Model Based Definition A Method of Drawingless Manufacturing
John Nolin
ASME/NNE Chairman
SolidXperts Technical Representative
jnolin
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“In the past 20 years, all our CAD investments (either 2d or 3d) were just to make a faster and better 2d drawing at the end of the day. Is that good enough? Is that all we can do? Can’t we do better?” - Tyco Electronics Connectivity
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Who is current using MBD?
jnolin
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These are not just North American engineers. There are global teams like GE and Baker Hughes, European firms like Rafael and Patek Philippe. Some are piloting with MBD using DimXpert like GE Measurement and Control group who set a goal to put 20% of the fabrication on MBD this year.
jnolin
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Accepted set by jnolin
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What is Model-Based Definition (MBD)?
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PMI stands for Product and Manufacturing Information including datum, dimensions, tolerances, bill of materials (BOM), notes, surface finishes, weld symbols, and coordinate systems. MBD: Model based definition. MBE: Model based enterprise. What is MBD? The best way to explain it is to walk through a real manufacturing case, instead of an academic definition. Let’s say we want to machine this aluminum bracket or donut. How? Easy! Build the model in SW, cut the aluminum stock and go through all the machining steps and then we have a finished product. From 3D design and 3D machining to 3D product. Very intuitive and streamlined. But wait a second, we are missing some critical product and manufacturing information (PMI) such as dimensions, tolerances, surface finishes and so no. In order to convey PMI, somebody in the history invented 2D drawings hundreds years ago, which works well. But the design and manufacturing are in 3D! Why not the PMI? 2D drawings are counterintuitive involving lots of coding and decoding, mental reconstructions of the 3D objects, which leads to extra cycle time and errors. So the gist of MBD is to marry the advantages of 3D modeling and 2D drawings into one 3D master document file to guide the manufacturing process.
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2D Drawings
Manufacturing Process
“1/3 of engineering dollars are spent in 2D drawings. Yet 60% of them don’t match
3D models.”
- Office of the U.S. Secretary of Defense (OSD)
jnolin
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Start with the problem: What are the problems with 2d drawings? The manufacturing process is complex involving 3D design, 2D drawings, Operating method definition, Procurement, Fabrication, Assembly Quality, supply chain management and so on. However, 2D drawings turn out to be very time-consuming and expensive. Regarding the collaboration between the DoD Engineering departments (like ARDEC Engineering) and their Supplier Channel: “1/3 of engineering dollars are spent in creating and maintaining 2D drawings. Yet 60% of them don’t match 3D models.” - Office of the U.S. Secretary of Defense (OSD) This estimation is confirmed by some other commercial firms as well such as GE and MTS. “Sounds about right” “We have the same problem.”
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jnolin
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Another perspective on the problem. One is the BAE system ground combat vehicle for U.S. DoD. The other side is all the paperwork to fully define the this vehicle, such as part drawings, assembly drawings, specifications, bill of materials, QA provisions, Inspection report, maintenance guide, product manuals and so on. Guess which one is heavier? Turns out all the paperwork to define this BAE ground combat vehicle heavier than this huge vehicle itself. Textron also made similar comment: “every time we ship a product, we have to ship a truck load of paperwork. We hate it and don’t want to do it anymore.”
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Why Now? Government agency requirements & maturity of related standards
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MBD is not new. The concept was brought up over 20 years ago. Why now? DoD is pushing hard on MBD. A new military standard Mil-std-31000A was released early 2013. Fiscal year 2014, MBD is the recommended deliverable format for all DoD suppliers. It’s a huge advantage in winning the contracts. DoD along with other large enterprises like Boeing and Ford are generating the ripple effects driving the adoption through all their 1st, 2nd, 3rd, and downstream suppliers. The other timing factor is 2D drawings are less and less taught at schools. Engineering user’s quote: “Hired a young mechanical engineer out of school. Brilliant. Very sharp and creative. But when I asked him to define a 2D drawing, he didn’t know how because it wasn’t covered at school.” Manufacturing user’s quote: “Not everybody on my shop floor can read 2D drawings well. They didn’t learn it at school and 2D drawings require strong mental capabilities to reconstruct the 3D models, which could be a challenge to some people. And no matter of what, it’s error prone.”
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Why Now?
2009: 1.5%
2013: 16%
Source: SOLIDWORKS customer base survey, 2009 (n=700) and 2013 (n=847).
Doing or planning drawingless manufacturing in 3 years
jnolin
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This Geoffrey Moore bell curve summaries the typical technology adoption trends: from innovators, to Early adopters, early majority, late majority, and laggards. This is generally applicable to technologies like Personal computers, 3D printing, smart devices and so on.
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User’s Comments on MBD
“We send lots of 3D PDF to our vendors. To our surprise, the supply
chain (vendors) hasn’t had any problems.”
- Richard Hawes, Senior Designer, AS&E
“Our customers (aerospace and defense) are currently requesting
both MBD “documentation” as well as 2D drawings.
- Peter Buzyna, Senior mechanical engineer, Cubic defense
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Business Drivers
Cost Saving
Reduce scrap and rework
Cut procurement cost
Time Saving
Faster response by suppliers
Save the time to create and
maintain 2D drawings
Quality Improvement
Remove model to drawing
discrepancy
Communicate more intuitively and accurately
Standard Compliance
MIL-STD-31000A
ASME Y14.41 and Y14.5
jnolin
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MIL-STD-31000A is free from US gov, ASME Y14.41 2012 $135 - $150, the MIL-STD covers most of the Y14.41 At high level, cost and time saving, quality improvement, and comply with industry standards, but we need to look at the specifics. Take scrap and rework reduction as an example, Viecelli Moveis, a Brazilian furniture manufacture. They are able to cut it down by 50%: “Our ERP system extracts all of the required bill of materials (BOM), geometry, and dimensioning information to manufacture the design from the eDrawings file, eliminating the time and effort required to create 2D engineering drawings while simultaneously improving accuracy and quality.” Another example is faster response by suppliers. Remember the comment made by AS&E:“We send lots of 3D PDF to our vendors. To our surprise, the supply chain (vendors) hasn’t had any problems.” GE is actually aiming at cutting supplier quoting time by 40%.
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2D Drawings
Manufacturing Process
jnolin
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The 2D drawings go away, so do the problems go away. And the money is freed up for the mfg process. The goal is to reduce file management overhead by 1/3 or more.
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The Output
3D PDF, eDrawing, JT2Go
MBD
CAD File
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3D PMI definition 3D PMI organization 3D PDF template customization 3D data sharing in eDrawings and 3D PDF
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Process Drawingless
Manufacturing
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Desired Results
Thorough 3D PMI definition and
organization
Easy output customization
MIL-STD-31000-A & ASME
Y14.41-2012 compliance
Viewing independent of MCAD
system used for creation
jnolin
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Rich Eckenrode estimates that current MBD tools have achieved about 90% compliance with Military-Standard-31000A. Furthermore, the PRC 3D PDF format used is in the process of being officially published as an ISO standard. Also, eDrawings 2015 enhanced the cross highlight between 3D PMI and geometries to comply with the “visual response” requirement in the above standards.
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Resources Sources for related standards & test cases
http://quicksearch.dla.mil/
Free PDF copy of MIL-STD-31000A and many other standards
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