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VFF NEWS Issue  3;  October  2011   2  

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Editorial Marco  Sacco  ITIA-­‐CNR    

VFF   project   is   now   at  the   beginning   of   its  third  year  of  work.    The   partners   worked  hard   for  answering  at  t h e   i n d u s t r i a l  requirements   and   to  find   out   appropriate  t e c h n i c a l   a n d  t e c h n o l o g i c a l  soluLons   for   making  t h e i r   a n s w e r s  feasible.  

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VFF is a big project and having 30 partners collaborate and communicate was a hard work.  In   this   issue   of   the   VFF   newsleMer   all   the   modules   are  described.   In   the   image  up  here  the  modules  have  their  place   in   the   factory   process.  Discover   in   the  next   pages  the  meaning  of  the  Ltles  here  on  leQ.        

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1  Control Station for Production fine planning        PSI  The  PSI  Planning  Board  is  a  soluLon  for  producLon  planning  and  scheduling  tasks.    It   combines   powerful   scheduling   funcLonality  with   a   customable   and   easy   to   use  GUI.  The  module  is  easy  to  use  and  integrates  seamless  to  an  exisLng  environment.    

DAM: Dysfunction Analysis Module UTCN  This   module   aims   at  gathering,   filtering,  a n a l y z i n g   a n d  e l a bo r aLng   d a t a  related   to   machine  failures   and   repair  acLviLes.   The   main  objecLve  of  DAM  is  to  s u p p o r t   t h e  p e r f o r m a n c e  improvement   of   a  producLon  system,   in  parLcular   during   the  ramp-­‐up  phase.    

•  Easy  and  fast  chart/report  generaLon,  no  manual  work  

•  DrasLcally  reduced  Lme  for  the  enLre  analysis  process  

•  Improved  producLon  system  performance  

BENEFITS  •  Automated  process  for  

failure  analysis  •  Integrated   fa i lure  

results   accessible   by  one  tool  

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BENEFITS  •  OpLmal   resource   usage   in  

so lv ing   fin i te   schedul ing  problems  

•  Ov e r v i ew   b y   g r a p h i c a l  representaLons   for   planning  situaLons  in  real  Lme  

•  IntegraLon   of   producLon  process   by   interfaces   to   ERP  and  shop  floor  control  systems  

The   module   provides   decision   support   concerning   the   selecLon   of   alternaLve   producLon   line  configuraLons.  The  module  takes  into  account  the  criteria  (KPIs)  that  have  been  esLmated  for  each  alternaLve   configuraLon   and   proposes   a   line   that   can   be   considered   as   the   best   alternaLve  with  respect   to   the   specified   criteria.   The   module   incorporates   normalizaLon   of   the   criteria   and   a  weighLng  factors  methodology  in  a  user  friendly  environment.    

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1  Decision Support LMS-­‐CASP  

BENEFITS  •  Simple   and  effecLve  decision  making  based  

on  KPIs  •  SystemaLc   evaluaLon   of   producLon   line  

alternaLves  

DSM: Design Synthesis Module UTCN  The  main  objecLve  of  this  module  is  to  improve  the  Proposal  and  Design&Development  processes  and  at  the  same  Lme  to  facilitate  and  fasten  up  the  work  of  the  departments  involved  in  these  business  phases.    

•  Speed  up  the  definiLon/evaluaLon  of  the  producLon  resources  

•  Enable   quick   reuse   of   data   (other   proposals,   other  projects),  easy  adjustments  of  the  proposals  

•  Shorten  the  Lme  needed  today  for  proposal  phase  

BENEFITS  •  Avoid  using  the  exisLng  excel  files    •  Avoid  having  so  many  manual  computaLons  •  ParallelizaLon  of  the  work  for  several  departments  •  Enable   concurrent   design,   integraLon   with   other  

tools  

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1  EUVEDES EUVE  TECNALIA  

It’s  the  applicaLon  of  EUVE  discrete  event  simulator  for  producLon  line,  with  the  goal  of  thinking  the  factory  as  a  product.  Via  simulaLons  and  trials,  the  user  can  determine  the  best  approach  to  improve  efficiency,   throughput   and  energy   consumpLon  of   the   line   in  order   to  determine   the  best  design  of  it.  

BENEFITS  •  Friendly  interface  •  Easy  to  be  used  •  New   features   different   from   the  

exisLng   tools   that   are   linked   to  t h e   p r o du cLon   p l a n n i n g  generaLon  tools.    

FLP: Factory Layout Planning ICIMSI  

The  FLP  is  a  mulL-­‐client  -­‐  server  applicaLon  that  supports   collaboraLve   factory   layout   planning.  Planners   located   at   different   remote   sites   can  collaborate   at   the   same   Lme   on   the   same  layout.    FLP   allows   to   construct   a   3D   model   of   the  building   and   to   define   points   of   availability   of  the   plant   services   (electricity,   pressurized   air,  etc.).   FLP   enables   a   “what   if”   analysis   of   the  system   performances   using   a   discrete   events  simulaLon  (DES)  engine.    

BENEFITS  •  Easy  configuraLon  and  reconfiguraLon  of  producLon  based  on  user  friendly  intuiLve  drag  &  drop  interface    •  Real-­‐Lme  plant  redefiniLon  from  different  actors  and  different  locaLons    •  Discrete  events  simulaLon  capabiliLes  of  the  FLP  will  foster  layout  performance  staLsLcs  gathering.  

Giove VF ITIA-­‐CNR  

FP3   is   a   VFF   module   for   the   monitoring   and   evaluaLon   of   technical   performance   indicators  (inventory  capacity,  efficiency,  etc.)  and  economic  performance   indicators  (profitability,  payback  Lme,  etc.).  Further  it  is  used  for  process,  equipment  and  layout  planning.  

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1  FP3 IPA  BENEFITS  •  Improved  approximated  value  of   life  

cycle   costs   as   well   as   technical  performance  of  producLon  faciliLes  

•  Forecast  funcLon  for  idenLficaLon  of  savings  or  addiLonal  costs  at  an  early  planning  phase    

•  Methodical  procedure  •  Easy  and  quick  imaging  of  alternaLve  

planning  scenarios    

GIOVE  Virtual  Factory   is  a  virtual  collaboraLve  environment  aimed  at  supporLng  the  factory   layout  design.  Machines,   operators   and  other   resources   can   be   selected   from  a   library   and  placed   in   the   3D   scene.   The  environment  can  display  performance  measures  that  are  provided  by  simulators  and/or  monitoring  tools.    

BENEFITS  •  IntuiLve  interface  •  Building   and   producLon  

resources   can   be   added/moved/removed  

•  Di rec t   co l l aboraLon  among  two  or  more  users  sharing   the   same   Virtual  Environment  

•  Voice   conference   control  and   automaLc  messaging  can  be  enabled  via  Skype      

The   iDecisionSupport   (iDS)   Module   is   a   collaboraLve   decision   making   environment,   accessible   via   web-­‐browsers,  where  team  members  aMend  do  different  types  of  decisional  meeLngs.    

iDecision ROPARDO  

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1  HIL: Hardware in Loop FATRONIK  TECNALIA  The  planning  of  a  new  factory  or  the  update  an  exisLng  one  requires  to  use  the  most  accurate  process  and  machine  performance  data.  Therefore,  why  not  join  the  Discrete  Event  SimulaLon  with  a  Hardware  In  the  Loop  simulaLon?  In  such  a  way,  we  will  have  the  best  of  two  worlds,  we  can  simulate  the  whole  factory  and  simulate  criLcal  points  in  detail.  

BENEFITS  •  Analysis   of   the   strong  

interrelaLon   of   internal  variables  on  stochasLc  mulL-­‐s t e p ,   mu l L -­‐ r e f e r e n c e  industrial  scenarios    

BENEFITS  •  Easily   access   remotely   and  

asynchronously    •  NoLficaLon  via  e-­‐mails    •  AutomaLcally   Protocols  

generated   and     sent   via  email    

•  Simple   acLons   like   grading  an   issue   or   expressing   the  agreement  

•  Support   synchronous   and  asynchronous  collaboraLon  

•  Reduce  Lme  for  Decision    

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1  IMPACT LMS   BENEFITS  •  I n te l l i gent   opLmizaLon   o f  

producLon  systems  scheduling  •  Task   allocaLon   to   the   most  

suitable  resources  

IPS:Interactive Projection System CEIT  

IPS  represents  an  integrated  concept  for  intuiLve  team-­‐oriented  factory  planning.  It  contains  tools  for  layout  design  and  opLmizaLon,  material  flow  and  transport  routes  opLmizaLon.    

BENEFITS  •  AcceleraLon   and   opLmizaLon   of  

the   planning   process   (layout  planning).  

•  Layout   and   mate r i a l   flow  opLmizaLon.  

•  3D  visualizaLon.  •  Physics  simulaLon  •  Collision  detecLon    

The  Intelligent  Manufacturing  Planning  And  Control  Tool  (IMPACT)  is  responsible  for  producLon  scheduling  and  process  planning.  It  considers  resources  and  tasks  simultaneously  and  can  assign  each  task  to  a  specific  resource  while  taking  into  consideraLon  mulLple  criteria  which  can  be  defined  by  the  user.    

•  Reduced  cost  and  Lme  for  producLon  scheduling  

•  Automated   generaLon   of  alternaLve   scheduling  soluLons  and  evaluaLon.    

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1  iPortal ROPARDO  

iPORTAL   Virtual   Factory   is   a   virtual   locaLon   with   a   dashboard-­‐like   interface   integraLng   different  modules  and  therefore,  offering  the  user  a  central  informaLon  point  for  distributed  and  collaboraLve  working  environment.    

PMD   is   a   soluLon  designed   to   support  performance  measurement,   in   the  most   reliable  way,   in  order   to   feed  performance  management  systems.    It  provides  the  means  to  store,  organize  and  analyse  large  volumes  of  data  in  order  to  allow  the  performance  of  simple  and  understandable  analysis  as  well  as  give  measurements  that  empower  managers  decisions.    

BENEFITS  •  MulL  Source  and  Data  Fusion  Features  •  Fast   and   Accurate   ReporLng   through  

Extensible  Dashboard  SoluLon    •  Quick  KPI  calculaLon  with  low  resources  •  Eliminate  redundancy  •  Fully  Scalable  •  Support   Development   of   Performance  

ForecasLng  tool    

BENEFITS  •  Increase  the  collaboraLve  work  (email,  

message-­‐board,  Skype,  agenda)  •  Support  for  File  Management    •  Effi c i e n t   a n d   e ff e c L v e   d a t a  

management    •  Knowledge  Repository  (wiki)  •  IntegraLon  with  other  web  tools    •  Access  the  external  data  bases    

PMD: Performance Measurement Dashboard INESC  

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1  PLM SPF  

Used   in   steel   fabricaLon,   PLM   handles   producLon   management   from   material   purchase   to   shipping.   It  breaks  down  CAD  drawing  imports  to  elementary  work-­‐orders  that  can  be  sent  to  CNCs.  The  operator  can  perform   scheduling,   based   on   imported   and   refined   shop   floor   layout,   provisional   execuLon   Lmes   and  context-­‐sensiLve   best   path   computaLon.   A   strong   factory   feedback   ensures   monitoring   and   dynamic  adaptaLon  of  parameters.    

BENEFITS  •  Lower  producLon  

Lmes  •  BeMer  

workstaLon  saturaLon  

•  BeMer  throughput  

•  Overall  producLon  Lme  opLmizaLon  .    

PROD SIM SZTAKI  

BENEFITS  •  Off-­‐line  analysis  in  the  design  phase  •  On-­‐line  analysis  during  the  operaLonal  phase    •  The simulation models are built and parameterized upon a totally automated way thus could be

referred to as a self-building simulation system.

The   ProducLon   SimulaLon   is   based   on   TecnomaLx   Plant  SimulaLon  (PS)  SW.  The  VF  Manager  provides  the  versioning  of  different   simulaLon  model   files   (mirroring   the   different   states  of   the  producLon  system),  while   the  module  enables   the  real-­‐Lme  database  connecLon  to  the  Factory  Image  database  where  all   the  simulaLon  data  are  collected   (ERP,  SCADA,  OPC  server)  and  required  for  the  simulaLon  experiments.    

The   RDV   provides   a   flexible   graphical   user   interface   of   the   producLon   related   data   and   the  simulaLon  experiments  result.  It’s  as  a  simulaLon  cockpit  with  which  simulaLon  experiments  are  iniLated  and  maintained.  MulL-­‐user  funcLonality  is  strongly  supported.    

RMP: Requirements Management & KPI Planning ETHZ  NOVA  

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1  RDV: Reporting Data Visualization SZTAKI  BENEFITS  •  All-­‐in-­‐one   cockpit   applicaLon   for  

discrete   event   simulaLon   (DES)  experimentaLon   and   producLon  data  analysis.  

•  Plaiorm   independent,   can   be  aMached   to   any   other   VF  Modules  encapsulaLng  DES    

The   RMP   Tool   aims   at   linking   the  intenLon  of  all   involved  stakeholders  with   an   accurate   and   tailored  performance   measurement.   The  approach   bases   on   a   network   of  funcLonal   requirement   specificaLon  for  new  producLon  systems.  

BENEFITS  •  SpecificaLon  of  factory  funcLons    •  Stakeholder-­‐driven  goal  modeling  capabiliLes    •  IdenLficaLon  and  mapping  of  KPIs  and  resources  •  Set-­‐up  of  target  system  for  performance  measurement  •  Embedding  sustainability  aspects  explicitly  

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SAVCP: Site & added value chain planning WZL  

VC: Visual COmponents SimX  

Visual   Components   is   a   one   of   the   leading   soQware   products   for   the  modelling   (in   3D)   and   simulaLon   of  complete   manufacturing   systems.   The   most   important   features   of   VC   are   the   possibility   of   performing  material  flow  and  roboLc  simulaLon  on  the  same  plaiorm,  authoring  components  in  order  to  create  a  library  of   re-­‐usable   equipment,   open   architecture   and   enhanced   connecLvity   through  Windows   COM   and   Python  APIs.  

BENEFITS  •  Provide   valuable   informaLon   about   logisLcs,  

operaLonal   details   of  Material   Handling   Systems  and   Equipment,   process   planning,   resource  definiLon   and   allocaLon,   line   balancing,  equipment   and   workplace   planning,   manual  procedures,   ergonomic   assessments   and  planning,  Health  &  Safety  ExecuLve  (HSE)  records,  automaLon  and  control  Planning,  factory  KPIs.  

The   Site   and  Value-­‐added  Chain  Planning  Module   enables   the   configuraLon  and  opLmizaLon  of   a  site  with   its  value-­‐added  chain.   It  uses  the  criteria  costs  and   lead  Lme  in  order  to  find  the  opLmal  producLon  scenario.    

BENEFITS  •  Quick  evaluaLon  of  value-­‐added  chain  •  Flexible  input  of  process  steps  •  InteracLve  adaptaLon  of  data  and  fast  

generaLon  of  new  scenarios  

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1  WITNESS LMS  

WITNESS   is   an   established  dynamic   process   simulaLon  tool   used   by   thousands   of  organisaLons   to   validate   a  proposed   facility   or   business  process,  to  achieve  a  desired  

BENEFITS  •  IntegraLon   of   a   commercial   DES  

SW  with  the  VF  Manager    

PotenLal   failure  modes   and   Effects  Analysis     (PEA)   is   a  web   tool   that   facilitates   analysis,   data  management   and  reporLng  for  FMEA.  The  PEA  Module  permits  the  rapid  entry  of  data  and  also  check  of  the  exisLng  data  from  past  projects  using  pop-­‐up  dialogs  which  may  be  accessed  simply  by  clicking  on  the  buMon.  

BENEFITS  •  CollaboraLve  work  •  CBR  soluLon  integrated  •  Reuse  Engineer’s  know-­‐how  •  StaLsLcs  with  most  important  failure  

modes,  effects  and  causes  •  Reduce  the  Lme  of  this  procedure  •  Support  mulLple  users  by  leveraging  

a  Web  interface    •  AutomaLc  criLcality  calculaLons    

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PEA: Potential Effects Analisys ROPARDO  

process  performance  metric  or  to  support  conLnuous  process  improvement  acLviLes.    The  connector  developed  by  CASP  and  LMS  allows  the  uLlizaLon  of  this  commercial  DES  tool  within  the  framework  of  VF  Manager.    

Requirements  Management  Workflow  (RM  Workflow)  is  a  web  and  an  intuiLve  tool  that  facilitates  the  flow  of  informaLon,  tasks  and  events.  The  RM  Workflow  engines  interpret  the  documents  in  the  server  and  acts  according  to  the  computer  defined  process.    

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1  RM Workflow: Requirements Management ROPARDO  

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BENEFITS  •  Supports   the   collaboraLon  

between  the  members    •  NoLficaLon   via   e-­‐mails   with   the  

status  of  documents    •  Easi ly   accessing   the   r ight  

informaLon   depending   on   given  access  rights  

•  Access   to   the   last   version   of  documents  

•  Easy  to  track  the  status  of  started  projects  

•  Provides   conceptual   integraLon  of  business    

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Visit  VFF  web  site  www.vff-­‐project.eu  

Edited  by  ITIA-­‐CNR  Text  by  VFF  consorLum    If  you  want  to  receive  the  NewsleMer  directly  in  your  mail  box  write  an  e-­‐mail  to:  info@vff-­‐project.eu