Integrated Product, Process and Production Engineering Dr. Richard A. Wysk Leonhard Chair in Engineering The Pennsylvania State University University Park, PA 16827 [email protected]http://www.engr.psu.edu/cim
Transcript
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Integrated Product, Process and Production Engineering Dr.
Richard A. Wysk Leonhard Chair in Engineering The Pennsylvania
State University University Park, PA 16827 [email protected]
http://www.engr.psu.edu/cim
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Traditional Engineering
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Quick Vision of Integrated Product, Process and Production
Engineering
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Product Engineering
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Process Engineering
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Production Engineering
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A Vision of Integrated Engineering Systems (cont.) INTEGRATED
PRODUCT, PROCESS AND PRODUCTION ENGINEERING (IPPPE) tools and
techniques that can be used to assist in combining planning,
design, construction and management of a product.
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A Vision of Manufacturing Systems (cont.) IPPPE planning,
designing, construction and management of a product.
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Research Motivation Enterprise-based Engineering Integration
Prevalent of manufacturing globalization, i.e., distributed
manufacturing Small batch production Leverage manufacturing
capability Leverage capital investment Core competency focus
Geographically separated engineering experts Communication problem
Time and availability Manufacturing cost saving during early design
stage -- concurrent engineering Business motivation
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The Acid Test
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Instance specific solutions Group Technology
Parametric/feature-based modeling (most existing applications) CAPP
DFx
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How do we work on generic solutions? Were all going In
different directions!!!
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Product Engineering Tools include: CAD, FEM, Dynamic
simulations, Good instance specific remedies
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Process Engineering CAPP Very instance specific knowledge
Fixture and tool planning Path planning and NC code generation
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Production Engineering Few tools Complex systems
Interfaces
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Models Used in IPPPE PDES/STEP for Product Engineering Very Big
Project Scope Grows with Need PSL for Process Engineering Not Real
Process Plans Very Large Scope Manufacturing Resource Model
Descriptive Entities Not Very Detailed
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Business Enterprise Model Product Model Production Model Form
Function Material Tolerance Useful Life Method Equipment reqts
Fixturing Tooling Operating conditions Resources Resource
capacities Resource status Resource cost Resource capabilities
Process Model
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IPPPE Directions Geographically Separated Engineering
Activities Best Practice Only Time Compressed Horizons Open Access
(Data and Manufacturing) Intelligent Access to Non-Expert
Domains
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Geographically Separated Engineering Web Connected Translators
and Interpreters to/from Other Domains Software Assistants (or
Agents) into Non-Expert Areas Use Best Method to Produce Design Use
Best Manufacturing System/Practice to Produce Product Immediate
Awareness of Capital Critical Constraints
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Best Practice Only Domain Prejudice Dominates Process
Engineering Hybrid Manufacturing We Seldom Use A Single
Manufacturing Technique DFx $ (DFx)
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Time Compressed Horizons and Open Access Better Late than Never
Has Become Better Never Be Late Manage All of Your Resources
Carefully Immediate Access to Supplier Critical Activities Well
Informed Early Decision Making
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Intelligent Access to Non-Expert Domains Critical Size and
Tolerance Constraints Should be Available to the Product Engineer
Non-Traditional Methods Domain Prejudice (Powdered Process)
Software (Intelligent) Agents Span Various Domains
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Some Examples Resource Independent Process Plans Control from
IPPPE
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Methodology Requirement specification Vs. Description Ex:
Require hole making process that can achieve 0.5 diameter and 0.008
positioning accuracy Ex: Twist drilling with 0.4687 diameter and
boring a hole with 0.5 diameter Feature composition Vs. Feature
decomposition Alternative processes -- AND/OR Directed graph
Process planning decomposition Universal level process knowledge
Process modeling abstraction Resource independent process
representation [Brown and Ray 1987], [Wysk et. al, 1995], [Shah and
Mantyla 1995], [Chang 1990], [Ray 1987]
Process Planning Decomposition in Association with the
Alternatives 1. Precedence constraints due to geometric and
topological constraints 2. Precedence constraints due to relocating
the part adversely affects the repeatability requirement of a part
3. Precedence constraints due to geometric tolerance requiring
extreme repeatability 4. Precedence constraints due to economical
rationalization of machining 5. Process accuracy constraints 6.
Technological constraints--available resources 7. Process economy
Generate RSRS Generate RIOS
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RIOS Schema
RIOS_GraphRIOSRIOS_Process_level_informationRIOS_Operation_level_informationRIOS_SupportRIOS_Transaction
Business and production requirements Alternative Resource type and
workholding requirements Process type, accuracy,topology, and shape
requirements Measurement, material, etc. specifications
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Cost and Time Estimation of the Example Part OLG: Get Feasible
Machines Haas VF-OE (3-axis) and Haas VF-3B (5-axis): Prefer VF-OE
due to cheaper burden rate
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Automatic Generation of Simulation Models from Neutral
Libraries: An Example Young-Jun Son, University of Arizona Albert
T. Jones, NIST Richard A. Wysk, Penn State University
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Example Job Shop System System Input Buffer System Output
Buffer Penn1_in Penn3Penn2_inPenn2 Penn1Penn1_out
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Database Information for the example system (1)
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Database Information for the example system (2)
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New concept of Simulation Modeling using Library Components
Library of Simulation Objects For shop floor (Flow of Jobs) Model
Builder Engine Simulation Data Analyzer Animation Visualization
Model Description (Neutral) Specific Simulation Model Shop Floor
(Real data) Statistical Results Animation Or Visualization Library
of Simulation Objects For all applications User
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Two Translators (Model Builders) Arena 3.01 ProModel 4.2 Model
builders in Visual Basic 6.0 Microsoft Access 8.0 Object Library
DAO (Data Access Object) 3.5 Library Arena Object Library ProModel
1.0 Type Library
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Generated ProModel Model (1)
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Generated ProModel Model (2)
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Generated ProModel Model (3)
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Generated ProModel Model (4)
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Generated Arena Model
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Summary Manufacturing systems are getting more complicated
Manufacturing is becoming a Broad Area Activity Communication
issues have increased Integration is key