Computer Network in
Manufacturing System
Nanang Ali Sutisna
Master Eng. in Computer Integrated Manufacture
Senior PLM Consultant, IBM Indonesia
Senior Manager, Product Development
Multistrada Arah Sarana
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e-Manufacturing Systems
Suppliers/
Vendor
Customer Support
Human
Resource
ISO Approval
Review,
Design Release
•
• Supplier chain • Pre/Post Sales Support•
• Purchasing
•
•
Digital Design Review
View & Markup
Recognition
Audit
•
•
•
•
Sales &
Marketing
Account / Finance
• Costing
Training
• Define
Corporate Communication
incentiv
Staff Development
e
Virtual Learning
program
•
•
•
•
•
BOM
e-Manufacturing
Engineering
Design
• CAD/CAM
• CAE / FEA
• Prototyping
IT Research &
Development
• Technology
• Methodology
• Integrating
Factory Manager/
Production
Planner
•
•
•
•
Manufacturing/
Assembly
Shop floor
Quality Control
• Product Assembly/
Actual vs. schedule
• Defect Analysis
Disassembly Sequencing
Scheduling
• Quality Control
• Robotic/Work Cell Animation
Work-to-lists
• Digital Factory
Route cards
PLM
Quick Response
Marketing Proposal
Easy to quote
Presentation
Product Launch
Distribution
• Fulfillment
• Delivery
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Product Lifecycle Management
Product
Engineering
Lifecycle Management &
Decision Support
Manufacturing
Engineering
PLM
PLM is a set of capabilities that enables an enterprise to effectively and
efficiently innovate and manage its products and related services throughout
the entire business lifecycle, from conception through recycling or disposal.
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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).
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Production System
Production System
Facilities
Facilities:
- Factory
- Equipment
Manufacturing
Support
Systems
The facilities of the production system
consist of the factory, the equipment in
the factory, and the way the equipment is
organized.
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.
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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.
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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.
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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.
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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
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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:
1. Low production: Quantities in the range of 1 to 100
units per year
2. Medium production: Quantities in the range of 100 to
10,000 units per year
3. High production: Production quantities are 10,000 to
millions of units per year
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Product variety
Product Variety vs Production Quantity
Low Prod.
Medium
High Prod.
100
10,000
1,000,000
Production quantity
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Facility and Layout
Fixed Position
Layout
Process
Layout
Product variety
Cellular
Layout
100
10,000
Production quantity
Product
Layout
1,000,000
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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
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Digital Manufacturing
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Today’s Business Requirements
Drive 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.
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Evolution of the Design/Build Process
Knowledge
Capture
Technological Advance
Design & Validation of
Manufacturing
Processes
Digital Mockup
Digital Manufacturing
3D
2D
Integration of Product
Design and Production
Process Design
80s
90s
2000
2006…..
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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. “
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Where Does Digital Manufacturing Fit?
Product Lifecycle: Design/Build/Automate/Maintain
Product Domain
Org
R&D
Processes
Materials
& Product
Research
Design
Engr
Product
Design
CAD/CAE (Digital Def.)
Function
(Systems)
Specs, E-BOM, M-BOM
Production Domain
Mfg Engr
Process
Planning
Industrial Engr
Work Flow,
Mfg
Processes
Controls/Tool
Engr
Factory Operations/
Production Systems
Design,
Produce
Tools, Jigs,
Fixtures, &
Automated
Systems
Obtain, Operate, Control,
& Maintain Equipment &
Automated Systems to
Manufacture Products
Digital Mfg/Production Process Design, Virtual
Factory Simulation
CAM/NC
Automated Assembly
Operations Mgmt
Scheduling
Resource Mgmt
Mfg Intelligence
Q/A
Collaborative PDM
Visibility
PLM Solutions: Interoperability & Collaboration
Supply Chain
Operations
Engineering
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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.
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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
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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
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Global Manufacturing Operations
Enterprise Infrastructure
Operations Infrastructure
Design/Engineering Infrastructure
= Manufacturing Node
= Design Node
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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 Endof-Life
Let Business Requirements Drive Technology Solutions
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Today’s Dynamic, Demanding Environment
Places a Premium on Information and Synchronization
Industry
Classic MES
New Requirements
Semiconductor
Complex Routing, Resource
Allocation, Quality, WIP Tracking,
etc.
Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Business System Synchronization,
KPIs, Performance, Change Mgmt, Security,
Electronic Manufacturing History etc.
Pharmaceutical
Compliance, Quality (Direct and
Enforce Production), Electronic
Batch Records, Electronic
Signature, etc.
Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Business System Synchronization,
Performance, Change Mgmt, Security, Electronic
Manufacturing History etc
Continuous
Process
Collection of Apps: Optimization,
Historian, Advanced Process
Control, etc.
Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Business System Synchronization,
Performance, Change Mgmt, Security, Electronic
Manufacturing History, etc
A&D (Complex
Discrete)
CAPP, Quality, Resource Allocation
(Operators, Workstations, Tooling,
etc.) WIP Tracking, Traceability,
Work Instructions, NCR Resolution,
etc.
Visibility, Analytics/Decision Support, Outsourced
Manufacturing, Supplier Quality Mgmt, Change
Management, Security, Electronic Manufacturing
History, etc
Automotive
Supplier
Quality, Resource Allocation
(Operators, Workstations, Tooling,
etc.) Work Instructions, Just-in
Sequence Manufacturing/ Packing/
Shipping, Error-proof Packout and
Labeling, etc.
Visibility, Analytics/Decision Support, Orchestrate
Inventory Replenishment by Operation,
Traceability and Recall Management, Business
System Synchronization, Performance, Change
Mgmt, Security, Electronic Manufacturing History,
etc
Automotive OEM
Visual Alarms, Stack Lights, and
Marquees, Line Control &
Broadcasting, Supplier Component
Sequencing, etc.
Visibility, Outsourced Manufacturing, Global
Manufacturing, Business System Synchronization,
Performance, Change Mgmt, Security, Electronic
Manufacturing History, Traceability and Genealogy,
etc
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CMM Applications Map
Let’s Get on the Same Page re: MES and OM
Business
ERP
FIN
HR
CRM
SCM
Suppliers
Customers
Enterprise Infrastructure
Gen 4
CAD
CAM
MPM
WMS
MI
Quality
MES
Sched
EAM
HMI
MES Gen 1
(Standalone, IndustrySpecific Application)
Equipment &
Automation
Production
(SOA)
TMS
Operations Infrastructure
T&A
etc.
Lean/CI
Operations
Gen 3
(Integrated Apps,
Management
Infrastructure, &
Connectivity)
MES Gen 2
(Collection of Applications)
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Production Mgmt Systems are Extension of PLM
Product Lifecycle Processes
Build
Design
Automate
Maintain
Manufacturing
Processes
Digital Manufacturing Solutions + MES
Create
Processes
Plan
Processes
Engineering Design
Simulate & Validate
Processes
Execute
Processes
Validate
As – Built Records
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PLM Integrated with Shop Floor Execution
ERP
Tailored Work Package
“As Designed”
Process Data
Process
Creation
• E-BOM
• Process Configuration
Production Mgmt
• Work Instructions
• Work Flow Routing
• Operations Scheduling
• Shop Floor Requirements
• M-BOM
• Data Exchange
• Bill of Process
• Performance Analysis
• Product Config.
• Quality Assurance
Shop Floor
Execution
(MES)
“As Built” Records
• Labor/Parts/Tooling
Product
Design
“As Designed”
Product Data
PLM
Maintenance
& Support
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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
3D Models
E-BOM
Digital Manufacturing/MPM
Process
Planning
Process
Simulation & Validation
Process
Modeling
Shop Floor Execution (MES)
Process Models,3D
Simulations, Work Order
Instructions
Process
Execution
E-BOM
Master Routings, M-BOM
Quality
Assurance
Unit Data &
Work History
Data Vault
Work Order
Release
Material /
Parts
Job Sign
On/Off
Work Orders
Inventory
Release & Status
Mgmt
Production
Scheduling
Labor
Reporting
Work Order
Status
ERP
Invoicing
Shipping
Financials
Parts
Purchasing
Receiving
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Merging Virtual Simulation and Automation
Simulation to Control: Making the Final Step from
Virtual to Real
Process Design
Virtual Simulation
Collaborative Environment
for Control Design & Digital
Validation
Production System
Real Operations
Digital Validation
Produces Real Control
Execution
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Interoperable Virtual to Real-World Environment
for Manufacturing and Control Engineering
VIRTUAL
Control
Design
DESIGN
Mfg Process
Modeling
PHYSICAL
Code
Generator
Target PLC or Controller
Platform
Developed with Automation providers
VALIDATE
Post-Processed
Machine Logic
Production
Simulation
Validate
Control
PLC/Controller
HMI
OPC Client/Server
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Merging Virtual Design and Automation Shortens
Time to Launch
3D Mechanical
Design
Control
Engineering
(Design)
Line Building
& Installation
Control
Engineering
(Commissioning)
Current workflow….
Workflow…with Virtual Automation
3D Mechanical
Design
Production
Startup
Line
Building
Control
Eng.
Control
Engineering
Validation & Virtual
Commissioning
Production
Startup
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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
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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
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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
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Thank You.
For more information, contact the author at
dslansky@arcweb.com or visit our web pages at
www.arcweb.com
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