018 10 30 Presenter name: Corsin ......• PMI (e.g. form tolerances) is used to...

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