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Optimizing Manufacturing Systems with SimulationPLM World 2006, Long Beach
Stefan Linner, UGS
2© UGS Corp. 2005. All rights reserved.
Agenda
Tecnomatix Simulation ApplicationsTecnomatix Simulation Applications
Integrated Planning + SimulationIntegrated Planning + Simulation
Tecnomatix PortfolioTecnomatix Portfolio12
3
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UGS – Solutions for Product Lifecycle Management
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Factory
Cell
Process
Tecnomatix Simulation Portfolio
Sequence orientedGeometry oriented
3D-Layout-planning
NC-Simulation
Pressline-simulation
Workplace design Robotic-
simulation
PLC-Simulation
Discrete eventsimulation
Process-Planning
5© UGS Corp. 2005. All rights reserved.
Agenda
Tecnomatix Simulation ApplicationsTecnomatix Simulation Applications
Integrated Planning + SimulationIntegrated Planning + Simulation
Tecnomatix PortfolioTecnomatix Portfolio12
3
6© UGS Corp. 2005. All rights reserved.
Factory
Cell
Process
Tecnomatix Simulation Portfolio
Sequence orientedGeometry oriented
3D-Layout-planning
NC-Simulation
Pressline-simulation
Workplace design Robotic-
simulation
PLC-Simulation
Discrete eventsimulation
Process-Planning
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Tecnomatix Plant Simulation
Tecnomatix Plant Simulation allows for creating a dynamic computer model of a complex system (e.g. production) to explore its characteristics and optimize the performance of the system.The computer model enables user to run experiments and what-if scenarios without disturbing an existing production or – used in the planning process – long before the real system is installed.
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Real System / Plan Simulation-Model Simulation result
Transparent analysis of complex systemsCalculation and comparison of real numbersComputer supported investment decisions
Principles ofmaterial flow simulation
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Benefits of simulation
Detect and eliminate problems that otherwise would have required cost and time consuming correction measures during the production ramp-upMinimize the invest costfor production lines without jeopardizing the required output
Optimize the performance of complex production systems with many variants
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Value
3 - 6 % savings on investment(VDI, Association of German Engineers)15 - 20 % productivity increase of existing systems5 - 20 % reduced cost of new systems20 - 60 % decreased throughput time and inventoryAverage savings found in European market survey
11© UGS Corp. 2005. All rights reserved.
Factory
Cell
Process
Tecnomatix Simulation Portfolio
Sequence orientedGeometry oriented
3D-Layout-planning
NC-Simulation
Pressline-simulation
Workplace design Robotic-
simulation
PLC-Simulation
Discrete eventsimulation
Process-Planning
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Robotics Applications
Arc Welding
Paint
Handling
Spot Welding
Laser
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Robot Gardens
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Cable Simulation
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Factory
Cell
Process
Tecnomatix Portfolio
Sequence orientedGeometry oriented
3D-Layout-planning
NC-Simulation
Pressline-simulation
Workplace design Robotic-
simulation
PLC-Simulation
Discrete eventsimulation
Process-Planning
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Today‘s situation
CommissioningCommissioning
Fixed SOPFixed SOPFixed ThroughputFixed ThroughputSigned OEMSigned OEM
ContractContract
OEM ChangesOEM Changes
Mechanical DesignMechanical Design
Robotics Simulation + OLPRobotics Simulation + OLP
MechanicalMechanicalDesignDesign Tecnomatix Tecnomatix eMeM--WorkplaceWorkplace
previously: previously: RobCADRobCAD
Buy,Buy,BuildBuild
Less Time for PlanningLess Time for PlanningHigher Complexity (e.g. Flexibility)Higher Complexity (e.g. Flexibility)
Effort forEffort forCommunicationCommunication
Electrical DesignElectrical DesignElectricalElectricalDesignDesign
PLC ProgrammingPLC Programming Time pressureduring commissioning
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Step 7 ProfessionalStep 7 Professional
The Solution: Process Simulate Commissioning
ProgrammingDebuggingProgrammingDebugging
Virtual / Real PLCVirtual / Real PLC
3D Modeling3D ModelingKinematicsKinematicsLayoutLayoutSequence Sequence (Simulation)(Simulation)
11
Connecting the Connecting the Signals (mapping)Signals (mapping)
22
Virtual Test &Virtual Test &CommissioningCommissioning
33
EE--CAD CAD (e.g. E(e.g. E--Plan)Plan)
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Benefits
CommissioningIdentify problems before building the cellTime- and Cost-Reductions due to:
Increased program-qualityBetter preparation
Risk-reduction during the commissioningFaster ramp-up
ProductionTraining of shopfloor-personnel upfront using the virtual linePlanning of changes and maintenance work shorter breakdown-times
19© UGS Corp. 2005. All rights reserved.
Factory
Cell
Process
Tecnomatix Portfolio
Sequence orientedGeometry oriented
3D-Layout-planning
NC-Simulation
Pressline-simulation
Workplace design Robotic-
simulation
PLC-Simulation
Discrete eventsimulation
Process-Planning
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Process EngineeringProcess Engineering ShopShop--floorfloor
On-line Program Test
Set-upPlanning Programming
Machine / CNC Controller
CAM-System
Final program testCheck part qualityProgram adjustments
CAD-System
Production
Enhanced CAM Process Chain -NC-Simulation after Post-Processing
eM-RealNC
Post-Processing
Simulation of machine-specific G code programTotal workspace simulationCycle time optimization
Define tool-pathSelect toolsDefine machining parameters
Determine number of required set-upsSelect machine toolFixture design
Create machine-specific NC program (G code)
Machine partsChange managementOptimization
NC-Simulation
Early ErrorEarly ErrorRecognitionRecognition
OptimizedOptimizedProcessProcessFasterFaster
RampRamp--UpUp
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Virtual ControllerNC-Simulation using Siemens 840D VNCK
eM-RealNC 840D VNCK
Boot Controller with specific machine dataset (including canned cycles)Time discrete NC-program executionTransmit values to simulation (e.g. joint values)Support multi-channel applications
Machinemodel(geometric, kinematics)Simulation of all peripheral operations such as tool-changer, palet-changer, …VisualizationMaterial removal simulationCollision DetectionVirtual Time ManagementData Viewer VNCK
VNCK-Interface
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Example: Index Virtual Machine
Siemens 840D VNCKwith original HMI of the machine eM-RealNC Simulation with machine-model
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Agenda
Tecnomatix Simulation ApplicationsTecnomatix Simulation Applications
Integrated Planning + SimulationIntegrated Planning + Simulation
Tecnomatix PortfolioTecnomatix Portfolio12
3
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Deliver Industry based solutions
ApplicationsApplications
Value chainValue chain
Industry focused solutionsIndustry focused solutions
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Assembly Planning Solution (Automotive, Aerospace, Heavy Industry)
-30PR
-10P1
-3J1
Prototype Build
Shop Floor Verific.High Level Operation & Labor Planning
Product & AssemblyVerification
-40
Series Planning
ProcessPlanning Commis. Series Life
SOP-20PF
-25PA
Project Managment
Detailed Operation Planning
DetailedPlanning
Cost /Space /TP Analysis
Layout Design
Plant Specific Labor Planning & Balancing
Detailed Plant Layout
Detailed Verification (Time /Ergo /TP etc.)
Process Audits
Process Optim.
Continuous Improvements
Production Planning & Manag.
PrePlanning
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Summary
Simulation delivers strong and proven values.
Simulation e. g. allows forVerification of planning results.Optimization of existing production lines.Smoother ramp-up of production lines.
Integration with planning applications and data management maximizes the value of Digital Manufacturing.
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Thank you