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Models for IPPE

Models for IPPE. ISE789 Product and Process Engineering R. A. Wysk. A Resource Independent Process Representation in Enterprise-based Engineering Integration for Manufacturability Analysis. Boonserm Kulvatunyou. Preview. Research motivation Research objective and scope Methodology

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Models for IPPE

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  1. Models for IPPE ISE789 Product and Process Engineering R. A. Wysk

  2. A Resource Independent Process Representation in Enterprise-based Engineering Integration for Manufacturability Analysis BoonsermKulvatunyou B.K

  3. Preview • Research motivation • Research objective and scope • Methodology • RIOS Schema • Example RIOS construction • Engineering integration architecture • Example integration • RIOS Verification and Validation • Conclusion B.K

  4. mawmeow: Enterprise-based engineering integration is necessary for the distributed manufacturing environment. This is because engineering experts are geographically separated and are subjected to communication, time, and availability problem. Enterprise-based engineering integration also emulates the concurrent engineering; thus, it would enable the manufacturing cost saving during the early design stage. In the enterprise-based engineering integration environment engineering experts collaborate thru a common data pool which consists of Design data, process data,….. Research MotivationEnterprise-based Engineering Integration Business motivation • 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’ B.K

  5. Enterprise-based Engineering Integration Technological challenge • Communication and scheduling problems • Information infrastructure • Content-based infrastructure • Network infrastructure • Insufficient product data • Integration difficulty -- relying on single view point of product data, i.e., design data • Feature recognition challenge -- feature interaction, design misinterpretation, unrecognized feature, time consuming computation • Business objective communication -- design data does not provide vocabulary for business collaboration • STEP AP224 Machining features for process planning • Use of compound feature and no alternative representation • A resource specific view of product model B.K

  6. mawmeow: This research propose to supply process model which interlinks with the design data as part of the product data in the engineering integration. However, traditional process model is resource specific..thus the first objective of this work is to….. 2nd to construct information model for this resource independent process representation. And then develop and implement an integration architecture to demonstrate the use of RIOS data in engineering activity integration, in particular the manufacturability analysis and cost & time estimation Research Objective and Scope • Provide an approach to specify process model view of the product data • Resource independence • Facilitating enterprise integration • Construct information model for resource independent process representation--Resource Independent Operation Summary (RIOS) • Develop a structure of Resource Specific Process Planning (RSPP) module for enterprise-level manufacturability analysis • Manufacturability • Manufacturing Cost & Time estimation • Demonstrate example RSPP module of a manufacturing vendor that integrates with its engineering information pool--process knowledge and resource model • Scope: 3-axis milling machine in flexible manufacturing system, excluding material handling B.K

  7. Methodology Resource independent process representation • 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 [Brown and Ray 1987], [Wysk et. al, 1995], [Shah and Mantyla 1995], [Chang 1990], [Ray 1987] B.K

  8. Universal Process Knowledge [http://www.cybercut.berkeley.edu] B.K

  9. Process Modeling (ABS) Operation_level_information 1 (ABS) Mfg_oper_info (ABS) Business_oper_info 1 (ABS) Matl_transf_oper_info (ABS) Matl_transp_oper_info 1 (ABS) Property_ change_oper_info (ABS) JoinAsm_ oper_info (ABS) Matl_ rem_oper_info (ABS) Geometry_ change_oper_info 1 Therm_rem _ oper_info Mech_rem _oper_info Chem_rem _oper_info Elec_rem _oper_info B.K

  10. mawmeow: The first step in this process planning decomposition is to resolve ….. Process Planning Decompositionin 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 RIOS Generate RSRS B.K

  11. Constraints B.K

  12. Presentation Map -- RIOS Specifications • Research motivation • Research objective and scope • Methodology • RIOS Schema • Example RIOS construction • Engineering integration architecture • Example integration • RIOS Verification and Validation • Conclusion • Possible extension B.K

  13. RIOS_Graph RIOS_Support RIOS_Transaction RIOS RIOS_Operation_level_information RIOS_Process_level_information RIOS Schema Business and production requirements Alternative Process type, accuracy,topology, and shape requirements Resource type and workholding requirements Measurement, material, etc. specifications B.K

  14. RIOS_Transaction schema (1) B.K

  15. Example Part Hot-rolled carbon steel wrought medium carbon, 350 BHN All dimensions are +/- 0.01" unless otherwise specified A-7 B.K

  16. RIOS_Operation_level_information schema (ABS) Operation_level_information 1 (ABS) Mfg_oper_info (ABS) Business_oper_info 1 (ABS) Matl_transf_oper_info (ABS) Matl_transp_oper_info 1 (ABS) Geometry_ change_oper_info (ABS) Property_ change_oper_info (ABS) JoinAsm_ oper_info (ABS) Matl_ rem_oper_info 1 Therm_rem _ oper_info Mech_rem _oper_info Chem_rem _oper_info Elec_rem _oper_info B.K

  17. Example Part Discussion D A B • Need at least 2 setups--Top and bottom. • Economical utilization of process can • be used to rationalize the sequence. • An SERIAL AND connection may be specified. • Processing the top side first results in depth reduction of 4 holes. • There is a tolerance stack up of the c-bore hole, if all features • are processed in single setups. • Provide alternative to separate the processes on the top side into • two setups. B.K

  18. 2 Operation Level Graph (OLG) OP3 Specification B.K

  19. Process Level Graph (PLG), PLG3 of OP3 Summary of PLG3 Data B.K

  20. B.K

  21. Presentation Map -- Activity Integration • Research motivation • Research objective and scope • Methodology • RIOS Schema • Example RIOS construction • Engineering integration architecture • Example integration • RIOS Verification and Validation • Conclusion • Possible extension B.K

  22. Implementation Architecture Software architecture • Facilitate integration -- minimum cost and time to implement • Modular and extensible • Software architecture includes: • XML Data Parser • RSPP module Utility Classes • MR Model • PN Architecture B.K

  23. XML Data Software Packages Tree Data Structure UML Package Diagram • Facilitate data access • Provide utility functions such as • traversing the directed graph B.K

  24. Implement by vendor Implement by vendor RSPP Module Utility Classes Utility classes automatically: • Traverse graph • Eliminate non-manufacturable nodes • Facilitate digraph linearization • Linearize digraph with only OR connections (alternate paths) B.K

  25. CIM Lab RSPP Module Implementation • Manufacturability analysis as well as cost and time estimation • Manufacturing resource model • Machine: Haas VF-OE (3-axis) and Haas VF-3B (5-axis) • Tool body: Solid tool body types including twist drill, reamer, solid boring bar, endmill, counterbore, and countersink • Fixture: Vise • Process knowledge architecture • Client-service architecture • Plug-and-play with resource model • RSPP module utility classes implementation • Producibility analysis • Process selection and cost estimation B.K

  26. Manufacturing Resource Model Object-oriented Schema B.K

  27. Manufacturing Resource Model Indicate resource capability Owns(x1, x4) and HasAttrVal(x4, a2, c2) -> HasAttrVal (x1, a2, c2) Ex: Milling machine owning a 1” diameter twist drill implies that the milling machine has capability to twist drilling a 1” diameter hole ‘Owns’ relationship is transitive Owns(x1, x4) and Owns(x4, x5)  Owns(x1, x5) Subtype Is(x1, x2) ‘Is’ relationship is transitive Is(x1, x2) and Is(x2, x3)  Is(x1, x3) B.K

  28. Object-oriented Implementation of the MR Model B.K

  29. Process Knowledge Architecture • Java interface based architecture, i.e., client-service architecture • Allow plug-and-play compatibility with the MR model • Shape producing capability knowledge • Process accuracy knowledge • Process selection knowledge • Machining parameters -- Machining data handbook (MetCut 1980) B.K

  30. Java Interface-based Process Knowledge Architecture • MR are service providers • RSPP module is client • Interfaces are services • Define service specifications • An MR provides a service by implementing the service specification • Ex:Hole_making_capable • verifyProcessAccuracy( ) • planHoleBody( ) • planHoleTop( ) B.K

  31. UML Package Diagram showing Collaboration • Ex: Twist drill, reamer, endmill implement Hole_making_capable • When RSPP module encounter a Hole_making_process requirement, it queries knowledge base for all Hole_making_capable resources to find the most efficient one. • New Hole_making_capable resource can be added without effecting the RSPP module B.K

  32. Process Knowledge Architecture Predicate y2 is an interface. B.K

  33. Implement by vendor Implement by vendor RSPP Module Utility Class ImplementationCIM LAB Manufacturing Agent B.K

  34. RSPP Module Utility Class ImplementationCIM LAB Manufacturing Agent • Producibility analysis -- shop level manufacturability evaluation • Cost and time estimation • Equipment selection: machine burden rate or resource utilization (dynamic conflict resolution) • Process selection • Graph linearization • Group -- graph-based pattern matching • AND -- process economy heuristic • Geometry • Topology • Process accuracy & Process economy -- process bounds and process efficiency (e.g., twist drilling is more efficient hole making process than endmilling (plunging)) • Graph linearization • OR -- network flow problem formulation B.K

  35. mawmeow: Supposed producibility is okay Example Cost and Time Estimation of the Example Part (1) OLG OP3 Data B.K

  36. mawmeow: Dynamic conflict resolution can be introduced 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 B.K

  37. Cost and Time Estimation of the Example Part‘Linearize GROUP and AND Connection’ • Pattern matches a group of multiple holes with decreasing diameters • Check step drill resources owned by the Haas VF-OE for geometric compliance -- No match • Replace the Group connection with a Serial AND connection • Linearize the Serial AND connection --> heuristic --> EX: “Sequence to minimize the processing depth” B.K

  38. mawmeow: Select all Hole_making_capable tools belonging to the Haas-VFOE, e.g., twistdrill, endmill, boring, etc. Evaluate each tool against the process requirements in the order respect to ordered list of process economy. This ordered list is twistdrilling, endmilling, reaming, and boring. Cost and Time Estimation of the Example Part‘Assign Cost and Time PLG’ For each Manufacturing process node, the RSPP module: • Select all Hole_making_capable service providers belonging to the Haas-VFOE, e.g., twistdrill, endmill, boring bar, etc. in order of ‘process efficiency’ • Verify geometry, accuracy, and topological capability to find an appropriate tool (service provider) • Ask the selected service provider (e.g. solid boring bar -0.008”) to plan and return cost and time to achieve the process requirements • Total cost of utilizing the machine, tools, and fixture associated with the machining time B.K

  39. Cost and Time Estimation of the Example Part‘Assign Cost and Time OLG’ Obtain total cost of the PLG: • Linearize the PLG, which has only the OR connection left • Shortest path formulation • Cost of traversing from node A to B is cost associated with the node A • Cost of traversing from non-procedure node is zero Obtain cost associated with the Operation node • Total cost of the PLG plus setup cost of the operation B.K

  40. Cost and Time Estimation of the Example Part‘Total cost of the batch and delivery time’ • Linearize the OLG to obtain total cost of the OLG • Ignore the AND Connection -- assume scheduling problem when each node has different resources assigned • Shortest path formulation for the OR Connection • Obtain the batch cost • Obtain per-piece cost -- profit margin times OLG cost plus other indirect and direct costs, e.g., stock material, cost of setting up equipment • Obtain total batch cost • Obtain total operating time similar approach to obtaining total operating cost • Delivery time is: current time + Max(total MPS, max lead time) + total operating time • Note • Did not consider material handling Run Example RFQ B.K

  41. RIOS Verification and Validation • Verification for machining activity through implementation demonstration • Validation for machining activity • Functional requirements • Representational requirements • Analysis of existing process representation • System analysis -- Ex: IDEF0 • Process documentation -- Ex: IDEF3 • Activity planning and scheduling -- Ex: Gantt chart • Information interchanging and knowledge sharing -- Ex: PSL, STEP 213 • In conclusion: • Lacking of one or more process representation requirements necessary for the business collaboration of engineered product • Possessing unnecessary capabilities that RIOS may not have • Lacking of low level information necessary to communicate the process requirement (only provide construct) • RIOS specification facilitating business collaboration of engineered product better than other representations Evaluation Matrix B.K

  42. Research Conclusion and Contribution • For the first time, a resource independent approach to process specification and planning has been developed • Successfully demonstrated how one can incorporate RIOS to product data to conduct a RFQ activity of machining processes • Developed integration architecture including: • RIOS data • Manufacturing resource model (schema) • Process knowledge architecture • RSPP module • Process plan graph linearization • Process knowledge procedure B.K

  43. Research Conclusion and Contribution • Software components and integration architecture have been developed and formalized for reuse • RIOS has been validated for machining activity through analysis of representational and functional requirements as well as benchmarking with other process representations • NIST is interested in pursuing this program because RIOS data is becoming critical for enterprise level integration B.K

  44. Questions? • Thank you • Any questions? B.K

  45. RIOS_Transaction schema(2) B.K

  46. Possible Extension • Web-based knowledge sharing to maintain evolving specification • Expert system module • Agent-based integration • Cost estimation scheme • Automation associated with the RIOS • Computer-assisted RIOS generation • Semantic and consistency checking • Process intersection algorithm B.K

  47. PLG1 (Exhaustive) B.K

  48. PLG1 (Concise) B.K

  49. PLG2 Exhaustive Concise B.K

  50. PLG3 and PLG4 PLG3 PLG4 B.K

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