Data Communication & Networking in Manufacturing System

1. Data Communication & Networking in Manufacturing System Nanang Ali Sutisna Master Eng. in Computer Integrated Manufacture Senior PLM Consultant, IBM Indonesia Senior Manager, Product Development Multistrada Arah Sarana

2. Data Communication & Networking in Manufacturing System Chapter 1Introduction to Manufacturing System

4. Sales &Marketing Suppliers/ Vendor Human Resource ISO Approval Review, Design Release Account / Finance Customer Support • Quick Response • Marketing Proposal • Easy to quote • Presentation • Product Launch • Costing • Define incentive program • Digital Design Review • View & Markup • Recognition • Audit • Training • Corporate Communication • Staff Development • Virtual Learning • Supplier chain • Purchasing • Pre/Post Sales Support Distribution Quality Control Manufacturing/ Assembly Shop floor Factory Manager/ Production Planner IT Research & Development • Fulfillment • Delivery Engineering Design • CAD/CAM • CAE / FEA • Prototyping • Product Assembly/ • Disassembly Sequencing • Robotic/Work Cell Animation • Digital Factory • Actual vs. schedule • Scheduling • Work-to-lists • Route cards • Defect Analysis • Quality Control • Technology • Methodology • Integrating e-Manufacturing Systems e-Manufacturing BOM P L M

5. Product Lifecycle Management Product Engineering Lifecycle Management & Decision Support Manufacturing Engineering P L M PLM is a set of capabilities that enables an enterprise to effectively and efficiently innovate and manage its products and related services throughout the entirebusiness lifecycle, from conception through recycling or disposal.

7. Production System The production system is the collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company (or other organization).

8. Production System Facilities The facilities of the production system consist of the factory, the equipment in the factory, and the way the equipment is organized. Facilities: -Factory - Equipment Manufacturing support Systems This is the set of procedures used by the company to manage production and to solve the technical and logistics problems encountered in ordering materials, moving work through the factory and ensuring that products meet quality standards. Product design and certain business functions are included among the manufacturing support systems. Production System Manufacturing Support Systems

9. Production System Facilities • The facilities in the production system are the factory, production machines and tooling, material handling equipment, inspection equipment, and the computer systems that control the manufacturing operations.

10. Production System Facilities • Facilities also include the plant layout, which is the way the equipment is physically arranged in the factory. The equipment is usually organized into logical groupings (equipment arrangements) and the workers who operate them as the manufacturing systems in the factory.

11. Manufacturing Systems • Manufacturing systems can be individual work cells, consisting of a single production machine and worker assigned to that machine. • We more commonly think of manufacturing systems as groups of machines and workers, for example, a production line. • The manufacturing systems come in direct physical contact with the parts and/or assemblies being made. They "touch" the product.

12. Manufacturing Types • One of the most important factors that determine the type of manufacturing is the type of products that are made. • Discrete products manufacturing: including automotive, aircraft, appliances, computers, machinery, etc. • Process manufacturing: products that are in liquid or bulk form, such as chemicals, pharmaceuticals, petroleum, basic metals, food, beverage, electric power generation, etc

13. Production Quantity • In discrete products manufacturing, the quantity produced by a factory has a very significant influence on its facilities and the way manufacturing is organized. • The annual part or product quantities produced in a given factory can be classified into three ranges: • Low production: Quantities in the range of 1 to 100 units per year • Medium production: Quantities in the range of 100 to 10,000 units per year • High production: Production quantities are 10,000 to millions of units per year

14. Product Variety vs Production Quantity Low Prod. Product variety Medium High Prod. 100 10,000 1,000,000 Production quantity

15. Facility and Layout Fixed Position Layout Process Layout Cellular Layout Job Shop Product Layout Batch Production Cellular Manufacturing Product variety Quantity Flow Line Production Production _________________________ Mass Production 100 10,000 1,000,000 Production quantity

16. Manufacturing Support System • Business Function - sales and marketing, order entry, cost accounting, customer billing • Product Design - research and development, design engineering, prototype shop • Manufacturing Planning - process planning, production planning, MRP, capacity planning • Manufacturing Control - shop floor control, inventory control, quality control

17. Data Communication & Networking in Manufacturing System Chapter 2Digital Manufacturing

18. Today’s Business RequirementsDrive Change & Determine Real-time Enterprise Needs • Globalization • Rapid Product Innovation • Process Innovation • Collaboration • Synchronization • Lean • Continuous Improvement • Compliance • Risk Management • Performance • Flexibility • Pull-based Production • Etc.

19. Design & Validation of Manufacturing Processes Integration of Product Design and Production Process Design Evolution of the Design/Build Process Knowledge Capture Digital Mockup Digital Manufacturing Technological Advance 3D 2D 80s 2000 2006….. 90s

20. What is Digital Manufacturing? “Digital Manufacturing represents an integrated suite of PLM tools that supports manufacturing process design, tool design, plant layout, and visualization through powerful virtual simulation tools that allow the manufacturing engineer to validate and optimize the manufacturing processes. “

21. Digital Mfg/Production Process Design, Virtual Factory Simulation CAD/CAE (Digital Def.) Operations Mgmt Where Does Digital Manufacturing Fit? Product Lifecycle: Design/Build/Automate/Maintain Product Domain Production Domain Controls/Tool Engr Factory Operations/ Production Systems R&D Design Engr 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 Function (Systems) CAM/NC CollaborativePDM Automated Assembly Specs, E-BOM, M-BOM PLM Solutions: Interoperability & Collaboration Operations Engineering

22. What Does Digital Manufacturing Do? • Manufacturing Planning • Define High-Level Manufacturing Processes • Process Planning (Assembly & Installation) • Define Work Instructions & Work Flow • Detailed Process Design & Analysis • Detailed Resource Modeling & Simulation • Process Definition and Validation • 3-D Factory Layout • Equipment, Tool & Fixture Simulation • Ergonomic Simulation • Validation & Virtual Commissioning • Control Logic Validation • Kinematic (Robotic) Validation • Quality Assurance/Process Improvement Validation • Sensor/Metrology Placement Validation • Virtual Commissioning/Validation of Automation Systems • Knowing that the Production System Works Prior to Launch: Priceless.

23. Digital Manufacturing Redefines Concurrent Engineering • Product Authoring (CAD) tools are employed to define “What" is to be built. • Manufacturing Process Design tools are used to define “How" it is to be built. • Integration of Product & Process Design directly supports the concept of Concurrent Engineering Digital Manufacturing facilitates the Holistic view of Product and Process Design as integral components of the overall product life cycle

24. Managing the Manufacturing Process PLM/Digital Manufacturing are Process-Centric • Integration of Product Design with Mfg Processes allows Production Management & Execution Applications to be Integrated with the PLM Solution Set • Manufacturing Process Design coupled with Digital Mfg Simulation Integrates the Definitions of the Product, Processes, Factory, and Resources into a Comprehensive and Consistent Manufacturing Solution • Manufacturing Process Mgmt (MPM), as a Component of the PLM Solution Set Generates traditional Operations Management Functions such as Process Planning, Work Instructions, and Operations & Quality Assurance Records Scheduling, Workflow, Resource Mgmt, WIP, and Visibility

25. Global Manufacturing Operations Enterprise Infrastructure Operations Infrastructure Design/Engineering Infrastructure = Manufacturing Node = Design Node

27. Operations Management Definition: Operations Management is the management of the people, business processes, technology and capital assets involved in: • Procuring and receiving raw materials and components • Especially as it relates to obtaining, storing, and moving necessary materials/components in a timely manner and of suitable quality to support efficient production • Implementing product designs, specifications, formulations, or recipes by manufacturing products • Including manufacturing process planning and validation • Distributing these products to customers • Especially as it relates to sequencing and in-house logistics • And for some products, supporting them through their End-of-Life Let Business Requirements Drive Technology Solutions

28. Today’s Dynamic, Demanding Environment Places a Premium on Information and Synchronization

29. CMM Applications MapLet’s Get on the Same Page re: MES and OM Lean/CI etc. Quality Sched SCM WMS CAM HMI HR MPM MI EAM CAD MES T&A ERP FIN Business Support TMS CRM Suppliers Customers Enterprise Infrastructure Gen 4 (SOA) Operations Infrastructure Design Gen 3 Operations Management (Integrated Apps, Infrastructure, & Connectivity) Equipment & Automation MES Gen 1 MES Gen 2 Production (Standalone, Industry-Specific Application) (Collection of Applications)

30. Production Mgmt Systemsare Extension of PLM Product Lifecycle Processes Build Design Automate Maintain Manufacturing Processes Digital Manufacturing Solutions + MES Execute Processes Simulate & Validate Processes Create Processes Plan Processes Validate Engineering Design As – Built Records

31. Tailored Work Package • Process Configuration • Work Instructions • Work Flow Routing • Operations Scheduling • Shop Floor Requirements • Data Exchange • Performance Analysis • Quality Assurance • Labor/Parts/Tooling Production Mgmt Process Creation “As Designed” Process Data Shop Floor Execution (MES) Maintenance & Support “As Built” Records Product Design “As Designed” Product Data PLM Integrated with Shop Floor Execution ERP • E-BOM • M-BOM • Bill of Process • Product Config. PLM

32. Digital Mfg + Shop Floor Execution = Validation of As-Built to As-Designed Product Design CAD Closing the Loop From As-Built Records To As-Designed Collaborative PDM Product Data Management Digital Manufacturing/MPM 3D Models E-BOM Process Planning Process Simulation & Validation Process Modeling Shop Floor Execution (MES) Process Models,3D Simulations, Work Order Instructions Process Execution Quality Assurance Unit Data & Work History Data Vault Job Sign On/Off Work Order Status Material / Parts Work Order Release E-BOM Work Orders Release & Status Inventory Mgmt Invoicing Shipping ERP Master Routings, M-BOM Parts Purchasing Labor Reporting Financials Receiving Production Scheduling

33. Merging Virtual Simulation and Automation Simulation to Control: Making the Final Step from Virtual to Real Process Design Production System Real Operations Virtual Simulation Digital Validation Produces Real Control Execution Collaborative Environment for Control Design & Digital Validation

34. PHYSICAL VIRTUAL Control Design Mfg Process Modeling OPC Client/Server Target PLC or Controller Platform Developed with Automation providers Code Generator Post-Processed Machine Logic Validate Control Production Simulation PLC/Controller HMI Interoperable Virtual to Real-World Environment for Manufacturing and Control Engineering DESIGN VALIDATE

35. Merging Virtual Design and Automation Shortens Time to Launch Control Engineering (Commissioning) Line Building & Installation Control Engineering (Design) 3D Mechanical Design Current workflow…. Workflow…with Virtual Automation Production Startup Control Eng. Line Building 3D Mechanical Design Control Engineering Production Startup Validation & Virtual Commissioning

36. Effective & Efficient Use of Digital Mfg (DM) Tools: Guidelines for Users • Integrate Use of DM Tools into the Manufacturing Design Process • Set and Implement guidelines for application of DM technology • Provide DM training for Mfg Engineering Discipline & Resources • Emphasize Re-use • Re-use dependent on a strategy common process design • Common components is a key enabler • Establish a library of virtual production devices & equipment • A modular approach is key for efficiently building virtual models • Start with basic virtual devices building blocks • Build virtual production systems by combining virtual devices • Integrate DM Tools into the Information & Control Architecture • Virtual models can be developed & maintained by multiple engineering disciplines (Manufacturing, Tooling, Controls) • Use latest Production Process data for Virtual Simulations

37. Digital Manufacturing Landscape • Manufacturers are focusing on Optimization of Production Processes • Reducing Time to Product Launch and Cost of Commissioning Production Systems • Today’s PLM Suppliers now offer robust Digital Manufacturing Solutions • Large Manufacturers Are Adopting End-to-End PLM Strategies, including Digital Manufacturing • A&D: Boeing, Lockheed-Martin, Northup-Grumman • Automotive: GM, Chrysler, Ford, Toyota, Nissan, BMW, Mercedes Benz • Heavy Equipment: Caterpillar, John Deere, Cummins Companies are Transforming how they Define their Manufacturing Processes

38. Key Benefits of Digital Manufacturing • Integration of Product Design and Manufacturing Processes • Reduce Cost and Development Time for Process Design • Shorten Time-to-Launch for New Product Introduction with Faster Ramp-up for Production Systems • Provide Manufacturability by Simulating Manufacturing Operations before the Start of Production • Increase Quality by Validating Production Process Design • Reduce and/or eliminate Prototypes and Physical Mockups with Virtual Simulations • Improve Collaboration with Suppliers by Providing Early Access to Design, Production Process, and Resource information • Improve Concurrent Design Methods by Linking Product Design to Manufacturing & Controls Engineering • Validate Manufacturing Processes, Production Systems, and operational resources through Virtual Commissioning prior to physical implementation

39. Data Communication & Networking in Manufacturing System Chapter 3Computer System Fundamental

40. The Primary Components Of A Computer • Input devices. • Central Processing Unit (containing the control unit and the arithmetic/logic unit). • Memory. • Output devices. • Storage devices.

41. Central processing unit • A central processing unit (CPU), or sometimes just called processor, is a description of a class of logic machines that can execute computer programs. • This broad definition can easily be applied to many early computers that existed long before the term "CPU" ever came into widespread usage. However, the term itself and its initialism have been in use in the computer industry at least since the early 1960s (Weik 1961). • The form, design and implementation of CPUs have changed dramatically since the earliest examples, but their fundamental operation has remained much the same.

42. Central processing unit • Early CPUs were custom-designed as a part of a larger, usually one-of-a-kind, computer. However, this costly method of designing custom CPUs for a particular application has largely given way to the development of mass-produced processors that are suited for one or many purposes. • This standardization trend generally began in the era of discrete transistormainframes and minicomputers and has rapidly accelerated with the popularization of the integrated circuit (IC). • The IC has allowed increasingly complex CPUs to be designed and manufactured in very small spaces (on the order of millimeters). Both the miniaturization and standardization of CPUs have increased the presence of these digital devices in modern life far beyond the limited application of dedicated computing machines. Modern microprocessors appear in everything from automobiles to cell phones to children's toys.

43. Early Computers ENIAC (Electronic Numerical Integrator And Computer), was the first general-purpose electronic computer. ENIAC was designed and built to calculate artilleryfiring tables for the U.S. Army's Ballistic Research Laboratory. EDVAC, one of the first electronic stored program computers.

44. later packaged in small IC’s • eventually came VLSI • Very Large Scale Integration • millions of transistors per chip transistor evolution • first transistor made from materials including a paper clip and a razor blade

45. the integrated circuit (IC) • invented separately by 2 people ~1958 • Jack Kilby at Texas Instruments • Robert Noyce at Fairchild Semiconductor (1958-59) • 1974 • Intel introduces the 8080 processor • one of the first “single-chip” microprocessors

46. Microprocessor • Processors were for a long period constructed out of small and medium-scale ICs containing the equivalent of a few to a few hundred transistors. • The integration of the whole CPU onto a single VLSI chip therefore greatly reduced the cost of processing capacity. • From their humble beginnings, continued increases in microprocessor capacity has rendered other forms of computers almost completely obsolete (see history of computing hardware), with one or more microprocessor as processing element in everything from the smallest embedded systems and handheld devices to the largest mainframes and super computers.

47. Microprocessor • Three projects arguably delivered a complete microprocessor at about the same time, namely Intel's 4004, the Texas Instruments (TI) TMS 1000, and Garrett AiResearch'sCentral Air Data Computer (CADC). The 4004 with cover removed (left) and as actually used (right).

48. Architectures • 8-bit designs • 16-bit designs • 32-bit designs • 64-bit designs in personal computers • Multicore designs • RISC • Special-purpose designs • microcontrollers, digital signal processors (DSP) and graphics processing units (GPU).

49. Architectures • 65xx • MOS Technology 6502 • Western Design Center 65xx • ARM family • AlteraNios, Nios II • Atmel AVR architecture (purely microcontrollers) • EISC • RCA 1802 (aka RCA COSMAC, CDP1802) • DEC Alpha • Intel • 4004, 4040 • 8080, 8085 • 8048, 8051 • iAPX 432 • i860, i960 • Itanium • LatticeMico32 • M32R architecture • MIPS architecture • Motorola • Motorola 6800 • Motorola 6809 • Motorola 68000 family, ColdFire • MotoG4, G5

50. Architectures • NSC 320xx • OpenCoresOpenRISC architecture • PA-RISC family • National Semiconductor SC/MP ("scamp") • Signetics 2650 • SPARC • SuperH family • TransmetaCrusoe, Efficeon (VLIW architectures, IA-32 32-bit Intel x86emulator) • INMOS Transputer • x86 architecture • Intel 8086, 8088, 80186, 80188 (16-bit real mode-only x86 architecture) • Intel 80286 (16-bit real mode and protected mode x86 architecture) • IA-32 32-bit x86 architecture • x86-64 64-bit x86 architecture • and others