digital factory를위한 bill of process production 정보와 …통계적품질관리 dpv & spc...
Post on 31-Jan-2020
4 Views
Preview:
TRANSCRIPT
Digital Factory를 위한 Bill of Process
검증과 Production 정보와 Integration2016년 12월 15일 박세종 상무 / PfD 팀
siemens.com/hm16© Siemens AG 2016
Unrestricted © Siemens AG 2016
09.07.2016Page 2 Siemens PLM Software
목차
Real FactoryVirtual Factory
1. Plant-Centric BOP
2. BOP Validation
3. BOP Output
4. BOP & MES
5. 사례
- Siemens Amberg
- ITP Aircraft Engine
- ZeMA (CPS)
Unrestricted © Siemens AG 2016
09.07.2016Page 3 Siemens PLM Software
Trend
- in Heavy Equipment
Emerging global demand
“John Deere expects 50% of their
revenue to come outside of the US by
2018.”
-- Business Week
Global Production
“From March 2011 to March 2012, John
Deere says, customers ordered more
than 7,800 different configurations of
the 8R.”
-- Business Week
Massive configuration possibilities
Unrestricted © Siemens AG 2016
09.07.2016Page 4 Siemens PLM Software
Trend
- Get digital proof of product & production success
Digital Product Model
Digital Twin with Collaborative MFG
To fulfill the needs
Digital Production Model
For autonomous
production, configure-to-
order and plant specific
driven
Unrestricted © Siemens AG 2016
09.07.2016Page 5 Siemens PLM Software
Trend
- Evolution of Synchronized Information
PLM에 생성된 BOM, 공정계획, 작업표준서 등의 BOP 정보는 MES, 생산 라인과 유기적으로 연동되어 유연한 생산 및 제품
변경에 따른 변경관리 프로세스를 지원합니다.
PLM
상품 기획 설계 개발
생산 계획
영업
마케팅
생산테스트
단종
서비스
ERP
MES
작업 계획/ 진척관리
공정/설비 관리
Parts / Assys / EBOM/MBOMVariant Conditions / BOP / Work Instruction
OrdersVariant RulesOrder BOMMat’l Consumes
TransactionsMaterial MovesCompletionsDates/OperatorEWI
MBOM, Routing
Process BOMEWI Sheets
Order Configuration
As-Built Result
Production Order Progress
Results
Unrestricted © Siemens AG 2016
09.07.2016Page 6 Siemens PLM Software
Trend
- Information Flow - Current State
Development Planning Manufacturing
Digital Factory Manufacturing Control
Product
Process
PlantWork Plan
Ind. Engineering
Based on Vehicle Modules
Unrestricted © Siemens AG 2016
09.07.2016Page 7 Siemens PLM Software
1. Plant-Centric BOP
- Connected and Integrated Data
Requirements
Customer
Regulatory
Design
Build
Systems
Engineering
Function
Logical
Architecture
Verification
Simulation
Behaviour
Reliability
CAE
Manufacture
Support
Engineering
MCAD
ECAD
Software
PhysicalManufacturing
Assembly
MBOM
Process
As-tested
As-built
As-maintained
Benefit
디자인~생산: 요구 사항 추적
변경 관리 – 변경에 대한 모든 영향
Unrestricted © Siemens AG 2016
09.07.2016Page 8 Siemens PLM Software
1. Plant-Centric BOP
- Connected and Integrated Data
공정 계획(BOP) 정보는 제품(자재), 공정, 공장 및 생산 리소스(치구, 공구 등)이 체계적으로 관리되어 공정 Structure에 관련정보를 Logical하게 연결함으로써 구성됩니다.
Cell A
Rev A
Rev B
Part A
Assy A
Rev A
Rev B
Op 1: Move part to machine
Op 2: Machining Milling
Act. 1: Assign Tool A
Act. 2: Assign Fix. A
Op 3: Machining Turning
Building A
Building B
Line A
Line B
Cell B
Op 4: Move part to inspection
Op 5: Ship part to line A
Robot 1
Gun 1
Mill 1
Part 1
Part 2Fixture library
Tool library
Tool A
Tool B
Product Process Plant
Resources
작업순서, 작업시간 정의 포함
Bill of Materials
Bill of Process
Unrestricted © Siemens AG 2016
09.07.2016Page 9 Siemens PLM Software
1. Plant-Centric BOP
- Connected and Integrated Data
BOP 구조
E-BOM 구조Product
P1
P2
pa
pb..
..
pd
pcE/Item
comp
M-BOM 구조 ERP ; Super M-BOM 구조
동기화 구조
. BPN, 작업표준서
. Part, 공정, 작업표준서
. M-BOM구조
. BPN. E-BOM과 M-BOM구조 동기화
Interface
Product
P1
P2
pd
Body
Paint
Chasis
Trim
E/Item
사급
pa
Relationship
P3R 관리
Vehicle UnitAssy, Module
Plant
Line
Line
공정
공정
OP
OP
OP
OPPress
Welding
Assy
Paint 정합성
E-BOM, M-BOM, BOP 정합성고려된 Architecture
BOM Data 관리 Architecture
설계 변경 정확성과 효율성 고려된Architecture
Product
P1
P2
pa
pb..
..
pd
pcE/Item
comp차종별 구성 및 BP 적용 차량별 구성
2
1
3
2
1 1 1Pd.001 Pd.002
3
. ECO,BP,공정
E-BOM, M-BOM & BOP Data 정합성과 업무 효율성을 고려한 기능조직과 관련 프로세스가 필요합니다.
Unrestricted © Siemens AG 2016
09.07.2016Page 10 Siemens PLM Software
1. Plant-Centric BOP
- Enterprise BOP
BOP B Plant 3BOP A Plant 3BOP A Plant 1
Product BOP - BProduct BOP - A
Std. Tooling Std. Processes
Generic ProductGeneric BOP
Product BProduct A
Level 1
Level 2
Level 3
Level 4The same product
in multiple plants
and/or Multiple
products in the
same plant
BOP A+B Plant 3
Plant 1 Plant 3
Global 환경 에서는 하나의 제품을 여러 곳의 공장에서 생산하는 경우가 일반화 되고 있어 Plant-Centric Process Planning 과관리가 필요 합니다.
Unrestricted © Siemens AG 2016
09.07.2016Page 11 Siemens PLM Software
1. Plant-Centric BOP
- Enterprise BOP
Process
Plant C
Plant A
Plant B
Process
Process
Plant C
Plant B
Plant A
Part X
Part Release
지역별 제조 환경과 고객 요구 사항에 따른 Plant-Centric Process Planning이 필요 합니다.
Support product configurations and
variants - as business grows globally
Enable Re-Use in Product Families and
production standardization
Business Goal
Save time when propagating changes
on generic parts
Create Manufacturing BOM partly
automatically based on rules
Standard product skeletons to support
downstream production planning
process
Adapt product to local markets
Unrestricted © Siemens AG 2016
09.07.2016Page 12 Siemens PLM Software
1. Plant-Centric BOP
- Enterprise BOP
표준 공법을 재 활용하여, 해당 공장 별 제조 환경 (부품 공급사, 설비 etc.) 을 반영한 Plant Specific BOP를 생성 관리 하며,공장별 공정계획, 작업표준서 등의 정보를 해당 공장의 MES와 유기적으로 연동되어 유연한 생산을 지원합니다
M-BOM for Plant A
M-BOM for Plant B
M-BOM for Plant C
Process
Plant C
Plant A
Plant B
Process
Process
Deliver production plans up to 40% faster
Plant specific production planning, with
process standardization and shared best-
practices
Business Goal
Integrate new sales options into
existing plant processes
Pool of best practices to support
standardization and re-use
Derive production and supply strategy
and adapt to local needs
Unrestricted © Siemens AG 2016
09.07.2016Page 13 Siemens PLM Software
Unrestricted © Siemens AG 2016
09.07.2016Page 14 Siemens PLM Software
2. BOP Validation
Manufacturing Process Management (디지털 생산 준비 시스템)
공장 계획 공정 계획 공정 검증 투자 관리금형/설비
설계 및 제작설비 설치 및
Tryout시험 가동
설계 PLM
2D/3D 도면, 형상
E-BOM, 속성
문서, 부품정보변경정보,…
자원관리
(ERP)
QIS
설비관리
(M-Ware)
생산관리
(MES)
금형자산관리
제품D
ata
인터페이스
Layout 및 공장내외물류계획,생산능력 검토
조립공차 분석
DPV : Dimensional Planning & ValidationSPC : Statistical Process Control
설비 가동률자재 재고 사전 검토
통계적 품질관리DPV & SPC
• 작업지시서,공법서
• 공정현황 정보
• 가동실적, 공정개선 정보
공정계획 / 공정편성 설비 및 치구 계획Resource배분(ST분석) 작업지시서,공법서
기본 3D 뷰잉문서관리 / 검색 송부 / 통지 Classification
Workflow BOM 관리 MS Office 연동도면 관리
Legacy
인터페이스
• Cost 정보
• Resource 정보
• Routing 정보
Process
Part
Resource
Plant공정기반정보관리
BOP
Unrestricted © Siemens AG 2016
09.07.2016Page 15 Siemens PLM Software
2. BOP Validation
BOP내 공정 별로 정의된 3D 제품, 설비, 조립순서를 기반으로 검증 시뮬레이션을 수행하고, 제품과 설비, 공구간 간섭,
작업자의 작업 성, 조립작업 시간 등을 검증합니다.
Process
Part
Resource
Plant공정기반정보관리
BOP
Digital Twin
Final assembly process Final/modular assembly simulation
Man-machine
operation analysis
Virtual manufacturing
Static process
prototype analysis
Robot simulation
SMT shop floor layout planning
Detailed design of work
station layout
Assembly line balance analysis
Beat / Bottleneck analysis
SMT production line layout
planning
Factory planning
Time evaluationLogistics analysis
Virtual verification of assembling
Unrestricted © Siemens AG 2016
09.07.2016Page 16 Siemens PLM Software
2. BOP Validation
BOP내 공정 별로 정의된 공장 Layout, 물류, CAPA,C/Time 등을 검증 합니다.
Process
Part
Resource
Plant공정기반정보관리
BOP
Digital Twin
Unrestricted © Siemens AG 2016
09.07.2016Page 17 Siemens PLM Software
2. BOP Validation
BOP내 공정 별로 정의된 리소스 자동화 설비, Robot의 가공, 용접 ,조립 작업 및 C/Time 등을 검증 합니다.
Robot Spot용접 작업 Operation
# 101 공정
Part1/A.000 내수 두께1 재질1 중량1, MIP
Part2/A.000 수출 두께2 재질2 중량2, VDR
용접점 001 결합 판넬 (Part1,Part2) ..
용접점 002 결합 판넬 (Part1,Part2) ..
Robot
Gun
이송 및 클램핑 Operation
Digital Twin
Unrestricted © Siemens AG 2016
09.07.2016Page 18 Siemens PLM Software
2. BOP Validation
BOP내 공정 별로 정의된 조립 라인의 Robot의 조립 작업 및 C/Time 등을 검증 합니다.
Robot 조립 작업 Operation
# 55 공정
Part1/A.000 내수 두께1 재질1 중량1, MIP
Part2/A.000 수출 두께2 재질2 중량2, VDR
Mfg 001 결합 판넬 (Part1,Part2) ..
Mfg 02 결합 판넬 (Part1,Part2) ..
Robot
Hand & Gripper
이송 및 클램핑 Operation
Digital Twin
Unrestricted © Siemens AG 2016
09.07.2016Page 19 Siemens PLM Software
2. BOP Validation
BOP에 정의된 공정, Line, Factory Level의 가상 시운전을 통하여 상세 작업을 검증 하고, Real Factory와 연계하여 생성된
로봇, PLC 프로그램을 전송, 생산 라인의 이슈 또는 문제 빠른 대응
공법 계획
Process
Part
Resource
Plant공정기반정보관리
BOP
Digital Twin
Unrestricted © Siemens AG 2016
09.07.2016Page 20 Siemens PLM Software
3. BOP Output
완성된 BOP로 부터 전자 공법서 및 작업 지시서 생성, 현장 전송과 생산 라인의 정보 즉각적인 Feedback
웹기반EWI 조회
3D PDF배포
Unrestricted © Siemens AG 2016
09.07.2016Page 21 Siemens PLM Software
3. BOP Output
검증 후 BOP Data에 Robot 및 PLC 프로그램을 저장하여 현장 생산 정보 시스템과 연계 관리 하며, 제품 사양 또는 공법
변경에 따른 업데이트를 자동화 합니다.
로봇프로그램
Real Factory
ETHERNET
FLOOR 라인
30 공정
10 공정
40 공정
FLR ASSY-COMPL
Robot 1
BIW 용접
1라인
Floor Panel1
용접점1
조립공법1
40 공정
창원공장
20 공정
Weldgun 1
Robot 2
Weldgun 2
Download
로봇프로그램생성
Upload
여러 공장별로봇 프로그램생성 관리
로봇프로그램
상세공정의로봇
및특정로봇프로
그램 선택가능
Unrestricted © Siemens AG 2016
09.07.2016Page 22 Siemens PLM Software
3. BOP Output
NC 검증 후 BOP Data에 머시닝 센터 Off Line NC 프로그램을 저장하여, 해당 공구 Tool 정보와 함께 현장 생산 정보
시스템과 연계 관리 하며, 제품 사양 또는 공법 변경에 따른 업데이트 작업을 자동화 합니다.
Teamcenter Shop Floor Connect for Teamcenter DNCFailoverDatabase
Shop Floor Connect Services
▨ Transparency ▨ Revision control▨ One logical database▨ Compliance▨ Security ▨ Closed loop
Unrestricted © Siemens AG 2016
09.07.2016Page 23 Siemens PLM Software
4. BOP & MES- PLM-MES-ERP
Teamcenter Manufacturing
Enterprise BOP
SIMATIC IT
Executable BOP
SIMATIC IT
Preactor APS
Unrestricted © Siemens AG 2016
09.07.2016Page 24 Siemens PLM Software
4. BOP & MES- PLM-MES-ERP
Avoid disturbances on mix-model production lines when applying process changes
Manage different plants from centralized place
ERP
MES양산 품질 추적 관리
실시간 생산 Data 수집
APS생산 일정 계획
Simulation
Shop FloorShop Floor
Integration
Digital Factory
Product A
Complete
프로젝트 관리
개발단계 품질 문제 관리
Process
Definition`
Engineering
Feedback
Part Program
& Instructions
Production
Feedback
Scheduled
OperationsProduction
Snapshot
Production
Performance
Order
List
Component
List
Component
Availability
Tool
Tool A
BOP
Master
Schedule
Digital Backbone for Enterprise Manufacturing System (Data & Process Management)
. .
. .
Unrestricted © Siemens AG 2016
09.07.2016Page 25 Siemens PLM Software
4. BOP & MES- PLM-MES-ERP
BOP에 저장된 BOM, 공정계획, 작업표준서 등의 정보는 MES, 생산 라인과 유기적으로 연동되어 유연한 생산 및 제품 변경에
따른 변경관리 프로세스를 지원합니다.
Unrestricted © Siemens AG 2016
09.07.2016Page 26 Siemens PLM Software
60,000+ customers worldwide each year
24 hour lead time for new orders
75% OEE plus 20% buffer for overcapacity
~1 Million monthly production of SIMATIC products
1200+ Teamcenter managed products shipped to
Siemens Amberg plant
Fast!
Flexible!
Efficient
~11 dpm means near perfect quality – every timeQuality!
Unrestricted © Siemens AG 2016
09.07.2016Page 27 Siemens PLM Software
MES Software (Simatic IT)
Customer
PCB-program-generator ERP
Product data management
Manufacturing Planning (BOP)
5. 사례 – Siemens AmbergPLM / MES Integration
Templates SMT SPI AOI ICT / FP
X-Ray THT Labels IFT Inspection
PLM Software
Supplier
Production order
Capacity
Inventory Mgmt.Process interlocking
Traceability
Serial number report
Test protocol
Relevant product data
information
Recipe
Intelligent
preprocessing
Material forecast
Automatic order
Delivery
BOM
Resource
Process
Unrestricted © Siemens AG 2016
09.07.2016Page 28 Siemens PLM Software
5. 사례 – Siemens AmbergPLM / MES Integration
Unrestricted © Siemens AG 2016
09.07.2016Page 29 Siemens PLM Software
5. 사례 – Siemens AmbergPLM / MES Integration
Enterprise Level
Management Level
Operator Level
Control Level
Field Level SIMATIC NETIndustrial
Communication
SIMATICControllers
SIMATIC IDENTIndustrial
Identification
SIMATIC Distributed I/O
SINAMICSDrive Systems
SIRIUSIndustrialControls
SINUMERIKCNC
SIMATICHMI
SIMOTIONMotion Control
TIA PORTALEngineering
Framework for
Automation Tasks
SIMATIC IT
Intelligence Suite
SIMATIC IT
Production Suite
SIMATIC IT
R&D Suite
PLMERP
MES
SCADA
SIMATIC WinCCSCADA System
TECNOMATIX
Digital
Manufacturing
TEAMCENTER
Collaborative
PDM
NX
Product
Development
Plant Cloud
Services
BOP
MES
Collaborative Operational Approach - Seamless Lifecycle Integration
Prg.
Unrestricted © Siemens AG 2016
09.07.2016Page 30 Siemens PLM Software
5. 사례 – Siemens AmbergPLM / MES Integration
Program and Project management
Sales Manufacturing ExecutionProduct Engineering Manufacturing Planning
Customer RequestOffer
discussion/orderRequirements management
Conce
ptionDesign Serial Design Prototyping Ramp-up Execution
Manufacturing conception Process planning Manufacturing Tryout
Customer
requests/
forecast
Order
Management
EBOM
Technical
Material
Master
Qual. prdt.
Ideas with
requirements
and features
MCAD
ECAD
SW
Bill of
Material
Bill of
Resource
Order handling (eq:
availability capa,
material, releasing)
Production order management
Production Execution-S-ITPool of
product
ideas
Data Transfer-
via COMESA
Document Management
APQP( Audit, FMEA, Review, Quality Function Deployment, Deisgn of experiment)
ERP
Master
Material-
SAP-A2P
MBOM
definition
including
configuration
rules, NC prog
Project management
Production
tracking
Production
traceability and
data collection
Production
Performance
Analysis-line out.
Production
Definition
Management
Production Quality
and defect
management
Production
Dispatch
Production Data
Collection-QME
Production
Resource and
Gage
Management
+Access tool
MDE/ OEE- for
equipments utilization
APLAUS
Unicam
Stab
Doors
S-IT
Production order
prioritization and
creation
Scout
WSS
APLAUS
WSS
S-IT
KapMes
methods
PNBs
TFS
TFS
SCM-plan
methods
Unrestricted © Siemens AG 2016
09.07.2016Page 31 Siemens PLM Software
5. 사례 – Siemens AmbergPLM / MES Integration; Employees are integrated into the Digital Factory
Unrestricted © Siemens AG 2016
09.07.2016Page 32 Siemens PLM Software
Light Guide Video
Unrestricted © Siemens AG 2016
09.07.2016Page 33 Siemens PLM Software
SIT Manufacturing
Service APIs
Unrestricted © Siemens AG 2016
09.07.2016Page 34 Siemens PLM Software
5. 사례 – ITP (Aircraft Engine)
PLM / MES Integration
Every time you
are flying a
newer Airbus,
chances are
that the plane
was built with
the help of
SIMATIC IT(MES)
Aircraft structure
Mechanical part manufacturing (Zamudio)
Composite part Manufacturing and Assembly (Ajalvir)
Unrestricted © Siemens AG 2016
09.07.2016Page 35 Siemens PLM Software
5. 사례 – ITP (Aircraft Engine)
PLM / MES Integration
설계에서 생성된 CAD도면 과 Engineering BOM를 기반으로 생산 프로세스를 연결하여 BOP를 생성하고 SMATIC IT를
이용하여 MES와 연계 합니다.
ITP
(Industria de Turbo Propulsores)
Unrestricted © Siemens AG 2016
09.07.2016Page 36 Siemens PLM Software
5. 사례 – Rolls-Royce
BOP & Planning Shop Floor Operations
Unrestricted © Siemens AG 2016
09.07.2016Page 37 Siemens PLM Software
5. 사례 – ZeMA (CPS)
Cyber-physical assembly planning in Siemens Teamcenter
- Virtuality meets Reality
Unrestricted © Siemens AG 2016
09.07.2016Page 38 Siemens PLM Software
5. 사례 – ZeMA (CPS)
Three-pillar model of ZeMA is directed to the needs of education, application research and industrial problems
Unrestricted © Siemens AG 2016
09.07.2016Page 39 Siemens PLM Software
5. 사례 – ZeMA (CPS)Challenges for the assembly planning between product development and production
Unrestricted © Siemens AG 2016
09.07.2016Page 40 Siemens PLM Software
5. 사례 – ZeMA (CPS)Objective for assembly planning and operating of cyber-physical assembly system
Unrestricted © Siemens AG 2016
09.07.2016Page 41 Siemens PLM Software
5. 사례 – ZeMA (CPS)Approach to connect virtual and real world during planning
Unrestricted © Siemens AG 2016
09.07.2016Page 42 Siemens PLM Software
5. 사례 – ZeMA (CPS)
Using the data from the virtual planning by requesting assembly services from the assembly modules in reality
Unrestricted © Siemens AG 2016
09.07.2016Page 43 Siemens PLM Software
5. 사례 – ZeMA (CPS)
Identification of the configuration and update of the planning model
Unrestricted © Siemens AG 2016
09.07.2016Page 44 Siemens PLM Software
5. 사례 – ZeMA (CPS)
Summary
© Siemens AG 2016
25.-29. April 2016Seite 45 siemens.de/hm16
© Siemens AG 2016
25.-29. April 2016Seite 46 siemens.de/hm16
Digital Enterprise Software Suite –
Siemens’ answer to Industrie 4.0 requirements
TIASIMATIC / SINUMERIK
PLMTeamcenter / NX
MES/MOMSIMATIC IT / QSYS
12.12.2016 Dr. Jan Mrosik | Siemens AG | CEO Digital Factory DivisionPage 46
© Siemens AG 2016
AnalyticsMindsphere / Omneo
top related