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SMART ASSEMBLY

SMART ASSEMBLY. Next generation capability in assembly systems and technology which integrates assembly processes, people, equipment, and information using both virtual and real time methods to achieve dramatic improvements in productivity, lead time, and agility. Jim Caie

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SMART ASSEMBLY

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  1. SMART ASSEMBLY Next generation capability in assembly systems and technology which integrates assembly processes, people, equipment, and information using both virtual and real time methods to achieve dramatic improvements in productivity, lead time, and agility. Jim Caie ARC Advisory Group

  2. Fierce Global Competition Industry Consolidation and Acquisitions Increasing Govt. Regulations Shrinking Product Lifespan High Energy Costs Security Threats Pressure for Profitability Legacy Equip & System Upgrades Relentless Technology Innovation Manufacturers Face Formidable Challenges What Is Driving Mfg Operations Today? Dynamic Customer Requirements Niche Products Worker Safety

  3. SMART ASSEMBLY MEETS THE CHALLENGE COMMON, SAFE, AND SMART ENVIRONMENT FOR MAN & MACHINE KNOWLEDGEABLE, EMPOWERED WORK TEAMS INTELLIGENT MODELLING, OPTIMIZATION, AND VALIDATION OF ASSEMBLY PROCESSES FLAWLESS EXECUTION OF SUPPLY CHAIN AND PRODUCT LIFE CYCLE PROCESSES EFFECTIVE INTEGRATION OF AUTOMATION AND INFORMATION TECHNOLOGY INTO THE HUMAN ASSEMBLY PROCESS

  4. SMART ASSEMBLY REQUIRES BOTTOM UP COLLABORATIVE MANUFACTURING Business Process Components Supply Chain Management Product Lifecycle Management Service-Based Architecture Manufacturing Operations Management Manufacturing Intelligence Factory Automation Systems Asset Management Collaborative Production Management Industrial Ethernet Fieldbus Standards OPC XML-DA/UA Machines, Work Cells, Production Equipment, Drives, Motors, Servos, Sensors, Embedded Intelligence, Device Networks Business Processes Enterprise Systems Standards-Based Integration Methods Network/Internet Standards OAGIS/S-95 Process Schemas Manufacturing Processes Factory Operations Control & Device Networks:

  5. Success in Smart Assembly Depends on Successful Product Lifecycle Management CPM Product Lifecycle Product Domain Production Domain Controls/Tool Engr R&D Design Engr Factory Operations Org Mfg Engr Industrial Engr Design, Produce Tools, Jigs, Fixtures, & Automated Systems Obtain, Operate, Control, & Maintain Equipment & Automated Systems to Manufacture Products Work Flow, Mfg Processes Materials & Product Research Product Design Process Planning Processes Scheduling Resource Mgmt Mfg Intelligence Q/A Visibility Supply Chain Synchronization . STRATEGIC ENGINEERING . VALIDATED PROCESS . VALIDATED EQUIP & . DESIGN FOR ASSEMBLY, DESIGN TOOL DESIGNS RECYCLING, ENERGY USE . ERGONOMICS . VALIDATED CONTROLS . VALIDATED SAFETY Function (Systems) CAD/CAM DIGITAL MANUFACTURING Engineering Operations

  6. NEXT GENERATION ASSEMBLY BUSINESS MODEL New Drivers • More Speed & Agility • Lower Investment • Continuous launches VOLUME NicheProd C Flex plant handles Peak volumes and Niche products Niche Prod B FLEX PLANT Niche Prod A Peak Prod #3 Peak Prod #2 Peak Prod #1 ____ Standard plants run at 100% capacity handing 70-80% of peak demand STD. PLANTS TIME

  7. Technology Processes Information People • Process Knowledge Capture • Identify Opportunities • Assess Technology Capabilities • Assess Workforce Shared, Safe Work Environment Model Smart Processes, Equip, & Systems Knowledge-based Workforce • People: • Assemble • Convey • Verify • Equipment: • Assemble • Convey • Verify Integration of Product Design & Mfg Processes Shared Real-Time Information Exchange SMART ASSEMBLY CONCEPTUAL MODEL • Finished Product: • On Schedule • Zero Defects • Lower Production Costs • Meets Market & Customer • Demands

  8. SMART ASSEMBLY - VISION • PEOPLE: Knowledgeable, Empowered Teams • INFORMATION: Event-driven, Real- time and Actionable • PROCESS: Strategic, Lean, Agile, Flawless Execution • TECHNOLOGY: Shared, Safe, Effective, Efficient Work Environment for Humans & Machines

  9. SMART ASSEMBLY VISION - PEOPLE • Corporate Culture Enabling Knowledgeable, Empowered Work Teams • Performance Oriented Training Practiced • Virtual Training Exploited • Effective Transfer of Process Knowledge • Initiatives to Empower Knowledge Workers • Empowered Teams Managing their Work • Plan • Execute • Verify • Continuously Improve

  10. SMART ASSEMBLY VISION - INFORMATIONReal time and actionable • Real time, actionable information enables knowledgeable, empowered teams to achieve: • Continuous learning and improvement • Zero defects, waste, and accidents • Cost effective, on time performance • Mutual support • Key elements of real time, actionable information • Open, modular, scalable, distributed, configurable • Vertical Integration of Plant Floor to Enterprise • Event Driven Manufacturing • 100% electronic collaboration capability • Visibility to all operations and operators • Adaptive control • Predictive management systems • Automatic parts/subassembly tagging and tracking • Wireless control, MES, and hand held HMIs PLC & SOFTWARE I/O HMI

  11. SMART ASSEMBLY VISION - PROCESSESStrategic, Lean, Agile, Flawless Execution • Seamless order to make capability • Build anywhere capability • Lean, Agile assembly & conveyance systems • Correctly Build in Work Station Capability • Fixtureless assembly processes • Sequenced material delivered to point of use • Flawless supply chain management execution • Flawless product life cycle management execution • Six sigma institutionalized TWO KEY ENABLERS Strategic Engineering Systematic approaches for designing families of products that can accommodate changes in market trends and evolving technology innovation Digital Manufacturing Virtual tools that optimize and validate manufacturing process, equipment, and controls designs

  12. SMART ASSEMBLY VISION - TECHNOLOGYOptimized assembly system • Intelligent, safe robots • Intelligent, flexible conveyance systems • Automatic error proofing • Virtual simulation and validation of processes and controls • Process knowledge capture/implementation • Visualization and mfg intelligence dashboards • Automatic safety and optimization of the assembly system • Automatic, intelligent adoption to assembly problems • Electric actuators • Nano devices Technology Enables shared, safe, effective work environment for people and machines

  13. USER’S Must understand the value and cost of moving to the next level of smart assembly best practice Must have a validated plan before executing SMART ASSEMBLY - USER STRATEGY Smart Assembly Best Practices

  14. SMART ASSEMBLY PROGRAM COLLABORATION MODEL • PLAN • DEVELOP • BUILD • VALIDATE • DEPLOY • All stakeholders involved in all program phases • Deliverables implemented in small pieces as soon as they are available • Standards strictly enforced to ensure competitive sourcing and easier deployment

  15. SMART ASSEMBLYPOTENTIAL PROGRAM STAKEHOLDERS ARC, RIA, SP-95,OAGIS,STEP Stakeholders Fund program with money and/or resources

  16. SMART ASSEMBLY PROGRAM MANAGEMENT MODEL Steering Committee • consists of Chair & voting members • $/labor contributions determine voting rights • Members from user, R&D, and suppliers organizations • Approves vision, R&D work, and detailed application plans Steering Committee R & D Working Group Planning Group Project Execution Teams • Proj teams execute specific projects • Teams disband after project completion Proj A • Establishes and refines vision • Defines objectives, timetables, resources & metrics • Measures actual performance • Identifies, finds, and/or develops technology that is leveraged across all projects Proj B Proj C Proj C Proj C

  17. SMART ASSEMBLY PROJECT EXECUTION MODEL RESEARCH AND DEVELOPMENT US CAR BUILD & VALIDATE DEPLOY PHASE 1 PLAN GM VISION NIST PHASE 2 PLAN BUILD & VALIDATE DEPLOY BOEING ALL STAKEHOLDERS PHASE 3 PLAN Planning Group BUILD & VALIDATE DEPLOY R&D Group Project Execution Teams

  18. SMART ASSEMBLY – PROJECT PLANNING Applications • Each company brainstorms to identify which assembly processes are the best to automate - Low hanging fruit - Cost/benefit of automating the application - Learning impact • Company representatives meet to: 1. Categorize and prioritize which assembly processes to automate 2. Identify deployment projects and commit to support them with $/resources 3. Get plant commitments to deploy at their sites

  19. SMART ASSEMBLY – PROJECT PLANNING Research and Development • All stakeholders interested in R&D form a R&D committee • R&D committee identifies the practices, processes, and technology required for Smart Assembly - What already exists - What needs R&D • R&D committee determines how to best execute the R&D and seeks required funds and resources - Government labs and agencies - Universities - User company R&D centers - Supplier R&D centers

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