Unapređenje upravljanja proizvodnim procesom sa
Windchill MPMLink-om
Agenda
Šta predstavlja upravljanje proizvodnim procesom?
Opseg, definicija i izazovi
PTC Windchill MPMLink
Deo PTC rešenja za proizvodnju
Istorija
Ključne mogućnosti
Summary
© 2009 PTC
Realnost proizvodnih preduzeća
Današnja realnost
Stvara se potreba za…
 Brži izlazak na tržište...
 Ako ne i prvi
 Nema više “univerzalnih”
proizvoda …
 varijabilan i kompleksan
 Sve veće odgovaranje na
potrebe klijenata …
 fleksibilan
 Dobavljači i i partneri širom
sveta
 Visok kvalitet…
 Ali ne po svaku cenu
 Reach faster ramp-up, shorter
development cycles and
quicker time-to-market
 Upravljanjem povećanom
varijabilnosti i kompleksnosti
proizvoda
 Upravljanjem i poslovanjem u
globalizovanom lancu
snabdevanja
 Poboljšanjem operativne
efikasnosti i preimućstvom
 Meet cost targets
 Postizanjem pravog kvaliteta
iz prvog pokušaja sa
razumnim troškovima
© 2009 PTC
Realnost proizvodnih preduzeća
Pressures
Pritisci
tržišta
Translates into the need to…
 Reach faster ramp-up, shorter
development cycles and
quicker time-to-market
 Upravljanjem povećanom
varijabilnosti i kompleksnosti
proizvoda
 Upravljanjem i poslovanjem u
globalizovanom lancu
snabdevanja
 Poboljšanjem operativne
efikasnosti i preimućstvom
 Meet cost targets
 Postizanjem pravog kvaliteta
iz prvog pokušaja sa
razumnim troškovima
 Reach faster ramp-up, shorter
development cycles and
quicker time-to-market
 Manage increased product
variability and complexity
 Manage and operate in a
globalized supply chain
 Improve operational efficiency
and excellence
 Meet cost targets
 Achieve first time quality at
reasonable cost
© 2009 PTC
Realnost proizvodnih preduzeća
Pressures
Market
Pressures
Problematične tačke/ Izazovi
 Reach faster ramp-up, shorter
development cycles and
quicker time-to-market
 Manage increased product
variability and complexity
 Manage and operate in a
globalized supply chain
Rezultuje
….
 Improve
operational
efficiency
and excellence
Neefikasnost
 Meet cost
Većitargets
troškovi
 Achieve
first time quality at
Pomeranje
reasonable
cost
rokova
Greške
 Nepovezanost inženjerskih,
proizvodnih i produkcionih
timove
 Poteškoće sa pronalaženjem i
upotrebom proverenih
proizvodnih procesa i resursa
 Poteškoće sa obezbeđivanjem
tačnih informacija iz
proizvodnje u produkciju na
vreme
 Procesi na papiru i u
manuelnim alatima (Word,
Excel, ..)
 Disconnected legacy systems
Kako preduzeća da se izbore sa ovim izazovima
…Pogledajte MPM i njegovu ulogu u procesu razvoja proizvoda (PDP)
© 2009 PTC
Jaz– od vizualnog do virtualnog
Kako
Šta
Gde i kada
--- da li moramo da proizvedemo?
… da preoizvedemo u skladu sa
vremenom, budžetom i zahtevima
kvaliteta
… da proizvedemo zahtevanu
količinu?
Inženjering
Proizvodni inženjering
Izrada
Prema učešću na tržištu
Prema profitabilnosti
Manufacturing Perspective
Functional System Perspective
Assembly Stations / Lines
…
Control Systems
Hydraulics
Electrical
Propulsion
Structure
Plants
?
Sub-Assemblies
Details Parts / Raw Materials
…
© 2009 PTC
The
Upravljanje
Gap – From
proizvodnim
Virtual toprocesom–
Physical Prevazilaženje jaza
How
… to produce meeting time, cost
budgets and quality requirements
Male izmene u Inženjeringu imaju veliki
uticaj na Proizvdonju i Izradu
Inženjering
MPM
?
Izrada
© 2009 PTC
Upravljanje proizvodnim procesom– Prevazilaženje jaza
Proces definisanje i upravljanje proizvodnim procesima koji se koriste za izradu
delova, za sklapanje finalnih proizvoda i izvršavanje inspekcije ,
AUTPUTI
INPUTI
Procesni plan dela &
sklopa
eBOM /
As-Designed
10
20
30
mBOM /
As-Planned
3D CAD
Modeli
Design
NC/CMM programi
Resursi &
Standardi
proizvodnje
Tools
Interno i u lancu
snabdevanja
Tools
Skills
Skills
Work Centers
Work Centers
Upravljanje
Proizvodnim
procesom
Tooling requests
Procena vremena &
troškova
Zahtevi za
izmenom
Radne
instrukcije
Milling Machines
Drilling Machines
Inženjer projektuje proizvod
Proizvodni inženjer projektuje proizvodne procese
© 2009 PTC
Agenda
What is Manufacturing Process Management?
Scope, definition and challenges
PTC’s Windchill MPMLink
Part of PTC’s Manufacturing Solution
History
Key capabilities
Summary
© 2009 PTC
PTC strategija proizvodnje
PTC-eva misija je da pomogne klijentima da
uvide vrednos u poboljšanju proces razvoja
proizvoda
Razvoj proizvoda uključuje razvoj
proizvodnih procesa i alata neophodnih za
izradu proizvoda
Za optimalne rezultate, proizvodni poslovni
procesi treba da se izvršavaju istovremeno
sa projektantskim procesima
Zahteva vizualne, asocijativne, digitalne
sposobnosti proizvodnje kao integralne
komponente PDS-a
“…(MPM / Digitalna proizvodnja) … je najefektivnija kada
predstavlja INTEGRALNU komponentu cele PLM strategije
preduzeća.”
[CIMdata: “Digital Mfg: Moving the Design into Production”, 2006]
© 2009 PTC
Istovremeni razvoj procesa i proizvoda
Razvoj koncepta
Sistemsko
projektovanje
Limited opportunity
for Manufacturing
to influence design
and reduce cost
Smanjenje
trajanja
ciklusa
Detaljno
projektovanje
Upravljanje
proizvodnim
procesom
Istovremeni
MPM proces
Production
Ramp-up
Potpuna proizvodnja
Smanjenje troškova
usled izmene
Smanjenje troškova
proizvodnje
Tipični
MPM
proces
“[Manufacturing companies] identified that the need to reduce manufacturing costs was driving
their need to improve their manufacturing planning process at practically the same rate as
compressed development schedules.”
Aberdeen Group, Digital Manufacturing Planning – Concurrent Development of Product and Process, 11/2007
© 2009 PTC
PTC’s rešenje za proizvodnju
Portfolio proizvoda
Pro/TOOLMAKER
Projektovanje kompletnog
kalupa
Tool Design Option
Complete Machining
Production Machining
Prismatic Milling
CAM Lite
Expert Moldbase eXtension
PTC sistem za razvoj proizvoda
Pro/PLASTIC
Advisor
Windchill
MPMLink
Computer
Aided
Verification
NC Sheetmetal
Progressive
Die
eXtension
© 2009 PTC
Windchill MPMLink - Istorija
x
v
PTC Acquired
Polyplan for MPM
Windchill Technical
Committees
• Osnovana 1999 u
Montrealu, Kanada
• CAB has now been
incorporated into the Windchill
Technical Committees
First LIVE
Customer !
Windchill MPMLink
first point release
Windchill MPMLink
X-20
• First customer in
production with
Windchill MPMLink
• Enhancing core functionality
and streamlining common
tasks
• Focusing on functionality,
productivity
improvements and
serviceability
x
v
x
2005
2006
2007
x
x
v
x
v
x
v
2009
2008
2010
x
9.0 F000
9.1 F000
Windchill “10”
Windchill MPM Customer Advisory Board formed
• Orient Windchill MPMLink roadmap with customers’ requirements and
priorities and therefore maximize customer and PTC benefits from use of
Windchill MPMLink
• Worked closely with Windchill MPMLink product management team during
initial development
• Objectives
Windchill MPMLink RELEASED!
• The industry’s first integral solution for Manufacturing Process
Management
• Part of Windchill release streams
• Transformed Polyplan capabilities into an Integral Windchill
module called MPMLink
•
• Allow PTC to gather real-world use cases from world-class customers
• Joint prioritization of future capabilities and use cases
•
• Various Industries represented
• Aerospace & Defense, Industrial Equipment & Hi-Tech Electronics
•
Control of critical manufacturing information and associated
development processes
Collaborative process development through the sharing of
knowledge, product information, concepts and ideas
Complete model supporting product, process and resource
definition
© 2009 PTC
Windchill MPMLink key capabilities …
….. enabling Concurrent Product and Process Development
An integral part of the
Product Development
System
Dynamically generated
visual work Instructions
Associative eBOM to
mBOM management
Integral change and
configuration management
Digital definition and
management of process
plans
Digital definition and
management of manufacturing
resources and standards
Streamline release to
Manufacturing
© 2009 PTC
An Integral part of the Product Development System
Supplier
Enable
the management
of manufacturing
Supplier
data and
deliverables as
trueParts
enterprise
Preferred
Supplier
Approved Vendors
data
Feasibility Feedback
Tooling Designs
Work Instructions
NC Programs
Distributed Mfg
Distributed Mfg
Distributed Mfg
By providing a common central repository
for engineering product and manufacturing
process planning data
Requirements
Design Feedback
Procurement
Complete model supporting
product, process and
resource definition
Manufacturing
Part Designs
BoMs
Changes
Windchill
Leveraging PLM and facilitating the …
Service
Control of critical
manufacturing
Engineering
information
and associated
Models
Drawings
development processes
PDMLink
Simulations
Collaborative manufacturing deliverables
Marketing
Local
Design
development
through the sharing
of knowledge,
Partner
product information,
concepts and ideas
Offshore
Design Partner
Captive ODC
Concepts
Requirements
Market Requirements
Brochures, Data Sheets
• Product Requirements
• Products
• As Designed (eBOM)
• CAD Files
Sales
• Documents
Custom
Configurations
Field Notices
MPMLink
Customer Concerns
Failure Reports
• As
Planned (mBOM)
User, Service Manuals
• Process
Plan / WI
Training guides
• Time
&
Cost
Estimates
Parts catalogs
• Mfg Standards Library
• Resources Library
Customers
Change & Configuration Management
Document Management
Customers
Proposals
Regulatory
Customer Requirements
ESI (Enterprise System Integration)
Authorities
Workflow
Access Control
© 2009 PTC
Associative eBOM and mBOM Management
Ensure that mBOMs are conform and reflect the ever-changing
engineering designs
By providing powerful capabilities to easily transform BOMs while
maintaining associativity using traceability links
Flexible mBOM definition and restructuring
– Use engineering parts as-is or create manufacturing parts
– Derive multiple mBOMs from a single eBOM
New 9.1
– Maintain multiple Alternate BOMs describing the different
manufacturing variations that can produce the same part
Leverage 3D designs using embedded 3D environment
provided by ProductView technology
– Visualize engineering designs, eBOMs and mBOMs
– Create mBOM by selecting parts from the 3D environment
– Automatically generate 3D manufacturing mockup
Reduce difficult and time consuming task of ensuring BOM
conformities
– Maintain associativity between eBOM and mBOM parts
– Visual indicators showing part reconciliation errors
New 9.1 –
BOM Compare report quickly identifying quantity
discrepancies between associated BOMs
© 2009 PTC
Digitally Define and Manage Process Plans
Enable the concurrent development of product and manufacturing processes
By providing powerful capabilities that support the
digital authoring and definition of manufacturing plans
Define process plans in terms of sequences and operations to
describe how a part is manufactured, assembled or inspected
– Define plant-specific process plans including part and
resources allocations, standard procedures, documents,
time breakdowns
– Define alternate process plans for the same part
– Reuse standard process plans from a standards library
Leverage 3D designs
– Allocate parts and resources directly from 3D
– Automatically generate 3D manufacturing mockup of the
process plan and view the in-process state of an assembly
Ensure process plan completeness
– Visual indicators showing parts remaining to be allocated
– Part allocation report listing parts with allocation issues and
parts that remain to be allocated
New 9.1 –
Review and analyze process plan definitions in an easy-touse, interactive Gantt chart, with resource loading and usage
© 2009 PTC
Digitally Define and Manage Manufacturing Resources and Standards
Re-use proven manufacturing plans, standards and knowledge and
plant A
systematically drive manufacturability
By providing powerful capabilities that
support the digital definition and management
of manufacturing resources and standards
Define and share a common libraries of both physical
manufacturing resources and human skills
Define and share a common libraries of standardized and
normalized processes
Supplier 1
...
...
work area
work cell
...
work
center
tooling
process skills
material
work
center 1
work
center 2
mandatory
optional
tool 1
tool 2
– Define a standard set of operations that can be used
and/or references within multiple process plans
– Define manufacturing capabilities indicating how the
process can be executed in terms of resources,
documentation and standards
Define technical compatibilities and enforce manufacturability
– Indicate how resources and/or manufacturing capabilities
must, can, or cannot be combined together
Manage the relationship between a resource and its CAD
design
– facilitates the creation of visual aids that include both
parts and resources
© 2009 PTC
Dynamically Generated Visual Work Instructions
Improve production ramp-up, reduce scrap and rework and improve quality
By providing powerful capabilities that dynamically
generate rich shop floor instructions
Accurate Work Instructions, on demand, according to the
process plan configuration
Eliminate discrepancies between the process definition and
the work instruction used on the shop floor
Can be accessed from the shop floor via a web browser
Navigate to Windchill detail
object pages from work
instructions via hyperlinks
New 9.1
– Set any image as
illustration within the Work
Instruction
Op
030
Sequence Main
Op
025
Sequence 1 (Parallel)
Op
025
Op
035
Sequence 2 (Alternate)
Process Plan
and Operation Headers
Embedded 3D information
– Directly interact with
embedded ProductView
3D visualization
Op
020
Op
010
Work Center
Visual Annotation
Time Breakdown and Description
Allocated Parts
Allocates Resources and
Documents
Change and Configuration Information and History
© 2009 PTC
Integral Change and Configuration Management
Reduce change cycle time, cost of change and fully manage manufacturing configurations
By providing robust data control services such as
change and configuration management as well as
enabling end-to-end process automation
Manage manufacturing changes and configurations with full
traceability and history of changes
– Configure part numbering and versioning schemes
– Track configuration by baseline, lot, serial effectivity and date
– Problem reporting, deviation/waiver requests, change
requests, change notices and change activities
Standardize, automate the change with robust workflow engine
– Repeatable, consistent and predictable processes including
automatic change routing and task notification
– Streamline and continuous change process between
engineering and manufacturing
Facilitate change impact
– Visibility to engineering changes and related product
information ensure accuracy and speed of changes
– Change Visual indicators, Reports and Navigate relations
New 9.1 • Easy to use “Related Manufacturing Item” Action
© 2009 PTC
Windchill MPMLink 9.1 - Integration to Production Systems
New 9.1
Efficiently communicate and ensure accurate and on-time availability
manufacturing planning data to the enterprise
Publish MPMLink objects via Windchill ESI or
Windchill ERP Connector
–
–
–
MBOMs
Windchill
• Parts
• eBOM
• mBOM
• Change
• Process Plans
• Documents URL
(Work instructions)
• Tooling
• Skills
• Process Material
Windchill ESI
(or) ERP Connector
By automating exchange and sharing of
manufacturing deliverables using secure
and reliable enterprise system integration
technology
Production Systems
(ERP/MES)
Process Plan, Sequence and
Operations
Tools, Skills, Process Materials
OOTB Integration to SAP and
Oracle Manufacturing
Flexible and open framework for
integration to other systems
© 2009 PTC
Agenda
What is Manufacturing Process Management?
Scope, definition and challenges
PTC’s Windchill MPMLink
Part of PTC’s Manufacturing Solution
History
Key capabilities
Summary
© 2009 PTC
Windchill MPMLink key capabilities …
….. enabling Concurrent Product and Process Development
An integral part of the
Product Development
System
Digital definition and
management of process
plans
Associative eBOM to
mBOM management
Digital definition and
management of manufacturing
resources and standards
Dynamically generated
visual work Instructions
Integral change and
configuration management
Streamline release to
Manufacturing
Windchill PDMLink & MPMLink
eBOM
NEW
Part 1
REVISION
Part 2
Rear Frame
Part 3
Part 4
Support
Sub-Assy
Op
020
Op
030
Op
040
Builds
Illustrations
Textual Description
Time Breakdown
Part 1
Part 2
Consumed
Part List
Operated on
Resource List
Plants
Part 8
Part 9
Resources
Performed
with
Lines
...
Windchill ESI
(or) ERP Connector
Op
010
Vehicle mBOM
Equivalent
Production Systems
(MES/ERP)
Vehicle eBOM
Frame Assy
Op
025
Process
Plan
mBOM
Support
Tooling
Work
Center
Skills
Process
Material
© 2009 PTC
Windchill MPMLink key capabilities …
…. driving value and addressing manufacturing pain points
Remember the
pain points?
Remember the
market pressures?
Challenges
TheBenefits
need to…
 Disconnected engineering,
manufacturing & production teams
 Difficulty to find and re-use proven
manufacturing processes and resources
 Struggling to provide accurate manufacturing
information to production on-time
 Paper based processes and manual tools
(Word, Excel, ..)
 Disconnected legacy systems
 Reach faster ramp-up, shorter development
cycles and quicker time-to-market
 Manage increased product variability and
complexity
 Manage and operate in a globalized supply
chain
 Improve operational efficiency and excellence
 Meet cost targets
 Achieve first time quality at reasonable cost
Addressed
by…
Driving…
Enabled by…
Manufacturing Initiatives
PTC’s PLM-Enabled
Manufacturing Capabilities
© 2009 PTC
Windchill MPMLink ključne karakteristike…
…. driving value and addressing manufacturing pain points
Manufacturing Initiatives
 Manufacturing data and
deliverables managed as true
enterprise master data
 Upravljanje i ponovna upotreba
proizvodnih planova, standarda i
znanja
 Istovremeni razvoj proizvoda i
procesa proizvodnje
 Leverage 3D digital design
 Enable end-to-end change
process automation and control
services
 Efficiently communicate
manufacturing planning data to
the enterprise
 Systematically drive
manufacturability
 Enable Collaboration and
securely exchange information
with suppliers
 Enforce product and process
compliance and traceability
 Embrace a manufacturing
philosophy
Windchill MPMLink ključne
karakteristike
 An integral part of the product
development system
 Associative eBOMs and mBOMs
 Digitally define and manage
process plans
 Digitally define and manage
manufacturing resources and
standards
 Dynamically generated visual
work instructions
 Integral change and
configuration management
Prednosti
 Reach faster ramp-up, shorter
development cycles and quicker
time-to-market
 Manage increased product
variability and complexity
 Manage and operate in a
globalized supply chain
 Improve operational efficiency
and excellence
 Meet cost targets
 Achieve first time quality at
reasonable cost
Pro/ENGINEER Production Machining
Pro/TOOLMAKER
Complete Mold Design
…
© 2009 PTC
Automotive
Automotive
Grand River Group Improves Manufacturing Process Management
with a Windchill® MPMLink™ Software Solution from PTC
Founded in 1991, Grand River Group (GRG) is China’s top motorcycle manufacturer.
GRG develops, manufactures and sells motorcycles, engines, and parts to both foreign
and domestic markets. They are the largest motorcycle manufacturer in China with a
production capacity of 3 million engines and 3 million motorcycles per year. GRG is the largest partner and export
base of Suzuki Motor Corp. in China. Based in Jiangmen City, GRG has over 9,000 employees.
BUSINESS INITIATIVE
 Grand River Group wanted to shorten their time to market by improving their manufacturing engineering
process in order to accelerate the engineering to manufacturing change process, improve reliability of
manufacturing data and standardize process plans and work instructions
SOLUTION
 PTC Global Services implemented Windchill PDMLink, Windchill MPMLink and Arbortext® software solutions
to streamline the creation of standardized manufacturing engineering deliverables and to implement a closed
loop process
 Processes improved: Manufacturing Process Management; New Product Introduction
 Capabilities implemented: Manufacturing Process Planning; Enterprise
Content and Process Management; Dynamic Publishing
RESULT
 Increased production and manufacturing engineering efficiency
 Improved product quality and consistency of manufacturing data
 Dramatically reduced the time to propagate a new product derivative to manufacturing
“Our PTC Windchill MPMLink solution is just the thing we need to help us improve our entire
manufacturing process.”
Dai JunXiang, Grand River Group
© 2006 PTC
Hvala