Unapređenje upravljanja proizvodnim procesom sa Windchill MPMLink-om

Unapređenje upravljanja proizvodnim procesom sa Windchill MPMLink-om

© 2009 PTC

Agenda

Šta predstavlja upravljanje proizvodnim procesom?

Opseg, definicija i izazovi

PTC Windchill MPMLink

Deo PTC rešenja za proizvodnju

Istorija

Ključne mogućnosti

Summary

© 2009 PTC

Realnost proizvodnih preduzeća

Reach faster ramp-up, shorter development cycles and quicker time-to-market

Upravljanjem povećanom varijabilnosti i kompleksnosti proizvoda

Upravljanjem i poslovanjem u globalizovanom lancu snabdevanja

Poboljšanjem operativne efikasnosti i preimućstvom

Meet cost targets Postizanjem pravog kvaliteta

iz prvog pokušaja sa razumnim troškovima







Brži izlazak na tržište... Ako ne i prvi

Nema više “univerzalnih” proizvoda …

varijabilan i kompleksan Sve veće odgovaranje na

potrebe klijenata … fleksibilan

Dobavljači i i partneri širom sveta

Visok kvalitet… Ali ne po svaku cenu

Brži izlazak na tržište... Ako ne i prvi

Nema više “univerzalnih” proizvoda …

varijabilan i kompleksan Sve veće odgovaranje na

potrebe klijenata … fleksibilan

Dobavljači i i partneri širom sveta

Visok kvalitet… Ali ne po svaku cenu

Stvara se potreba za…Stvara se potreba za…Današnja realnostDanašnja realnost

© 2009 PTC














PressuresPritisci tržištaPritisci tržišta


Manage increased product variability and complexity

Manage and operate in a globalized supply chain

Improve operational efficiency and excellence

Meet cost targets Achieve first time quality at

reasonable cost






reasonable cost

Translates into the need to…Translates into the need to…

© 2009 PTC






reasonable cost






reasonable cost

PressuresMarket PressuresMarket Pressures


Kako preduzeća da se izbore sa ovim izazovima…Pogledajte MPM i njegovu ulogu u procesu razvoja proizvoda (PDP)

Nepovezanost inženjerskih, proizvodnih i produkcionih timove

Poteškoće sa pronalaženjem i upotrebom proverenih proizvodnih procesa i resursa

Poteškoće sa obezbeđivanjem tačnih informacija iz proizvodnje u produkciju na vreme

Procesi na papiru i u manuelnim alatima (Word, Excel, ..)

Disconnected legacy systems

Nepovezanost inženjerskih, proizvodnih i produkcionih timove

Poteškoće sa pronalaženjem i upotrebom proverenih proizvodnih procesa i resursa

Poteškoće sa obezbeđivanjem tačnih informacija iz proizvodnje u produkciju na vreme

Procesi na papiru i u manuelnim alatima (Word, Excel, ..)


Problematične tačke/ IzazoviProblematične tačke/ Izazovi

Rezultuje ….NeefikasnostVeći troškoviPomeranje rokovaGreške

© 2009 PTC

Jaz– od vizualnog do virtualnogKako

… da preoizvedemo u skladu sa vremenom, budžetom i zahtevima

kvaliteta

Proizvodni inženjering

Prema učešću na tržištu Prema profitabilnosti

Inženjering Izrada

Functional System PerspectiveManufacturing Perspective

Str

uc

ture

Pro

pu

lsio

n

Ele

ctr

ica

l

Hy

dra

uli

cs

Co

ntr

ol

Sy

ste

ms

…

Plants

Assembly Stations / Lines

Sub-Assemblies

Details Parts / Raw Materials

…

Šta--- da li moramo da proizvedemo?

Gde i kada… da proizvedemo zahtevanu

količinu?

?

© 2009 PTC

?

The Gap – From Virtual to Physical

MPMIzrada

Inženjering

How … to produce meeting time, cost

budgets and quality requirements

Upravljanje proizvodnim procesom– Prevazilaženje jaza

Male izmene u Inženjeringu imaju veliki uticaj na Proizvdonju i Izradu

© 2009 PTC

Radne instrukcije

Tooling requests

eBOM /As-Designed

Procena vremena & troškovaZahtevi za izmenom

Des

ign

Procesni plan dela & sklopa

INPUTI AUTPUTI

3D CAD Modeli

2010 30

NC/CMM programi

Resursi & Standardi proizvodnje

Interno i u lancu snabdevanja

Milling Machines

Drilling Machines

Skills

Work Centers

Tools

Work Centers

Skills

Tools

Proces definisanje i upravljanje proizvodnim procesima koji se koriste za izradu delova, za sklapanje finalnih proizvoda i izvršavanje inspekcije ,

mBOM / As-Planned

Upravljanje proizvodnim procesom– Prevazilaženje jaza

Inženjer projektuje proizvodProizvodni inženjer projektuje proizvodne procese

UpravljanjeProizvodnim

procesom

© 2009 PTC

Agenda

What is Manufacturing Process Management?

Scope, definition and challenges

PTC’s Windchill MPMLink

Part of PTC’s Manufacturing Solution

History

Key capabilities

Summary

© 2009 PTC

PTC strategija proizvodnje

PTC-eva misija je da pomogne klijentima da uvide vrednos u poboljšanju proces razvoja proizvoda

Razvoj proizvoda uključuje razvoj proizvodnih procesa i alata neophodnih za izradu proizvoda

Za optimalne rezultate, proizvodni poslovni procesi treba da se izvršavaju istovremeno sa projektantskim procesima

Zahteva vizualne, asocijativne, digitalne sposobnosti proizvodnje kao integralne komponente PDS-a

“…(MPM / Digitalna proizvodnja) … je najefektivnija kada predstavlja INTEGRALNU komponentu cele PLM strategije preduzeća.”

[CIMdata: “Digital Mfg: Moving the Design into Production”, 2006]

© 2009 PTC

Tipični MPM

proces

Istovremeni razvoj procesa i proizvoda

Razvoj koncepta

Sistemsko projektovanje

Detaljno projektovanje

Smanjenje trajanja ciklusaLimited

opportunity for Manufacturing to influence design and reduce cost

Istovremeni MPM proces

Potpuna proizvodnjaProductionRamp-up

Upravljanje proizvodnim

procesomSmanjenje troškova

usled izmene

Smanjenje troškova proizvodnje

“[Manufacturing companies] identified that the need to reduce manufacturing costs was driving their need to improve their manufacturing planning process at practically the same rate as compressed development schedules.”

Aberdeen Group, Digital Manufacturing Planning – Concurrent Development of Product and Process, 11/2007

© 2009 PTC

Windchill MPMLink

Pro/PLASTIC Advisor

Expert Moldbase eXtension

Pro/TOOLMAKER

Tool Design Option

Projektovanje kompletnog kalupa

ComputerAided

Verification

NC SheetmetalProgressive

Die eXtension

CAM Lite

Prismatic MillingProduction MachiningComplete Machining

PTC’s rešenje za proizvodnjuPortfolio proizvoda

PTC sistem za razvoj proizvoda

© 2009 PTC

PTC Acquired Polyplan for MPM

•Osnovana 1999 u Montrealu, Kanada

Windchill Technical Committees

• CAB has now been incorporated into the Windchill Technical Committees

Windchill MPMLink first point release

• Enhancing core functionality and streamlining common tasks

First LIVE Customer !

• First customer in production with Windchill MPMLink

xv

Windchill MPM Customer Advisory Board formed

• Orient Windchill MPMLink roadmap with customers’ requirements and priorities and therefore maximize customer and PTC benefits from use of Windchill MPMLink

•Worked closely with Windchill MPMLink product management team during initial development

•Objectives

• Allow PTC to gather real-world use cases from world-class customers

• Joint prioritization of future capabilities and use cases

•Various Industries represented

• Aerospace & Defense, Industrial Equipment & Hi-Tech Electronics

Windchill MPMLink - Istorija

2005

Windchill “10”Windchill “10”

2006 2007 2009

Windchill MPMLink RELEASED!

• The industry’s first integral solution for Manufacturing Process Management

• Part of Windchill release streams

• Transformed Polyplan capabilities into an Integral Windchill module called MPMLink

• Control of critical manufacturing information and associated development processes

• Collaborative process development through the sharing of knowledge, product information, concepts and ideas

• Complete model supporting product, process and resource definition

9.1 F0009.1 F000

2010x

xv

x

2008x

9.0 F0009.0 F000

xv

Windchill MPMLink X-20

• Focusing on functionality, productivity improvements and serviceability

xv

xv

© 2009 PTC

Windchill MPMLink key capabilities …….. enabling Concurrent Product and Process Development

An integral part of the Product Development

System

Associative eBOM to mBOM management

Digital definition and management of process

plans

Digital definition and management of manufacturing

resources and standards

Dynamically generated visual work Instructions

Integral change and configuration management

Streamline release to Manufacturing

© 2009 PTC

An Integral part of the Product Development System

ProposalsCustomer Requirements

Part DesignsBoMsChanges

CustomConfigurationsField Notices

RequirementsDesign Feedback

ModelsDrawingsSimulations

ConceptsRequirements

Market RequirementsBrochures, Data Sheets

Preferred PartsApproved Vendors

Customer ConcernsFailure ReportsUser, Service ManualsTraining guidesParts catalogs

CustomersCustomers

SupplierSupplier

ServiceService

ProcurementProcurement

EngineeringEngineering

MarketingMarketing SalesSales

SupplierSupplier

SupplierSupplier

Captive ODCCaptive ODC

Local Design PartnerLocal Design Partner

Offshore Design Partner

Offshore Design Partner

CustomersCustomers

Regulatory AuthoritiesRegulatory Authorities

Distributed MfgDistributed Mfg

ManufacturingManufacturing

Distributed MfgDistributed MfgDistributed MfgDistributed Mfg

Windchill

Workflow Change & Configuration ManagementAccess Control Document Management

PDMLink• Product Requirements• Products• As Designed (eBOM)• CAD Files• Documents

ESI (Enterprise System Integration)

MPMLink• As Planned (mBOM)• Process Plan / WI• Time & Cost Estimates• Mfg Standards Library• Resources Library

Enable the management of manufacturing data and deliverables as true enterprise data

By providing a common central repository for engineering product and manufacturing process planning data

Complete model supporting product, process and resource definition

Leveraging PLM and facilitating the …

Control of critical manufacturing information and associated development processes

Collaborative manufacturing deliverables development through the sharing of knowledge, product information, concepts and ideas

Feasibility FeedbackTooling DesignsWork InstructionsNC Programs

© 2009 PTC

Associative eBOM and mBOM Management

Ensure that mBOMs are conform and reflect the ever-changing engineering designs

By providing powerful capabilities to easily transform BOMs while maintaining associativity using traceability links

Flexible mBOM definition and restructuring

– Use engineering parts as-is or create manufacturing parts

– Derive multiple mBOMs from a single eBOM

– Maintain multiple Alternate BOMs describing the different manufacturing variations that can produce the same part

Leverage 3D designs using embedded 3D environment provided by ProductView technology

– Visualize engineering designs, eBOMs and mBOMs

– Create mBOM by selecting parts from the 3D environment

– Automatically generate 3D manufacturing mockup

Reduce difficult and time consuming task of ensuring BOM conformities

– Maintain associativity between eBOM and mBOM parts

– Visual indicators showing part reconciliation errors

– BOM Compare report quickly identifying quantity discrepancies between associated BOMs

New 9.1

New 9.1

© 2009 PTC

Digitally Define and Manage Process Plans

By providing powerful capabilities that support the digital authoring and definition of manufacturing plans

Define process plans in terms of sequences and operations to describe how a part is manufactured, assembled or inspected

– Define plant-specific process plans including part and resources allocations, standard procedures, documents, time breakdowns

– Define alternate process plans for the same part

– Reuse standard process plans from a standards library

Leverage 3D designs

– Allocate parts and resources directly from 3D

– Automatically generate 3D manufacturing mockup of the process plan and view the in-process state of an assembly

Ensure process plan completeness

– Visual indicators showing parts remaining to be allocated

– Part allocation report listing parts with allocation issues and parts that remain to be allocated

– Review and analyze process plan definitions in an easy-to-use, interactive Gantt chart, with resource loading and usage

Enable the concurrent development of product and manufacturing processes

New 9.1

© 2009 PTC

Digitally Define and Manage Manufacturing Resources and Standards

By providing powerful capabilities that support the digital definition and management of manufacturing resources and standards

Define and share a common libraries of both physical manufacturing resources and human skills

Define and share a common libraries of standardized and normalized processes

– Define a standard set of operations that can be used and/or references within multiple process plans

– Define manufacturing capabilities indicating how the process can be executed in terms of resources, documentation and standards

Define technical compatibilities and enforce manufacturability

– Indicate how resources and/or manufacturing capabilities must, can, or cannot be combined together

Manage the relationship between a resource and its CAD design

– facilitates the creation of visual aids that include both parts and resources

...

work center

skillsprocess material

...

...

optional

plant A

Supplier 1

tool 1 tool 2

work center 2

work center 1

work area

tooling

work cell

mandatory

Re-use proven manufacturing plans, standards and knowledge and systematically drive manufacturability

© 2009 PTC

Op025

Op035

Op025

Op 020

Op 010

Op 030

Sequence Main

Sequence 2 (Alternate)

Sequence 1 (Parallel)

Op025

Op035

Op025

Op 020

Op 010

Op 030

Sequence Main

Sequence 2 (Alternate)

Sequence 1 (Parallel)

Dynamically Generated Visual Work Instructions

Process Planand Operation Headers

Allocated Parts

Time Breakdown and DescriptionWork Center

Visual Annotation

Change and Configuration Information and History

Allocates Resources and Documents

Navigate to Windchill detail object pages from work instructions via hyperlinks

Embedded 3D information

– Directly interact with embedded ProductView 3D visualization

– Set any image as illustration within the Work Instruction

Improve production ramp-up, reduce scrap and rework and improve quality

By providing powerful capabilities that dynamically generate rich shop floor instructions

Accurate Work Instructions, on demand, according to the process plan configuration

Eliminate discrepancies between the process definition and the work instruction used on the shop floor

Can be accessed from the shop floor via a web browser

New 9.1

© 2009 PTC

Integral Change and Configuration Management

By providing robust data control services such as change and configuration management as well as enabling end-to-end process automation

Manage manufacturing changes and configurations with full traceability and history of changes

– Configure part numbering and versioning schemes

– Track configuration by baseline, lot, serial effectivity and date

– Problem reporting, deviation/waiver requests, change requests, change notices and change activities

Standardize, automate the change with robust workflow engine

– Repeatable, consistent and predictable processes including automatic change routing and task notification

– Streamline and continuous change process between engineering and manufacturing

Facilitate change impact

– Visibility to engineering changes and related product information ensure accuracy and speed of changes

– Change Visual indicators, Reports and Navigate relations

• Easy to use “Related Manufacturing Item” Action

Reduce change cycle time, cost of change and fully manage manufacturing configurations

New 9.1

© 2009 PTC

Windchill MPMLink 9.1 - Integration to Production Systems

Efficiently communicate and ensure accurate and on-time availability manufacturing planning data to the enterprise

By automating exchange and sharing of manufacturing deliverables using secure and reliable enterprise system integration technology

Publish MPMLink objects via Windchill ESI or Windchill ERP Connector

Production Systems(ERP/MES)•Parts

•eBOM•mBOM•Change•Process Plans•Documents URL (Work instructions)

•Tooling•Skills•Process Material

WindchillW

indchill ESI(or) ERP Connector

– MBOMs

– Process Plan, Sequence and Operations

– Tools, Skills, Process Materials

OOTB Integration to SAP and Oracle Manufacturing

Flexible and open framework for integration to other systems

New 9.1

© 2009 PTC

Agenda

What is Manufacturing Process Management?

Scope, definition and challenges

PTC’s Windchill MPMLink

Part of PTC’s Manufacturing Solution

History

Key capabilities

Summary

© 2009 PTC

Windchill MPMLink key capabilities …….. enabling Concurrent Product and Process Development

Builds

Time Breakdown

Textual Description

Op025

Op 030

Op 010

Op040

Op 020

Process Plan

ConsumedOperated on

Tooling

Performed

with

Work Center

...Lines

Skills Process Material

Resource List

Part List

ResourcesPlants

Equivalent

Part 1

Part 2

Support

Sub-Assy

Vehicle mBOM

Part 8

Part 9

mBOM

Part 1

Part 2

Rear Frame

Support

Vehicle eBOM

Frame Assy

Part 3

Part 4

eBOM

Windchill PDMLink & MPMLink

IllustrationsNEWREVISION

NEWREVISION

An integral part of the Product Development

System

Associative eBOM to mBOM management

Digital definition and management of process

plans

Digital definition and management of manufacturing

resources and standards

Streamline release to Manufacturing

Dynamically generated visual work Instructions


Pro

du

ction

System

s (M

ES

/ER

P)

Windchill ESI

(or) ERP Connector

© 2009 PTC

Disconnected engineering, manufacturing & production teams

Difficulty to find and re-use proven manufacturing processes and resources

Struggling to provide accurate manufacturing information to production on-time

Paper based processes and manual tools (Word, Excel, ..)


Disconnected engineering, manufacturing & production teams

Difficulty to find and re-use proven manufacturing processes and resources

Struggling to provide accurate manufacturing information to production on-time

Paper based processes and manual tools (Word, Excel, ..)


ChallengesChallenges




Improve operational efficiency and excellence Meet cost targets Achieve first time quality at reasonable cost




Improve operational efficiency and excellence Meet cost targets Achieve first time quality at reasonable cost

The need to…The need to…

Remember the pain points?

Remember the market pressures?

Windchill MPMLink key capabilities … …. driving value and addressing manufacturing pain points

Manufacturing InitiativesManufacturing Initiatives PTC’s PLM-Enabled Manufacturing Capabilities

PTC’s PLM-Enabled Manufacturing Capabilities

Addressed by…

Enabled by… Driving…

BenefitsBenefits

© 2009 PTC






reasonable cost






reasonable cost

Manufacturing data and deliverables managed as true enterprise master data

Upravljanje i ponovna upotreba proizvodnih planova, standarda i znanja

Istovremeni razvoj proizvoda i procesa proizvodnje

Leverage 3D digital design Enable end-to-end change

process automation and control services

Efficiently communicate manufacturing planning data to the enterprise

Systematically drive manufacturability

Enable Collaboration and securely exchange information with suppliers

Enforce product and process compliance and traceability

Embrace a manufacturing philosophy

Manufacturing data and deliverables managed as true enterprise master data

Upravljanje i ponovna upotreba proizvodnih planova, standarda i znanja

Istovremeni razvoj proizvoda i procesa proizvodnje

Leverage 3D digital design Enable end-to-end change

process automation and control services

Efficiently communicate manufacturing planning data to the enterprise

Systematically drive manufacturability

Enable Collaboration and securely exchange information with suppliers

Enforce product and process compliance and traceability

Embrace a manufacturing philosophy

An integral part of the product development system

Associative eBOMs and mBOMs Digitally define and manage

process plans Digitally define and manage

manufacturing resources and standards

Dynamically generated visual work instructions


An integral part of the product development system

Associative eBOMs and mBOMs Digitally define and manage

process plans Digitally define and manage

manufacturing resources and standards

Dynamically generated visual work instructions


Manufacturing InitiativesManufacturing InitiativesWindchill MPMLink ključne

karakteristikeWindchill MPMLink ključne

karakteristike

Pro/ENGINEER Production MachiningPro/ENGINEER Production Machining

Pro/TOOLMAKERPro/TOOLMAKER

Complete Mold DesignComplete Mold Design

……






reasonable cost






reasonable cost

PrednostiPrednosti

Windchill MPMLink ključne karakteristike… …. driving value and addressing manufacturing pain points

© 2006 PTC

Founded in 1991, Grand River Group (GRG) is China’s top motorcycle manufacturer. GRG develops, manufactures and sells motorcycles, engines, and parts to both foreignand domestic markets. They are the largest motorcycle manufacturer in China with a production capacity of 3 million engines and 3 million motorcycles per year. GRG is the largest partner and export base of Suzuki Motor Corp. in China. Based in Jiangmen City, GRG has over 9,000 employees.

Grand River Group wanted to shorten their time to market by improving their manufacturing engineering process in order to accelerate the engineering to manufacturing change process, improve reliability of manufacturing data and standardize process plans and work instructions

PTC Global Services implemented Windchill PDMLink, Windchill MPMLink and Arbortext® software solutions to streamline the creation of standardized manufacturing engineering deliverables and to implement a closed loop process

Processes improved: Manufacturing Process Management; New Product Introduction

Capabilities implemented: Manufacturing Process Planning; Enterprise Content and Process Management; Dynamic Publishing

Increased production and manufacturing engineering efficiency

Improved product quality and consistency of manufacturing data

Dramatically reduced the time to propagate a new product derivative to manufacturing

“Our PTC Windchill MPMLink solution is just the thing we need to help us improve our entire manufacturing process.”

Dai JunXiang, Grand River Group

BUSINESS INITIATIVE

Grand River Group Improves Manufacturing Process Management with a Windchill® MPMLink™ Software Solution from PTC

SOLUTION

RESULT

AutomotiveAutomotive

Hvala