Heavy Equipment Machinery Segment Industry Workflow / Demo Outline INTEGRATED MANUFACTURING January 2014

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Heavy Equipment Machinery Segment

Industry Workflow / Demo Outline INTEGRATED MANUFACTURING

January 2014

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Page 2 © Siemens Product Lifecycle Management Software, Inc.

Content

Content ... 1

Introduction ... 4

Domain Challenges ... 5

Innovation ... 5

Compliancy ... 5

Costs ... 5

Primary Opportunity Area ... 6

Scenario Overview ... 7

Assemblies Manufacturing ... 8

Assembly Planning ... 8

BOM Management ... 8

Process definition ... 8

Equipment selection and costing ... 8

Assembly Design and validation ... 9

Tool and Fixture design ... 9

Layout design 9 Process validation and throughput validation ... 9

Assembly Production Support ... 10

Shop floor Documentation ... 10

Manufacturing Execution System ... 10

Production Management ... 错误!未定义书签。 Quality management ... 10

Part Manufacturing ... 11

Part Planning 11 Manufacturability analysis ... 11

Process Definition ... 11

Tool and fixture selection... 11

Part Design & Validation ... 12

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Tool & Fixture Design ... 12

NC programming 12 CMM programming ... 12

Part Production Support ... 12

Tool management ... 12

Direct Numerical Control ... 12

CMM inspection execution ... 13

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Introduction

This is a Technical overview demo showing the Integrated Manufacturing Domain Solutions, as it is supported in all its aspects by the NX, Teamcenter and Tecnomatix portfolios. Furthermore this scenario will also cover costing.

This scenario can be used for different types of events:

Initial customer demo: use at next stage of the sales cycle for new or existing customers, - Up sells other portfolio’s to existing customers,

- Seminars

- Technical presentation (Product demo for people outside of the core evaluation team),

The demonstration can be configured for SMB or MLE:

- Middle to Senior Management (Engineering VP, Director & Managers and Production Managers) in discrete manufacturing.

- SMB – Owner/MD

- MLE – Team leader and above...

- Also must appeal to everyone i.e. users, IT (how?)

It is meant to get acquainted with the product breadth and completeness of our manufacturing domain solutions, at an early stage of the sales cycle

It covers a technical deep dives as a follow-up session to the E2E overview material for the Heavy Equipment Industry segment. To keep the flow simple we use the following sequential model. But do realize that PLM allows parallel activities in the four stages to substantially shorten the time to market.

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Domain Challenges

Innovation

o Higher product complexity/ new technology

 Better performing materials

 Multi-functional products o Higher process complexity

 Multi-site in different time-zones

 Global Engineering/manufacturing o Intellectual property

Compliancy

o Scrap reduction

o Environmentally friendly manufacturing (cooling liquid usage etc etc.) o Energy efficient manufacturing

Costs

o Raw material prices and Energy prices are increasing

o Crises forces customers to manufacture more cost effective o Global competition results into pricing pressure

o Margins are under pressure so using software to optimize efficient costing is critical

o Warranty costs need to go down

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Primary Opportunity Area

How to reduce the cost of operation for manufacturing

 Deliver products that meets all requirements and regulations

 Informed Decision making. (Shift left)

 Integrated Product and Production Lifecycles

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Scenario Overview

This demonstration shows how PLM for manufacturing can support heavy equipment manufacturers to proactively manage the production of their vehicles on time, within

production budgets / rate targets and capabilities that meets all of its requirements in a global environment.

The scenario we are using is based upon a request to design brakes with higher performance.

This will need a big engineering change for the product design but also manufacturing engineering to find out what the impact will be on the part manufacturing and assembly processes on the shop floor.

The demonstration wants to emphasize that using PLM within the manufacturing domain will drastically improve the quality of the products as well as the processes. Sharing manufacturing information earlier in the design cycle by connecting the virtual with the physical world allows the engineer to make better decisions in a phase of the lifecycle where the costs of changes are still low.

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Demo Content:

Assemblies Manufacturing

Assembly Planning

BOM Management

Analyze product mix due to new project for the axle with the new high performance brakes. This activity is needed to reflect/analyze the engineering change (eBOM) on the manufacturing bill of material

o Role: Manufacturing planner

 Change management

 Create new mBOM from new eBOM ( AVI name BOM Management) Process definition

The Engineering Change will also impact the eBOP. The manufacturer engineer will use the generic eBOP and adapts this so it is aligned with the mBOM for the new axle assembly.

The next step is to plan the new brake assembly for a specific plant, in this scenario the Livonia assembly plant. Associate the new parts to the processes and the stations.

 mBOM creation to BOP (AVI name EBOP)

 Resource planning (AVI name Tool Requirement Creation)

 Line balancing (AVI name Line Balancing) Equipment selection and costing

Analyze the impact on the fixtures supporting the new brake assembly. The manufacturing planner informs the cost engineering to compare two different scenarios for the loading station. One manual option and one using a KUKA robot. The planner associates equipment and tools to the processes. In this case an air nut runner with the appropriate Torque value, associated to the brake assembly mBOM, is selected available at the Livonia plant.

o Role: Manufacturing Planner

 Associate the right tooling to the process (AVI name Tool Requirement Resolution)

o Role: Cost engineer

 Cost comparison between manual and automatic handling of the axle. (AVI name Tool Costing)

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Assembly Design and validation

Tool and Fixture design

The manufacturing engineer digitally finds out during the validation process that the new front axle assembly doesn’t fit the existing fixture at station 10. He informs tool

engineering to change the fixture (AVI) o Role: Manufacturing planner

 Process simulate (AVI name is Design Collaboration) o Role: Tool designer

 Use synchronous technology to change the front axle fixture (AVI name is Design Collaboration)

Layout design

The manufacturing engineer uses process simulate to design the loading station with the robot.

 Process simulate (AVI name is Layout) Process validation

This activity is being performed by the manufacturing engineer to simulate all the existing activities at the assembly stations. We can differentiate 3 main simulations:

 Process simulate for ergonomic study assembling the new brakes (AVI name is DPA Ergonomics Simulation)

 Process simulate to create the paths needed to position the brake with in detail interference checking (AVI name is Assembly Feasibility)

 Process simulate for robotics to createsimulte the paths needed for welding the chassis (AVI name is Welding)

Throughput validation

This activity is being performed by the manufacturing engineer to simulate all the existing activities at the assembly stations.

 Plant simulation to perform time studies calculating a different product mix for a 5 day sequence.(AVI name Throuhput Validation)

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Assembly Production Support

Activities needed to manage and monitor shop floor manufacturing information in real time. This information is mainly consisting plant information like personnel activities, machining processes and or support services. Production support show the actual shop floor conditions so the decision maker can improve the production. We recognize 3 major areas.

Shop floor Documentation

This digital document describes which activities are needed to assembly the new front axle with the new brakes . This can be a textual sequence in 2D or a 3D pdf. Another option is using a movies showing the process.

o Role: Manufacturing Engineer

 EWI. (AVI name is EWI) Manufacturing Operations Management (MOM)

These activities monitor and collect the shop floor conditions. In this scenario the axle Teamcenter BOP being opened in SIMATIC PLMXML.

o Role: Production Engineer

 Job execution ( AVI name is Order Execution)

 Genealogy (AVI name is Genealogy) Quality management

Specific activities to collect and analyze measured data. Statistical process control can produce process and product insight for other disciples like engineering to enhance product and process quality. Issues can be managed by CAPA . In this task the quality engineer finds out that one dimension of the brake rotor is still within tolerance but measurements show that it will run out of its tolerance range. The issue is being captured and communicated through Teamcenter CAPA to a plant engineer. After studying the measurements in detail the conclusion is that wear of one cutting tool was the cause of the issue. No engineering changes needed and the issue was closed with the message to the shop floor to change the tool and increase this more frequent.

o Role: Quality Engineer

 Quality Engineer. DPV

 Plant Engineer. CAPA

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Part Manufacturing

Part Planning

All planning activities needed to produce specific components. In this scenario we assume that components of the brake assembly are being produced in-house.

Manufacturability analysis

Within NX Check Mate there are solutions ( DFMPro) to analyze the features and dimensions on manufacturability and if the part tolerances are correct. As a part of Siemens Quality Management solutions the quality engineer can perform a 3D tolerance analysis to find out if the new break assembly can be assembled. Costs can be calculated at feature level.

o Role: Product designer

 Design for Manufacturing o Role: Quality Engineer

 Variation analysis o Role: Cost Engineer

 Product Cost analysis Process Definition

For each component the Production engineer can define a manufacturing process for each single component or subassembly. These processes can retrieved out of a manufacturing knowledge database and adapted to the new break assembly

o Role: Manufacturing Engineer (AVI name is Part Planning)

 Structure Manager Tool and fixture selection

Teamcenter manufacturing allows manufacturing engineers to create their tools and fixtures.

o Role: Manufacturing Engineer

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Part Design & Validation Tool & Fixture Design

The manufacturing engineer during simulation found out that the new break assembly is heavier so a fixture needs to be changed. Instead of 2 grippers 3 are needed and added to the load station fixture.

o Role: Tooling Design Engineer

 NX (AVI) NC programming

For programming all the necessary operations to manufacture the axle. NX CAM can simulate the NC code before sending it to the CNC Machine.

o Role: Manufacturing Planner

 NX CAM (AVI name is NC Programming) CMM programming

For programming all the necessary operations to manufacture the axle. NX CAM can simulate the NC code before sending it to the CMM Machine.

 NX CAM (AVI name CMM) Part Production Support

Tool management

These activities monitor and collect the shop floor conditions. . Unique to Siemens Teamcenter is integrated with the sourcing tools within Siemens MCIS TDI software.

o Role: Production Engineer

 MCIS Direct Numerical Control

These activities manage the collected shop floor information. Direct connection between the CNC Machines and the planning department can be managed by Teamcenter. In this scenario the operator at the Machining center finds out that during the facing operation a small vibration appears due to wrong federate. Through Shop floor connect he notifies the programmer to change this operation parameter.

o Role: Operator / Manufacturing Engineer

 Production control. (AVI name Shop Floor Control)

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CMM inspection execution

Specific activities to collect and analyze measured data. Statistical process control can produce process and product insight for other disciples like engineering to enhance product and process quality.

 DPV ( Dimensional Planning and Validation)

Licenses

This is the first draft of the licenses needed to perform the scenario.

ASSEMBLIES MANUFACTURING

Quality Management DPV DPV Foundation Package TNQ2002

CAPA Teamcenter Issue Management and CAPA TC050420

PARTS MANUFACTURING

Process Step Solutions Element Products Licenses

Manufacturability Analysis Product Costing Teamcenter Costing

Tolerance Analysis Variation Analysis TNQ1008

Quality Management ?

Design for manufacturing DFM Pro for NX PARTS MANUFACTURING

Process Planning Part Planning Teamcenter Part Planner Quality Management ?

Document Management ? PARTS MANUFACTURING

Tool and Fixture Selection Resource Management Resource Manager TCM055010 OR EFI40440 ? Tool&Equipment Selection Resource Manager TCM055010 OR EFI40440 ? Process Driven Tool Design Resource Manager TCM055010 OR EFI40440 ? PARTS MANUFACTURING

CMM Programming CMM Programming/Analysis CMM Inspection Programming NX10210 OR NX30210 OR TNQ1012 OR TNQ1014

CMM Inspection Analysis TNQ1016

Quality management ? Document Management ? PARTS MANUFACTURING

NC Programming Part Programming

Quality management ? Document Management ? PARTS MANUFACTURING

Tool and Fixture Design Integrated Design NX Modelling

Process Driven Tool Design Resource Management TCM055010 OR EFI40440 ? PARTS MANUFACTURING

Tool Management TDI Teamcenter ?

PARTS MANUFACTURING

Direct Numerical Control Shop Floor Connect Shop Floor Connect for Teamcenter TCM55021/TCM55022/TCM55023 PARTS MANUFACTURING

CMM Inspection Execution DPV DPV Foundation Package TNQ2002

CMM Inspection CMM Inpsection Execution TNQ1018

CMM Inspection Analysis TNQ1016