Optimos Prime 13 01 16 - University of Cambridge€¦ · Simulaon model Development of Distributed...

OPTIMOSPRIME:OrganisingProduc,onTechnologyIntoMOstResponsive

States-3DPRIntMachineEnabledNetworksDuncanMcFarlane,RonanDaly,Maurizio

Tomasella,RengarajanSrinivasan,AlanThorne,AlenaPuchkova,MudassarAhmed

3DP–RDMWORKSHOP

Cambridge,14January2016

Contents

•  Introduc,on•  Aims,Objec,ves,Approach•  IndustrialPrac,ces•  AcademicLiterature•  ControlRequirements&Architectures•  ExperimentalStudy•  GoingForward

Introduc,on•  Challengesindistributedmanufacturingsupplynetworks:–  Leanforcostandefficiency–  Responsivenesstodisrup,ons

•  Increasingneedtoevaluateaddi,vemanufacturingcapabilityfor:–  Flexibilityandresponsiveness–  Reconfigurability–  Customisa,on– Understandingtheabilitytointegratewithconven,onalmanufacturingsystems

Contents

•  Introduc,on•  Aims,Objec,ves,Approach•  IndustrialPrac,ces•  AcademicLiterature•  ControlRequirements&Architectures•  ExperimentalStudy•  GoingForward

AimsandObjec,ves•  Howcan3Dprintenableddistributedmanufacturingenvironmentproviderapidresponsecapability?– Howeffec,velycan3Dprin,ngbeusedtoaddrapidresponsecapabili,estoconven,onalproduc,on?

– Howcan3Dprin,ngsupport3rdpartysparesandrepairservicesintandemwithaproduc,onfacility?

– Howcanlatecustomisa,oncarriedoutbyretailerbepartofanintegratedproduc,onprocess?

–  (iv)Howcandistribu2onofproduc2onfacili2esbemanagedwithinasingle[cloudbased]produc2oncontrolsystem?

ApproachLiteratureReview

•  Compare3Dprin,ngwithconven,onalmanufacturing

•  Impactof3DPinenablingresilientsupplychainopera,ons

•  Controlandautoma,onrequirements

•  Technicalrequirementsfor3DP

•  Measuringthebenefitsofopera,onalbenefits

Developmentofpoten,alapplica,onscenariosfor3DPindistributedmanufacturing

Developmentofautoma,onandcontrolcapabilityfor3DP

Simula,onmodel

DevelopmentofDistributedLabDemonstrator

Outputs•  Feasibilityofemployingdistributed3DPinconven,onalmanufacturingenvironments

•  Evalua,onofcontrolprinciplesandopera,onalefficiencies

•  ChallengesandFutureResearch

ApproachLiteratureReview

•  Compare3Dprin,ngwithconven,onalmanufacturing

•  Impactof3DPinenablingresilientsupplychainopera2ons

•  Controlandautoma,onrequirements

•  Technicalrequirementsfor3DP

•  Measuringthebenefitsofopera2onalbenefits

Developmentofpoten,alapplica,onscenariosfor3DPindistributedmanufacturing

Developmentofautoma2onandcontrolcapabilityfor3DP

Simula,onmodel

DevelopmentofDistributedLabDemonstrator

Outputs•  Feasibilityofemployingdistributed3DPinconven,onalmanufacturingenvironments

•  Evalua,onofcontrolprinciplesandopera,onalefficiencies

•  ChallengesandFutureResearch

Contents

•  Introduc,on•  Aims,Objec,ves,Approach•  IndustrialPrac,cesReview•  AcademicLiterature•  ControlRequirements&Architectures•  Applica,onStudy•  GoingForward

IndustrialPrac,cesOverview

•  Focusonlyonaspectsoftodaysdevelopments&prac,ceswhichimpacton–  Integra,on– Automa,on– Controllability

•  Notacomprehensive3DPreview!

AMApproaches&Integratability

[InkjetResearchCentre,IfM]

Adaptedfromwww.ul,maker.com

ExtrusionJedng

[A.Wheeler,"CloudDDM'sNewStrategicEnd-of-Runway3DPrin,ngService",Engineering.com,July30th2015.]

[www.cloudddm.com]

•  ManychallengesspecifictoeachAMtechniqueinmaterialmanagement,componentremoval/transfer,post-processing,valida2on

•  Fixturing/Sensingcapabili,estotrackopera,ons•  supportmaterialin3Dprintedparts->impactonautoma,on•  Ongoingmovestosupportdistributedmanufacturingbyautoma2on:

“ThreeSignsthattheFullyAutomated3DPrin2ngFactoryIsComing”DavideSher,3DPrin,ngIndustry,2015“Louisvillefactory:100printers,3employees”ParijaKavilanz,CNNMoney,2015.“HowCloudDDMIsPuSngSpeedandAutoma2onInto3DPrin2ng”JoshMings,SolidSmack,2015

Automa,onReadiness

Comms&ControlPoten,al

• Needfornetworking/communica,onfacility• Abilitytocommunicatewithinandoutsideorganisa,onalboundaries(inter/intranetworkcapability)

• Needforstandardinterfacesforcommunica,on(TCP/IP,EtherCatetc)tointegratewithconven,onaldevices/technologies

Communica,on

• Limitedcapabilityforsomwaredevelopment/controlinterfacestoexecuteandmonitortasksin3DP

• ConversionofCADrelatedfilesinto3Dprinterenabledg-codesarenotstandardisedLimitedAbilitytocontrol/communicatewith3Dprintervariesbetweenmanufacturers(opensourcedevelopmentVsproprietarytools)

Interfaces/Control

Contents

•  Introduc,on•  Aims,Objec,ves,Approach•  IndustrialPrac,ces•  AcademicLiterature•  ControlRequirements&Architectures•  Applica,onStudy•  GoingForward

LiteratureOverview

•  Vastliteratureon3DP/AMtechnologiesandcapabili,esc.f.conven,onal

•  Lioleornoliteratureoncontrol/automa,onof3DP/AMtechnologies

•  Lioleornoliteratureonintegra,onof3DPwithconven,onalmanufacturing

•  Significantliterature[not3DPspecific]on–  distributedproduc,onnetworkdesign–  Distributedproduc,oncontroland–  Leanv/resilienceindistributedsupplychains

Prac,ceslightlyaheadofliterature

Op6maldesignofdistributednetworks[including3DPfacili6es]

Loca6on:offshoringvsreshoring

[4]DaSilveira,G.J.C.(2014).Anempiricalanalysisofmanufacturingcompe66vefactorsandoffshoring.Interna'onalJournalofProduc'onEconomics150,163–173.[5]Gylling,M.,Heikkilä,J.,Jussila,K.,andSaarinen,M.(2015).Makingdecisionsonoffshoreoutsourcingandbackshoring:Acasestudyinthebicycleindustry.Interna'onalJournalofProduc'onEconomics162,92–100.[6]Ellram,l.M.,Tate,W.L.,andPetersen,K.J.(2013).OffshoringandReshoring:AnUpdateontheManufacturingLoca6onDecision.JournalofSupplyChainManagement49(2)[7]DeTreville,S.,Trigeorgis,L.(2010).Itmaybecheapertomanufactureathome.HarvardBusinessReview88,84–87.

Op,malnumberandloca,onofresources

[8]Kalaitzidou,M.A.,Longinidis,P.,Tsiakis,P.,andGeorgiadis,M.C.(2014).Op,malDesignofMul,echelonSupplyChainNetworkswithGeneralizedProduc,onandWarehousingNodes.Industrial&EngineeringChemistryResearch:53(33),13125-13138.[9]Pasandideh,S,H.R.,Niaki,S.T.A.,andAsadi,K.(2015)Op,mizingabi-objec,vemul,-productmul,-periodthreeechelonsupplychainnetworkwithwarehousereliability.ExpertSystemswithApplica2ons42(5),2615-2623.

Op,malflowinthenetwork

[10]Ventuta,J.A.,Valdebenito,V.A.,andGolany,B.(2013).Adynamicinventorymodelwithsupplierselec,oninaserialsupplychainstructure.EuropeanJournalofOpera2onalResearch230(2):258-271.

Flexibility(cap’yrealloca,on)

[11]Rosenbaum,I.,Ben-Gal,I.,andYechiali,U.(2013)Nodegenera,onandcapacityrealloca,oninopenJacksonnetworks.IIETransac2onsVol45,Number3,259-272.

e.g.Op,malNetworkDesign

Mainstreamsupplychainnetworkstructure Generalizedstructure

Innova,ons:1)GeneralizedP/Wnodeswhosefunc,onisnotaprioriassumed2)Collabora,onamongP/Wnodes

Contents


ControlRequirementsfor3DPinDistributedProduc,onNetwork

•  (R1)Coopera6on—Effec,vecommunica,onb/w3Dprintersonanetworkandabilitytoresolveconflicts

•  (R2)Flexibility—Controlfeaturethatoffersliolechange-over,me/effort•  (R3)Re-configurabilityofOpera6ons—Changeofopera,onsover,me/order

–  Tackledisrup,ons(delaysona3DP)andtheop,ontore-configurethenetworktomeetgoals(delivery,me)

–  Priori,sa,on—fulfilsubsequentorders(insteadofwai,ngfor10unitsofplas,cs,makeuseoftheavailable8tomeet2otherordersrequiring3and2unitsonly)

•  (R4)Self-organisa6onCapability–  Autonomouslyaccommodatesachangeinduedate/rushorder/quickerdelivery/

premiumqualityofsomeparts.–  Autonomouslyaccommodateslatecustomisa,onrequestthatcannotbeproduced

byasinglefacilityonitsown.•  (R5)Seamlessintegra6on:

–  Level1-Distributedopera,onwithincompany–  Level2-Distributedopera,oninvolvingmul,plecompanies.

Ini,alSystemArchitecture[SingleOpera,on]

Control

Command

Respon

se

AMQP

CONTROL&MANAGEMENT

RawDataLogicOpera,onalLogic(EventIden,fica,on)

Tracking

DatabasesCo

mmand/Re

spon

se

Capture&

Que

ry

TRACKING

Opera,on/PLCLayer

OPCServer

ResourceLayer

Devicenet

Ethe

rnetIP

LOCALEXECUTION

TargetDistributedSystemArchitecture

Tracking&EventLogic Control1

Databases

AMQP

Execu,onLayer

ResourceLayer

Control2

Execu,onLayer

ResourceLayer

Execu,onLayer

ResourceLayer

Control3

CLOUDSYSTEM

LOCALEXECUTIONSYSTEMS

AGENTBASEDCONTROL

Contents


Applica,onScenariosObjec6ves(i)Howeffec,velycan3DPrin,ngbeusedtoaddrapidresponsecapabili,estoconven,onalproduc,on?(ii)Theextenttowhich3DPrin,ngsupports3rdpartysparesandrepairsservicesintandemwithaproduc,onfacility?(iii)Theextenttowhichlatecustomisa,oncarriedoutbytheretailerforexamplecanbepartofanintegratedproduc,onprocess?(iv)Howcandistribu2onofproduc2onfacili2esbemanagedwithinasingle[cloudbased]produc2oncontrolsystem?

Sparepartmanagementinproduc,on

Reac,vepartreplacement

Customisa,onofproduct

LateCustomisa,onofproduct

All

Scenarios

Example:ProductCustomisa,on•  Anorderfortengearboxesarrives•  Eightgearboxeswilluseconven,onalgearpairs•  Fourofthesearerequiredtohaveacolouredcapaoachedtothe

gearboxwiththeleoerM•  Twogearboxeswillusenonstandardgearsets[althoughusual

shamposi,ons]•  3DPacanmanufacturebothrequiredsetofgearsbutisexpensive•  3DPbcanproducethesmallerbutnotthelargergear.•  3DPbcanproducethecolouredcapsrequired•  Theproductsarerequiredtobeassembledinoneweek•  Thereisnowheretostorethecolouredcapssotheyneedtobe

producedJIT•  Thecustomerrequires100%inspec,onofthetwononstandard

gearboxes.

TestImplementa,onatIFM

Machining/ComponentManufacture Assembly

Conven'onalLocalManufacturer

PartsSupplier

RawMaterial

Conven'onalUpstreamSupplyChain

PartsSupplier

RapidResponse3rdPartyManufacturingServiceProvider

Warehouse/Retailer3Dprin,ngserviceProductcustomisa'on

Customer/3rdpartydesigner

Productcustomisa'onRequirements/Designs

CloudBasedDistributedControlofProduc'on

CloudServiceProvider

WAREHOUSE

MAINLAB DESIGNSTUDIO

WORKSHOP

FLUIDSLAB

SERVERWITHINIFM

1 2 3 4 5

T-Bar

A520 M6i M6i

6 7 8

LR Mate

Mazak

Inspection

Trolley

Inspection

Trolley

Shuttles

ProductCustomisa,on

Plas,cormetalgears

CustomisablenameplateOngearbox

Proof-of-conceptDemonstra,on

1 2 3 4 5

T-Bar

A520 M6i M6i

6 7 8

LR Mate

Mazak

Vac-Form

Inspection

Trolley

Inspection

Trolley

Shuttles

Part Manufacture Sub Assembly Final Assembly

3DP

3DP

ProofOfConceptDemonstra,on

•  Demonstra,ons– GearPrin,ng– GearBoxAssembly

– LateGearBoxCustomisa,on

ProofOfConceptDemonstra,on

•  Demonstra,ons– GearBoxPrin,ng

– GearBoxAssembly

– LateGearBoxCustomisa,on

DemoControlArchitectureInternet/Cloud

printerYprinterX

a.  Selec,onofsuitable3Dprinterfirm/Suppliermanagement

b.  Decision/Choicetodecidewhentoorderrushparts

c.  Customisa,onmanagement

Conven,onalManufacturingResources

LowLevelDeviceControl–TaskExecu,on

HighLevelControl–Planning/Scheduling/Ordermanagement/Disrup,onmanagement

Tradi,onalManufacturingControlArchitecture•  Distributedcontrol•  Centralised/Hierarchical

control•  Hybrid/Semi-heterarchical

control

1 2 3 4 5

T-Bar

A520 M6i M6i

6 7 8

LR Mate

Mazak

Inspection

Trolley

Inspection

Trolley

Shuttles

3DP–Conven,onal:controlInterface

JADEAgentEnvironment

Webserver(OctoprintS/W)

HTTPmessaging

Serialport/USBcomm

Internet/Cloud

TCP/IP

Conven,onalManufacturingResources

LowLevelDeviceControl–TaskExecu,on

JADEAgentEnvironment

TCP/IP

OPCMessage

Device-net/IO

Tradi,onalManufacturer

Contents


Next Steps

•  Further developments of distributed lab demonstrator –  Development of distributed intelligent control –  Assessment of additional scenarios and operational efficiencies.

•  Modelling of resilience in distributed manufacturing environments enabled by 3DP

•  Larger proposal to investigate 3DP integration / automation / cloud control requirements & limits

Simulation of 3DP and conventional manufacturing

Conventional manufacturing 3D printing

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