Digital manufacturing:

PLM in the Factory

What is digital manufacturing ?

How does it relates PLM ?

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Digital manufacturing is an approach involving people
,process/practice, and technology that uses PLM information
to plan ,engineer, and build the first instance of a product ;
Ramp that product up for volume production ;and produce,
monitor and capture for other purpose of life cycle the
remaining instants of that products production using
minimum amount of resources possible.

https://www.plm.automation.siemens.com/en/plm/digital-manufacturing.shtml
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“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. “

https://www.youtube.com/watch?v=p25gICT63ek
 Integration of Product Design and
Manufacturing Processes

Reduce Cost and Development Time for

Process Design •
Benefits of
Digital Shorten Time-to-Launch for New Product
Introduction with Faster Ramp-up for
Manufactu Production Systems

ring Provide Manufacturability by Simulating

Manufacturing Operations before the Start
of Production
Increase Quality by Validating Production
Process Design
Benefits of Digital Manufacturing

Reduce and/or eliminate Prototypes and Physical Mockups

Reduce with Virtual Simulations

Improve Collaboration with Suppliers by Providing Early Access

Improve to Design, Production Process, and Resource information

Improve Concurrent Design Methods by Linking Product Design

Improve to Manufacturing & Controls Engineering

Validate Manufacturing Processes, Production Systems, and

Validate operational resources through Virtual Commissioning prior to
physical implementation
Early promise of Digital Manufacturing

The output, a product with certain definitive specification and the

inputs-material, machinery, people and energy are well defined. Thus
process produce output while minimizing the inputs are amenable to
analysis and optimization.

The famous industrial engineer, Fredrick W. Taylor ,was working

successfully on these analysis and optimization problem.
 Taylor referred to as “scientific method” at the term of twentieth
century.
 Taylor’s time and motion study were precursor to developing process
and equipment to reduce waste of time ,energy and material.
While work continued for centuries to reduce wasted
time, material and energy there was a plenty of work to
waste with
Introduction of Lean Manufacturing in 1990s……….
 It could eliminate majority of non value added costs
 Some companies reduced cost 50% or more still
existed.

Other major opportunity to reduce inefficiency and waste

in manufacturing. function is CIM data………a noted
research firm in area of PLM ,has done some preliminary
investigation of improvements with digital
manufacturing. Which results are in table.
 Manufacturing the First One

 Manufacturing the first product is the first stage of the

manufacturing process.
 Organizations have myriad ways of dealing with this
intersection between engineering and manufacturing.
 The manufacturing function is completely responsible for
defining the processes that actually manufacture the
product.
 Organizations have well defined EXIT—ENTRY
specifications but they not match some time.
 Is this a process? Yes. Does it work? Yes. Is it a major
source of wasted time, energy, and material? You bet!
 If the digital substructure of PLM information is available,
then Digital Manufacturing can tap into it in a variety of
different areas And it can save on the one resource that can
never be recaptured, wall clock time.
Areas where Digital Manufacturing can be employed

 Process Planning and Reuse

 CAD specifications without process specifications are useful only for
generating pretty pictures to hang on the wall.
 The step-by-step specification of how to actually produce the
geometric specifications using physical material and tools is critical
to actually producing a viable product.

 Most product manufacturers deal with the process of building the

product in the design and engineering stage. there are generally two
distinct groups. They are
 Process designers
 Product designers
 Process Engineers

• Process engineers can use the math-based CAD

descriptions of the product and the machines to determine
if the process is feasible.
• Digital Manufacturing tools can determine if the tooling
is capable of performing the required operation.
• Digital Manufacturing tools can check for collisions of
the machine and tooling in the product being operated on
• Rather than specifying operations that theoretically work,
process engineers can validate the operations they are
specifying with the exact product and exact machine,
tools, and fixtures that are to perform those operations, all
in digital form
 Product designers

• The use of Digital Manufacturing integrates the

process planning from design and engineering into
the manufacturing area and makes manufacturing
a partner in the process, rather than a recipient of
the outcome of the design and engineering stage
• The next logical action is to reconcile
manufacturing's changes with the design team's
proposed process.
• Reusable processes are the manufacturing
equivalent of reusable parts in the design and
engineering function..
machines, tools, or fixtures

 When the machine and tool is given.

 When the machine and tool is to be designed and built as
part of the manufacturing process
 First case
 The constraints are imposed by virtue of the existing machines,
tools and fixtures.
 For simple products or components this may not that difficult.
 For more Complex components and products procedure was to
create simple parts and assemble
 For simple products ,the permutation and combination of the
machines and potential operation multiply quickly.
 Second case
 The second case of producing product when the machine, tools,
and fixtures are not given and are also to be built is simpler in
one respect, but more complicated in another.
 The simpler aspect is that by designing the machines, tools, and
fixtures we can be assured that the component or product can be
produced at least theoretically.
 This brings us to the more complicated aspect: that designing the
machines, tools, and fixtures is more challenging than designing
product itself.
 Building the machine tools and fixtures ,which endures a period
of shakedown and remediation
 Robotics and PLC Simulation and Programming
 Robotics and equipment controlled by programmable logic
controllers (PLCs)
 Robotics and PLC-controlled equipment can bring us a step closer
to realizing the Information Mirroring (IM)
 Without Digital Manufacturing, robotics and PLC-controlled
equipment are subject to the same issues of shakeout and testing.
 Programmers write programs to perform the operations required
to produce the product. The programmers must then run their
programs to debug them,
 Programs never do what the programmers think they are going to
do. This takes time to set the correct program so that final
product match the required specification

 Digital Manufacturing is applied to robotics and PLC-controlled
machines the situation is different. The link between the virtual
world and the physical does not require human intervention.
 Once the virtual machine's programming code is debugged and
the virtual machine produces the desired result, that
programming code is transmitted to the robot or PLC.
Ramp up
• Ramp up describes the period between product development,
and maximum capacity utilization, characterized by product
and process experimentation and improvements.
• Digital Manufacturing has the promise of greatly reducing the
ramp-up time of product manufacturing through simulation.
• The reality is that the ramp-up period has become a luxury that
most manufacturers cannot afford.
• When cycle times were long, the ramp-up period was a small
portion of the total manufacturing cycle.
• As cycle time decreases, ramp up increases. The waste during
ramp-up time becomes more prominent, and the focus is on
eliminating or greatly reducing it.
The virtual learning curve
 This roughly triangular figure represents the cost wasted during
the ramp-up process.
 What Digital Manufacturing strives to do is save this wasted time,
energy, and material by starting virtual production at the top of the
experience or learning curve and only starting physical production
when the learning curve begins to bottom out.
 Simulation is carried out using variety of factors For production
processes that are highly automated with production operations .
 Once the simulations show the required results, the instructions to
produce them can be downloaded into the computers controlling
the actual equipment.
 For process that have substantial amount of human interaction, the
actual action of human beings have to be learned and improved
through repetition
 ECO Simulation and Implementation
 Manufacturing ramp up of new products is invariably
accompanied by product changes, commonly referred to as ECOs
(Engineering Change Orders).
 ECOs occur for a variety of reasons. Sometimes the issue is that
the product does not have all the functionality that the designers
and engineers envisioned.
 These ECOs can introduce inefficiencies into the production
process that increase costs to a point higher than when production
was initially started, because the initial production method has to
be unlearned and a new method has to be learned.
 DM by providing better co ordination, communication and
simulation in the first stage of manufacturing will decrease the
need for ECO’s
Production Planning
• Production planning is an obvious use of the information
developed to create the factory flow simulation and analysis.
• Instead of allocating equipment time and schedule for
production on the basis of aggregate numbers , the DM uses
factory flow information, and discrete timing to efficiently
allocate and simulate that production to determine unnecessary
equipment changeovers, bottlenecks, or other production flow
problems.
• Production planning is simply finding a schedule that works.
Little attempt is made to reduce the waste of time, energy, and
material by finding better schedules.
• By using the models developed for, factory flow simulation and
analysis, production planners can develop production plans and
test those plans in simulation