DIGITAL TRANSFORMATION OF PLM TO ENABLE … speaker… · Life Cycle of Long Living Products ......

Prof. Dr.-Ing. Rainer Stark

Director of the chair Industrial Information Technology Technische Universität BerlinSchool of Mechanical Engineering and Transport SystemsDepartment of Machine Tools and Factory Management (IWF)

Director of the division Virtual Product CreationFraunhofer-Institute for Production Systems and Design Technology (IPK)

DIGITAL TRANSFORMATION OF PLM TO ENABLE INTELLIGENT SYSTEMS & LIFE CYCLE ENGINEERING

PLM 2017 Conference, July 10th, Seville, Spain

1

AGENDA

1. PLM Status today – cause for action!

2. What drives product creation process today & tomorrow?Transformation & Innovation in Engineering Activities

3. Selected Engineering Scenarios

Scenario 1 – Smart Factory, Digital Twin and Information Factory

Scenario 2 – PLM for Digital Factory and Industrie 4.0

Scenario 3 – Smart Manufacturing and Virtual Commissioning

Scenario 4 – Smart Product Engineering

4. Summary & Outlook

2

Life Cycle of Long Living Products - Airbus A320 fleetIntroduction

1981 1984 1987 1988 2006 2014use use 2027 2050

Go conceptphase

Start ofdevelopment

1st prototype

Start ofuse

~26 years of use

A320neo refresh

~36 yearsof use

End ofproduction

End oflife

Start ofrefresh

Product Life Cycle ~70 years

AIRBUS S.A.S. 2014 – photo by master films / A. DOUMENJOU

What does thismean for Life

Cycle Engineering?

3

Life Cycle of Long Living Products - Life Cycle PhasesIntroduction

Begin of Life Mid of Life End of Life

Development ~8 years

Production ~40 years~64% of use phase

Runout ~23 years~36% of use phase

Use Phase

Product Life Cycle

No guarantee on stock

End ofproduction

Start ofproduction

Parts for production on stock

Need of parts for MRO

4

Begin of Life Mid of Life End of Life

Development ~8 years

Use Phase

Product Life Cycle

End of production

Start of production

Life Cycle of Long Living Products - Life Cycle PhasesIntroduction

no guarantee on stockparts for production on stock

Need of parts for MRO

Fuselage / Hull / Body

Engine

Few long living parts

Sensors

Actuators

Many exchangeable parts

Mechanics

Electronics

I/Os

Interior

5

© Fraunhofer

Key Activities in Life Cycle Engineering (LCE)Introduction

PLM Product Lifecycle Management

CAD Computer-Aided Design

CAE Computer-Aided Engineering

CAM Computer-Aided Manufacturing

PDM Product Data Management

ERP Enterprise Ressource Planning

CRM Customer Relationship Management

SCM Supply Chain Management

CMMS Computerized Maintenance Management System

LCA Life Cycle Assesment

Challenge:Data & Information exchange betweenOEM and customer for MRO supportand Design changes

6

© Fraunhofer

LCE-based design – Holistic consideration of influencing factorsProspective Activities

Heterogeneous IT landscape

Interface problems

Industry 4.0 and Smart

Service World

Big Data

Cyber Physical Systems

Increasing demand for information

Processautomation

Newtechnologies

Internet ofThings

Traceability

Cloud services

Digitalfactory

Platform independencyProduct Service

Systems

Individua-lization

7

Evolution of digitalization in engineeringProduct to system to lifecycle-thinking

1850 1900 1950 2000 Year

Co

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eve

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2010

DIGITAL

TRANSFORMATION

Systems

Engineering

Technical

Design

Methodical

Design

Virtual Product

Creation & Product

Modelling

NC

Programming

Digital Factory &

global digital

Collaboration

Machine

Construction

INTEGRATIVE WORK

ON THE SHOP-FLOOR

8

2D Zeichnung

Try Out

2D drawing

Protoype Build

Final product Final product

3D

Design

Physical

Mok-Up

Final product

2D drawing 3D Design

2D drawing

Design Entwurf

3D Design

2D drawing

Design

concept

3D CAE-

simulation

Preseries-

prototyp

Digital

Mok-Up

Physical

Mok-Up

Preseries-

prototyp

Digital

Mok-Up

Final product

Physical

Mok-Up

Preseries-

prototyp

Final product

Component-

prototyp

3D Design

2D drawing

Design

concept

3D CAE-

simulation

Digital

Mok-Up

Multidomain.-

simulation

Physical

Mok-Up

Preseries-

prototyp

Final product

Component-

prototyp

3D Design

2D drawing

Design

concept

3D CAE-

simulation

Digital

Mok-Up

…

Final product

Vision 0

Prototypen

Multidomain.-

simulation

…

3D

Design

Physical

Mok-Up

Design

concept

Digital

Mok-Up

3D CAE-

simulation

Component-

prototyp

Multidomain.-

simulation

Evolution of digitalization in engineering

Digital

Real

Necessity:

Replacing physical

prototyping will result in

experience driven digital

validation & verificationFocussing on engineering, testing,

validation & verification

(time, cost, knowledge, competence, etc.)

Yesterday with focus on

physical models,

today and tomorrow with

focus on digital models

9

2D CAD CAM/CNC File saving Tape exchange Analytical calculation

(R)evolution of the „Virtual Product Creation Operating System“(timeline: lead automotive OEM)

Level 11975 - 1985

10

3D CAD CAE 1 (MBS/FEA) TDM/EDM MRP/PPS File transfer


Level 21985 - 1995

Level 11975 - 1985

11

3D Parametric CAD CAE 2 (CFD) PDM Product Structure Triggered data exchange DMU VR Manuf. CAE (robot simulation) E/E KBE


Level 21985 - 1995

Level 11975 - 1985

Level 31996 - 2003

12

3D Template CAD Global PLM (ERP link, Manf. PPR) Configuration BOM driven DMU Design in Context Real time ray-tracing CAE data management Digital Factory set-up (e.g. PPR linkage) New global collaborative engineering

solutions


Level 21985 - 1995

Level 11975 - 1985

Level 31996 - 2003

Level 42004 - 2013

13

Summary of PLM status today and cause for action!Code for PLM Openness (CPO): Openness in IoT / Industry 4.0

… manufacturing of the future will fulfill individual customer needs by a

collaborative and agile network of capabilities

While todays production is linearly organized and optimized within the boundaries of organizational and system siloes…

RIGID PAST SMART FUTURE

Source: Atos, 2016 Source: Atos, 2016

14

AGENDA


2. What drives product creation process today & tomorrow? Transformation & Innovation in Engineering Activ ities







15

What is smart?

S m a r t means the intelligent junction of technology, environment and people to create sustainable growth within a highly global andcompetitive market.

The difference between general trend and specific approach

Environment

People Technology

S : Sustainable + context-Sensitive

M : Multi-disciplined + Model-Based

A : Adaptive + Autonomous

R : Robust + Rewarding

T : Teamplay with Technology

16

Immersive modeling & reviewing Smart Systems Engineering X-discipline Functional Mock-up Smart Hybrid Prototyping Process enabled PLM

Real time Functional Product ExperienceMobile PLMSmart Data / Big Data „PLM“Industrie 4.0: Digital Twin


Level 21985 - 1995

Level 11975 - 1985

Level 31996 - 2003

Level 42004 - 2013

Level 52014 - 2020

new

new

17


Next generation engineering workspacePersonal digital avatar supportProduct Lifecycle Knowledge Intelligence (PLKI)Industrie 4.0 Smart Engineering (incl. semantic engineering analytics& Digital Twin) Immersive Engineering Reality (real-time product/plant adaptation)Sustainable Engineering andManufacturing Real time Digital Manufacturing Feasibility

Level 21985 - 1995

Level 11975 - 1985

Level 62020 - 2025

Level 31996 - 2003

Level 42004 - 2013

Level 52014 - 2020

new

new

new

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Digital TransformationAreas and challenges

DIGITAL

FACTORY

DIGITAL TWIN

OF FACTORY AND PRODUCTDATA- & INFORMATION -

MANAGEMENT

SMART

ENGINEERING

Cross-company

collaboration in

distributed locations

Horizontal integration

Challenges

Availability of data

everywhere anytime

Real-time data exchange

Increasing amount of

data

Data security & safety

Big Data to Smart Data

Different file formats

Compatibility of data

Reliability of data

DIGITAL

TRANSFORMATION

19

• Actions (activities) carried out by people and IT systems in product life

• Activities are person-specific dynamic or automated instantiations (IT activities) of the processes.

• Virtual and Physical Artefacts as well as models (data and information models)

• Are generated or manipulatedin the product life cycle by activities

• Management-, Core- andSupporting-Processes

• Organization (roles and responsibilities)

• Processes: who (role) should do what, which tools are used, and which results are expected

• Information technology andphysical tools

• The IT infrastructure includes application systems and operating resources (hardware and software).

Engineering environment

Process and Organization

Virtual and

Physical Artefacts

Toolsand

IT-Systems

Activities

Transformation in Engineering ActivitiesHolistic Model representing the engineering environment

20

Engineering environment

Process and Organization

Virtual and

Physical Artefacts

Toolsand

IT-Systems

Activities

Transformation in Engineering ActivitiesExamples

Way of workingchanges,

Agility of organisations

e.g. remote mobile work

Heterogeneous productlife cycles ,

Customization ofproducts

e.g. customers can track& customize their productduring manufacturing

The future activitiesperformed by an engineerchange:

e.g. designing parts ofan assembly remotelywith a mobile device

Emerging newtechnologies (e.g. 5G)

IT and internettechnologies areoptimized e.g. latencies decrease andbandwith increases

Trends

Global collaboration

(Model-based)Systems Engineering

Digital Twin

Industrie 4.0

Digital Transformation

Data driven Business

Information Factory

21

Definition of Industrie 4.0

With the interconnection of humans, objects and systemsdynamic, real-time optimized and self-organizing cross-company value

creation networks emerge.

Interconncection of humans, objects and systems

22

Definition of smart productsOverall context

Smart products

= CPS + Internet-based Services

E.g.: autonomic ship

Cyber-Physical Systems

(CPS) = IMP + ‘Communication’

E.g.: “Parking” assistant with ship to infrastructure

communication

Intelligent

mechatronic products

(IMP) = MP + ‘Intelligence’

E.g.: AIS supported collision avoidance

Mechatronic

products

(MP) E.g.: Steer-by-Wire

Internet of data, humans, services and things

‘SMART Products are Cyber Physical Systems with Internet-based Services ’Source: CIRP Encyclopedia of Production Engineering, 2015

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Intelligent networking in the factory ICT of the future

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Physical Factory

Plants, production, processes, products

Control and command level

horizontal integration

vertical integration

Management software

production, manufacturing

Control and regulation

software

Machines and plants

manufacturing processes

Information factories:

infrastructure data and

services

Living Digital Twin

-53-

Digital Factory

Management, planning, simulation and development

Management software

enterprise

Engineering software

Product design &

development

24

Digital Factory TwinThe mission to achieve true Industrie 4.0 factories

Continuous update & augmentation ofdigital twin with shopfloor data

Simulation & digital validation of physical equipment

Capture of: Changes due to

commissioning, maintenance, reconfiguration

Process parameters Operating and machine data Quality information

Usage of information of Digital Twins: Product development Production planning Logistic planning Plant and facility

development Quality assurance Virtual validation

Digital FactoryTwin

Physical Factory

25

Five disciplines of model-based systems engineering(to be adapted to product systems, factory production systems and industry branches)

Model-based

Systems

Engineering

SIM

CMM

SLE

SDD

SEA

Systems Environment Analytics

Specifying interacting systems and describing types of interaction

System Definition & Derivation

Creating models which describe systems from different views

Systems Interaction Modeling

Modeling and simulating the behavior of the system in focus

MBSE Capability and Maturation Matrix

Gaining and mastering the necessary MBSE competencies

Systems Lifecycle Engineering

Managing and integrating system models through product lifecycle

26

Sustainable innovationTransformation of business models by adaptable architectures and smart services

Pinterest.com

Flexibility of new product architectures

Cars are evolving to living service platforms with longerusage time by utilizing flexible electronic/softwarearchitectures and reconfigurable hardware

Individual customization of vehicles, enables newbusiness models (from car manufacturer to serviceprovider)

Impact on product design

Future mobility requirements need to be anticipatedfor current products already

Feeding back usage data into product design will become a core competence imposing strong demandson mechanisms for data acquisition and analysis

New product architectures needs to reflectheterogenous innovation and technical lifecycles ofproduct parts and embedded technlogies

[1]

[1] BMW Bordnetz der Zukunft (autonews-123.de)

…

27

Summary of drivers for future PLM(compare PLM 2014 paper „Intelligent information technologies to enable next generation PLM“)

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AGENDA









29

Liv ing Digital Factory Twin

Real time convergencefrom reality and virtuality

Scenario 1 – Smart Factory, Digital Twin and Information FactoryDemonstration Cell „Smart Factory 4.0“

Hybrid prototyping

Industrycompatible

Industrial IT standards

Self-organisation

IoT & Cloud-ready

Smart dataanalyses

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Scenario 1 - Smart Factory 4.0 (Video)

31

AGENDA

1. What drives product creation process today & tomorrow?








32

Scenario 2 – PLM for Digital Factory and Industrie 4.0PLM as an enabler for Digital Twin SolutionsShell model from Digital Factory (center) towards business value (outer)

Digital Factory Twins: Multi-User VR,

Smart Factory 4.0, Hybrid Prototypes,

Testbeds/ Demonstrators

Digitization (e.g. Digital Twins

solutions) as potential driver along all levels

Digital Twin solutionsand their potential

have to be evaluated; PLM solution strategyfor digitization has to

be developed and executed

The levels of the shell model represent the different views for

PLM digitization and address the necessary change dimensions

33

Scenario 2 – PLM for Digital Factory and Industrie 4.0PLM as an enabler for Digital Twin SolutionsIntegration of Automation pyramid and RAMI into the shell model

IT-Systems and landscape

Methodsand activities

Processesand procedures

Organizationof company and automotive brands

Use, added valueand business value

Digital Factory Twins: Multi-User VR,

Smart Factory 4.0, Hybrid Prototypes,

Testbeds/ Demonstrators

RAMI covers all levels of the shell

model

Automation pyramid covers the levels from the center to

processes and procedures of the shell model

34

AGENDA






Scenario 3 – Smart Manufacturing and Virtual Commiss ioning



35

Challenges in plant manufacturing today:

Mainly sequential development processes are executed in plant manufacturing

Commissioning represents the first true integration of discipline-specific design and construction drafts during physical assembly and physical implementation of manufacturing system

Resulting in late and costly change requests and unnecessary requirements discussion during the late phases of the manufacturing system development process

Objectives for future improvements:

Definition of development processes for virtual prototypes of manufacturing systems (context: Internet of Things)

Definition of an architecture for a software framework for virtual prototypes of manufacturing systems(Functional Mock-Up with interactive Virtual Reality (iVR), virtualization of plants for early virtual commissioning)

Definition of a construction kit: provision of design models for geometry, function (kinematics and behavior model) and logic (PLC-code)

Scenario 3 – Smart Manufacturing and Virtual Commissioning (VC)

source: www.bit-automation.de

36

Engineering disciplines and additional design models for virtual commissioning


37

AGENDA









38

Scenario 4 – Smart Product EngineeringDegrees of Virtuality in Prototyping

Physical Prototyping

Virtual Prototyping

Degree of virtuality*0 1

*Virtuality is the share of virtual representation of a prototype (Milgram, 1994)

Audi A7 pilot run prototype

Digital Mock-Up of Ford Fiesta

Toyota driving simulator in Higashi Fuji Technical Center

Virtual ergonomics test bed;

Volkswagen

Prototypes have different degrees of virtuality

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Digital Cube Test Center;

TU Berlin

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Scenario 4 – Smart Product EngineeringHybrid Prototyping to Enhance User Experience

Physical Prototyping

Virtual Prototyping

Hybrid Prototyping

Degree of virtuality0 1

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High costs

High user experience

Low costs

Low user experience

Smart HybridPrototyping

to combine the advantages of physical and

digital models

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Smart Hybrid

Prototyping

Simulation Model

DMU

Haptic User-Interface

Scenario 4 – Smart Product EngineeringArchitecture of Smart Hybrid Prototyping

Virtual Prototype

Main Advantage:

Realistic interaction with the prototype

while being able to modify and analyze

design parameters within the digital

model

-20-

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Scenario 4 – Smart Product EngineeringDriving Simulator at Digital Cube Test Center Berlin

-21-

42

AGENDA









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Outlook and challenges

Funkschau.de

Collaboration in Multi-User

Virtual Reality

environment Digital validation and Smart

data analytics using digital factory twins

Assembly validation through hybrid

prototyping with haptic

devicesKnow-How

in Model-

based

Systems

Engineering

Limitless data

exchange between all IT systems

PLM solution for digital

continuity in engineering

Inno

vatio

n

Digital Transfor-mation

-58-

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Prof. Dr.-Ing. Rainer Stark

Director of the division Virtual Product CreationPhone: +49 30 39006-244E-Mail: [email protected]

Director of the chair Industrial Information TechnologyPhone: +49 30 314-25416E-Mail: [email protected]

Dr.-Ing. Kai Lindow

Department Information and Process ControlPhone: +49 30 39 00 6-214E-Mail: [email protected]

Dr.-Ing. Bernard Faneye

Department Model based EngineeringPhone: +49 30 39 00 6-125E-Mail: [email protected]

CONTACT

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Thank you for your attention!

DIGITAL TRANSFORMATION OF PLM TO ENABLE … speaker… · Life Cycle of Long Living Products ......

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