Drive digital transformation to digital twin

Drive digital transformation to digital twin

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  Drive Digital Transformation Onthe road to the Digital Twin (Insights for Discrete Part Manufacturing) Christopher J. Garcia - April 2018 www.linkedin.com/in/chrisgarciaMBAIIoT [email protected]
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  Digital Twins (Factory &Asset) Track & Optimize KCs & CTQs MBD Define Product KCs & CTQs* MBE-Publishing Visual Digital Thread MBE-Automation Generative Digital Thread (2) (3) (4) (5) To stay competitive in discrete part manufacturing... 2 We must Accelerate Digital Transformation MBSE Design Complex IIoT enabled Products & Systems (mCAD, eCAD & Software) (1) *CTQs = Critical to Quality KCs = Key Characteristics
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  Digital Twin Promises View,predict and optimize: • Reduce equipment failures, • Streamline factory operations • Increase operational efficiency • Perform enhanced product engr. To deliver in on these promises... MBE – Visual Digital Thread Promises Improvements in Production • 40-50% in Tooling & Fab Time • 30-40% in Sub & Final Asm. Time • 40-50% in Supplier Cycle Time • 10-20% in Scrap and Rework MBE – Generative Digital Thread Promises Engr driven Generative Manufacturing Processes • 60-80% Reduction in CAM / NC Prog. • 60-80% Reduction in Quality/Insp/CMM • 60-80% Reduction in Process Planning Time • 80-90% Reduction in Process Updates on ECN.(2) (3) (4) (5) We must Accelerate Digital Transformation MBD Promises Make 3D MBD the Master (not 2D Draw) • 30% - 40% Productivity in Engr. • 10-20% Reduction in EC Requests • Engr Clarity means less mistakes 3 (1) MBSE Promises Design Complex IIoT enabled Products & Systems • Reduced Engineering Costs of Complex Systems • Assess Total System Impact on EC Requests • Keep mCAD, eCAD & Software Designs in Sync
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  And to achievethese Productivity & Quality improvements 4 We must Accelerate Digital Transformation
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  Accelerating Digital Transformation... 5 (followthis road to the Digital Twin)
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  Defines a HighLevel Model of the Entire System Includes High Level Definition of: • Systems Requirements • System Interfaces & Interactions • System Analysis & Simulation • System Verification • Models created using SysML MBSE 6 What is MBSE (Model Based Systems Engineering) Typical MBSE Software • PTCs – Integrity • Teamcenter– Systems Engineering Solution • Enovia – 3DEXperience Systems Engr Solution • IBM – Rational DOORs • MagicDraw • Cameo, Dymola, Matlab, Simulink
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  MBSE 3D CAD Design ECAD Design Software Design MBSE Unites Mechanical,Electrical & Software Component Design: • Mechanical Components designed in 3D CAD + MBD • Electrical Components designed in ECAD • Software Components in UML -> Source Code Generators 7 Typical Design Software • MCAD Design - Creo, NX, CATIA, SolidWorks, Inventor • ECAD Design Siemens - Mentor Graphics SolidWorks – Electrical Altium • Software Design PTC’s-ALM, Siemens – Polarion ALM, IBM - Rational IIoT enabled Products require MBSE to keep designs in sync.
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  3D MBD* isthe product design practice performed inside the 3D CAD system which defines a parts fit, form & function (its design intent) and key characteristics (KCs & CTQs) in a manner sufficient for the part to be manufactured, purchased, inspected and assembled without the need of 2D Drawings as the master. • The 3D Model & its MBD data become the Product Definition master instead of the 2D Drawings. What is MBD (Model Based Definition) 8* MBD is sometimes called PMI: Product Manufacturing Information and includes 3D Dims/Tolerances & 3D Views
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  MBSE 3D CAD Design MBD ismore than just adding PMI* to 3D CAD Robust 3D Part Design Assemble 3D Part Designs Add MBD/PMI Tolerances Identify Key Char & CTQs Should Cost Anal (make/buy) Release to PLM The Fundamental MBD Engineering Practices (1) thru (6) (1) (2) (3) (4) (5) (6) 9
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  MBD Promises to: Replace2D Drawings as the master & 2D Paper Processes with 3D MBDs as the master & 3D MBE Processes From this 2D Master to this 3D MBD Master to this 3D MBE Processes 10
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  3D MBE isthe manufacturing, supply channel and quality practices which reuses the 3D MBD data (outside the CAD system) combined with additional information from PLM, ERP, MES, CRM in the “context” of the process being performed (i.e. Engr. Release, Supplier RFQs, Bill of Characteristics, Assembly Plans, etc.) • 3D MBE information is typically viewed in high fidelity light weight templates like 3D PDF, 3D HTML and can replace the need 2D Paper based processes. What is MBE* (Model Based Enterprise) 11* This MBE definition is consistent with Mechanical Systems Design for Discrete Part Manufacturers
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  MBD Engineering Practice MBEReady PLM Apps Delivering MBD Value Depends on MBE Ready PLM Apps (1) (2) (3) (4) (5) (6) 12
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  What is theMBE Digital Thread (steps 1 thru 6) Is a communication framework that connects traditionally siloed elements in the manufacturing, supplier and field service processes and provides an integrated view of the product (its 3D + MBD data) in the context of those processes. • Visual Digital Thread: The visual (human readable) communication of the product’s design intent (its MBD data) in the context of those processes. • Generative Digital Thread: The semantic (machine readable) communication of the product’s design intent (its MBD data) in the context of those processes. 13
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  (1) (2) (3) (4) (5) (6) MBE ReadyPLM Apps MBD Engineering Practice MBE Digital Thread Killer Apps The MBE Digital Thread includes these Killer Apps 14
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  These MBE AppsMUST provide high fidelity MBD Visualization High Fidelity MBD* Visualization * To replace 2D Drawings as the master the 3D MBD Digital Thread Visualization must be PERFECT 15
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  What are “as-ManufacturedDigital Twins” steps 7 & 8 Are multiple digital models of a particular asset that includes design specifications, CAD and behavior models (the as-Designed Twin) plus the physical products operational data (i.e. process variables, inspection, assembly, test)...The as-Manufactured Twins as-Manufactured Twins 16
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  What are “as-MaintainedDigital Twins” steps 9 thru 12 Are multiple digital models of a particular asset that includes design specifications, CAD and behavior models (the as-Designed Twin) plus the physical products field data (i.e. as used, performance, environmental and maintenance & repair)... The as-Maintained Twin 17
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  (1) Drives Digital Transformation (2) (3) (4) Thisroad to the Digital Twin 18 Digital Twin Promises View, predict and optimize: • Reduce equipment failures, • Streamline factory operations • Increase operational efficiency • Perform enhanced product engr. MBE – Visual Digital Thread Promises Improvements in Production • 40-50% in Tooling & Fab Time • 30-40% in Sub & Final Asm. Time • 40-50% in Supplier Cycle Time • 10-20% in Scrap and Rework MBE – Generative Digital Thread Promises Engr driven Generative Manufacturing Processes • 60-80% Reduction in CAM / NC Prog. • 60-80% Reduction in Quality/Insp/CMM • 60-80% Reduction in Process Planning Time • 80-90% Reduction in Process Updates on ECN. MBD Promises Make 3D MBD the Master (not 2D Draw) • 30% - 40% Productivity in Engr. • 10-20% Reduction in EC Requests • Engr Clarity means less mistakes MBSE Promises Design Complex IIoT enabled Products & Systems • Reduced Engineering Costs of Complex Systems • Assess Total System Impact on EC Requests • Keep mCAD, eCAD & Software Designs in Sync (5) And delivery of the promises...
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  HCL Technologies https://www.hcltech.com/ Baker Hughes,a GE company (BHGE) https://www.bhge.com/products-services/digital Candid Industrial Internet https://www.linkedin.com/in/chrisgarciambaiiot/ Anark Corporation http://www.anark.com/ Acknowledgments This presentation was made possible through lessons learned with: 19