1. Models for IPPE ISE789 Product and Process Engineering R. A. Wysk

2. B.KMay 7, 2001 Boonserm Kulvatunyou A Resource Independent Process Representation in Enterprise-based Engineering Integration for Manufacturability Analysis

3. B.KMay 7, 2001 Preview Research motivation Research objective and scope Methodology RIOS Schema Example RIOS construction Engineering integration architecture Example integration RIOS Verification and Validation Conclusion

4. B.KMay 7, 2001 Research Motivation Enterprise-based Engineering Integration Prevalent of manufacturing globalization, i.e., distributed manufacturing – Small batch production Leverage manufacturing capability Leverage capital investment Core competency focus – Geographically separated engineering experts Communication problem Time and availability Manufacturing cost saving during early design stage -- ‘concurrent engineering’ Business motivation mawmeow: Enterprise-based engineering integration is necessary for the distributed manufacturing environment. This is because engineering experts are geographically separated and are subjected to communication, time, and availability problem. Enterprise-based engineering integration also emulates the concurrent engineering; thus, it would enable the manufacturing cost saving during the early design stage. In the enterprise-based engineering integration environment engineering experts collaborate thru a common data pool which consists of Design data, process data,….. mawmeow: Enterprise-based engineering integration is necessary for the distributed manufacturing environment. This is because engineering experts are geographically separated and are subjected to communication, time, and availability problem. Enterprise-based engineering integration also emulates the concurrent engineering; thus, it would enable the manufacturing cost saving during the early design stage. In the enterprise-based engineering integration environment engineering experts collaborate thru a common data pool which consists of Design data, process data,…..

5. B.KMay 7, 2001 Enterprise-based Engineering Integration Communication and scheduling problems Information infrastructure – Content-based infrastructure – Network infrastructure Insufficient product data – Integration difficulty -- relying on single view point of product data, i.e., design data – Feature recognition challenge -- feature interaction, design misinterpretation, unrecognized feature, time consuming computation – Business objective communication -- design data does not provide vocabulary for business collaboration STEP AP224 Machining features for process planning – Use of compound feature and no alternative representation – A resource specific view of product model Technological challenge

6. B.KMay 7, 2001 Research Objective and Scope Provide an approach to specify process model view of the product data – Resource independence – Facilitating enterprise integration Construct information model for resource independent process representation- -Resource Independent Operation Summary (RIOS) Develop a structure of Resource Specific Process Planning (RSPP) module for enterprise-level manufacturability analysis – Manufacturability – Manufacturing Cost & Time estimation Demonstrate example RSPP module of a manufacturing vendor that integrates with its engineering information pool--process knowledge and resource model Scope: 3-axis milling machine in flexible manufacturing system, excluding material handling mawmeow: This research propose to supply process model which interlinks with the design data as part of the product data in the engineering integration. However, traditional process model is resource specific..thus the first objective of this work is to….. 2nd to construct information model for this resource independent process representation. And then develop and implement an integration architecture to demonstrate the use of RIOS data in engineering activity integration, in particular the manufacturability analysis and cost & time estimation mawmeow: This research propose to supply process model which interlinks with the design data as part of the product data in the engineering integration. However, traditional process model is resource specific..thus the first objective of this work is to….. 2nd to construct information model for this resource independent process representation. And then develop and implement an integration architecture to demonstrate the use of RIOS data in engineering activity integration, in particular the manufacturability analysis and cost & time estimation

7. B.KMay 7, 2001 Methodology Requirement specification Vs. Description – Ex: Require hole making process that can achieve 0.5” diameter and 0.008 positioning accuracy – Ex: Twist drilling with 0.4687” diameter and boring a hole with 0.5” diameter Feature composition Vs. Feature decomposition Alternative processes -- AND/OR Directed graph Process planning decomposition Universal level process knowledge Process modeling abstraction Resource independent process representation [Brown and Ray 1987], [Wysk et. al, 1995], [Shah and Mantyla 1995], [Chang 1990], [Ray 1987]

8. B.KMay 7, 2001 Universal Process Knowledge [http://www.cybercut.berkeley.edu]

9. B.KMay 7, 2001 Process Modeling Mech_rem _oper_info Chem_rem _oper_info Elec_rem _oper_info Therm_rem _ oper_info (ABS) Operation_level_information (ABS) Matl_transf_oper_info(ABS) Matl_transp_oper_info (ABS) Matl_ rem_oper_info (ABS) Geometry_ change_oper_info (ABS) Property_ change_oper_info (ABS) JoinAsm_ oper_info (ABS) Mfg_oper_info (ABS) Business_oper_info 1 1 1 1

10. B.KMay 7, 2001 Process Planning Decomposition in Association with the Alternatives 1. Precedence constraints due to geometric and topological constraints 2. Precedence constraints due to relocating the part adversely affects the repeatability requirement of a part 3. Precedence constraints due to geometric tolerance requiring extreme repeatability 4. Precedence constraints due to economical rationalization of machining 5. Process accuracy constraints 6. Technological constraints--available resources 7. Process economy Generate RSRS Generate RIOS mawmeow: The first step in this process planning decomposition is to resolve ….. mawmeow: The first step in this process planning decomposition is to resolve …..

11. B.KMay 7, 2001 Constraints

12. B.KMay 7, 2001 Presentation Map -- RIOS Specifications  Research motivation  Research objective and scope  Methodology  RIOS Schema  Example RIOS construction  Engineering integration architecture  Example integration  RIOS Verification and Validation  Conclusion  Possible extension

13. B.KMay 7, 2001 RIOS Schema RIOS_GraphRIOSRIOS_Process_level_informationRIOS_Operation_level_informationRIOS_SupportRIOS_Transaction Business and production requirements Alternative Resource type and workholding requirements Process type, accuracy,topology, and shape requirements Measurement, material, etc. specifications

14. B.KMay 7, 2001 RIOS_Transaction schema (1)

15. B.KMay 7, 2001 Example Part All dimensions are +/- 0.01" unless otherwise specified A-7 Hot-rolled carbon steel wrought medium carbon, 350 BHN

16. B.KMay 7, 2001 RIOS_Operation_level_information schema Mech_rem _oper_info Chem_rem _oper_info Elec_rem _oper_info Therm_rem _ oper_info (ABS) Operation_level_information (ABS) Matl_transf_oper_info(ABS) Matl_transp_oper_info (ABS) Matl_ rem_oper_info (ABS) Geometry_ change_oper_info (ABS) Property_ change_oper_info (ABS) JoinAsm_ oper_info (ABS) Mfg_oper_info (ABS) Business_oper_info 1 1 1 1

17. B.KMay 7, 2001 Example Part Discussion A B D Need at least 2 setups--Top and bottom. Economical utilization of process can be used to rationalize the sequence. An SERIAL AND connection may be specified. Processing the top side first results in depth reduction of 4 holes. There is a tolerance stack up of the c-bore hole, if all features are processed in single setups. Provide alternative to separate the processes on the top side into two setups.

18. B.KMay 7, 2001 Operation Level Graph (OLG) OP3 Specification 2

19. B.KMay 7, 2001 Process Level Graph (PLG), PLG3 of OP3 Summary of PLG3 Data

20. B.KMay 7, 2001

21. B.KMay 7, 2001 Presentation Map -- Activity Integration  Research motivation  Research objective and scope  Methodology  RIOS Schema  Example RIOS construction  Engineering integration architecture  Example integration  RIOS Verification and Validation  Conclusion  Possible extension

22. B.K May 7, 2001 Implementation Architecture Facilitate integration -- minimum cost and time to implement Modular and extensible Software architecture includes: – XML Data Parser – RSPP module Utility Classes – MR Model – PN Architecture Software architecture

23. B.KMay 7, 2001 XML Data Software Packages UML Package Diagram Tree Data Structure Facilitate data access Provide utility functions such as traversing the directed graph Facilitate data access Provide utility functions such as traversing the directed graph

24. B.K May 7, 2001 RSPP Module Utility Classes Implement by vendor Traverse graph Eliminate non-manufacturable nodes Facilitate digraph linearization Linearize digraph with only OR connections (alternate paths) Utility classes automatically:

25. B.KMay 7, 2001 CIM Lab RSPP Module Implementation Manufacturability analysis as well as cost and time estimation Manufacturing resource model – Machine: Haas VF-OE (3-axis) and Haas VF-3B (5-axis) – Tool body: Solid tool body types including twist drill, reamer, solid boring bar, endmill, counterbore, and countersink – Fixture: Vise Process knowledge architecture – Client-service architecture – Plug-and-play with resource model RSPP module utility classes implementation – Producibility analysis – Process selection and cost estimation

26. B.KMay 7, 2001 Manufacturing Resource Model Object-oriented Schema

27. B.KMay 7, 2001 Manufacturing Resource Model Owns(x1, x4) and HasAttrVal(x4, a2, c2) -> HasAttrVal (x1, a2, c2) Owns(x1, x4) and Owns(x4, x5)  Owns(x1, x5) Indicate resource capability ‘Owns’ relationship is transitive Is(x1, x2) Subtype Is(x1, x2) and Is(x2, x3)  Is(x1, x3) ‘Is’ relationship is transitive Ex: Milling machine owning a 1” diameter twist drill implies that the milling machine has capability to twist drilling a 1” diameter hole

28. B.KMay 7, 2001 Object-oriented Implementation of the MR Model

29. B.KMay 7, 2001 Process Knowledge Architecture Java interface based architecture, i.e., client-service architecture –Allow plug-and-play compatibility with the MR model Shape producing capability knowledge Process accuracy knowledge Process selection knowledge Machining parameters -- Machining data handbook (MetCut 1980)

30. B.KMay 7, 2001 Java Interface-based Process Knowledge Architecture MR are service providers RSPP module is client Interfaces are services – Define service specifications – An MR provides a service by implementing the service specification – Ex:Hole_making_capable verifyProcessAccuracy( ) planHoleBody( ) planHoleTop( )

31. B.KMay 7, 2001 UML Package Diagram showing Collaboration Ex: Twist drill, reamer, endmill implement Hole_making_capable When RSPP module encounter a Hole_making_process requirement, it queries knowledge base for all Hole_making_capable resources to find the most efficient one. New Hole_making_capable resource can be added without effecting the RSPP module

32. B.KMay 7, 2001 Process Knowledge Architecture Predicate y2 is an interface.

33. B.KMay 7, 2001 RSPP Module Utility Class Implementation CIM LAB Manufacturing Agent Implement by vendor

34. B.KMay 7, 2001 RSPP Module Utility Class Implementation CIM LAB Manufacturing Agent  Producibility analysis -- shop level manufacturability evaluation  Cost and time estimation  Equipment selection: machine burden rate or resource utilization (dynamic conflict resolution)  Process selection  Graph linearization  Group -- graph-based pattern matching  AND -- process economy heuristic  Geometry  Topology  Process accuracy & Process economy -- process bounds and process efficiency (e.g., twist drilling is more efficient hole making process than endmilling (plunging))  Graph linearization  OR -- network flow problem formulation

35. B.KMay 7, 2001 Example Cost and Time Estimation of the Example Part (1) OLG OP3 Data mawmeow: Supposed producibility is okay mawmeow: Supposed producibility is okay

36. B.KMay 7, 2001 Cost and Time Estimation of the Example Part ‘OLG: Get Feasible Machines ’ Haas VF-OE (3-axis) and Haas VF-3B (5-axis): Prefer VF-OE due to cheaper burden rate mawmeow: Dynamic conflict resolution can be introduced mawmeow: Dynamic conflict resolution can be introduced

37. B.K May 7, 2001 Cost and Time Estimation of the Example Part ‘Linearize GROUP and AND Connection’ Pattern matches a group of multiple holes with decreasing diameters – Check step drill resources owned by the Haas VF-OE for geometric compliance -- No match Replace the Group connection with a Serial AND connection Linearize the Serial AND connection --> heuristic --> EX: “Sequence to minimize the processing depth”

38. B.KMay 7, 2001 Cost and Time Estimation of the Example Part ‘Assign Cost and Time PLG’ Select all Hole_making_capable service providers belonging to the Haas-VFOE, e.g., twistdrill, endmill, boring bar, etc. in order of ‘process efficiency’ Verify geometry, accuracy, and topological capability to find an appropriate tool (service provider) Ask the selected service provider (e.g. solid boring bar - 0.008”) to plan and return cost and time to achieve the process requirements – Total cost of utilizing the machine, tools, and fixture associated with the machining time For each Manufacturing process node, the RSPP module: mawmeow: Select all Hole_making_capable tools belonging to the Haas-VFOE, e.g., twistdrill, endmill, boring, etc. Evaluate each tool against the process requirements in the order respect to ordered list of process economy. This ordered list is twistdrilling, endmilling, reaming, and boring. mawmeow: Select all Hole_making_capable tools belonging to the Haas-VFOE, e.g., twistdrill, endmill, boring, etc. Evaluate each tool against the process requirements in the order respect to ordered list of process economy. This ordered list is twistdrilling, endmilling, reaming, and boring.

39. B.KMay 7, 2001 Cost and Time Estimation of the Example Part ‘Assign Cost and Time OLG’ Obtain total cost of the PLG:  Linearize the PLG, which has only the OR connection left  Shortest path formulation  Cost of traversing from node A to B is cost associated with the node A  Cost of traversing from non-procedure node is zero Obtain cost associated with the Operation node  Total cost of the PLG plus setup cost of the operation

40. B.KMay 7, 2001 Cost and Time Estimation of the Example Part ‘Total cost of the batch and delivery time’ Linearize the OLG to obtain total cost of the OLG – Ignore the AND Connection -- assume scheduling problem when each node has different resources assigned – Shortest path formulation for the OR Connection Obtain the batch cost – Obtain per-piece cost -- profit margin times OLG cost plus other indirect and direct costs, e.g., stock material, cost of setting up equipment – Obtain total batch cost Obtain total operating time similar approach to obtaining total operating cost Delivery time is: current time + Max(total MPS, max lead time) + total operating time Note – Did not consider material handling Run Example RFQ

41. B.KMay 7, 2001 RIOS Verification and Validation Verification for machining activity through implementation demonstration Validation for machining activity – Functional requirements – Representational requirements – Analysis of existing process representation System analysis -- Ex: IDEF0 Process documentation -- Ex: IDEF3 Activity planning and scheduling -- Ex: Gantt chart Information interchanging and knowledge sharing -- Ex: PSL, STEP 213 In conclusion: – Lacking of one or more process representation requirements necessary for the business collaboration of engineered product – Possessing unnecessary capabilities that RIOS may not have – Lacking of low level information necessary to communicate the process requirement (only provide construct) – RIOS specification facilitating business collaboration of engineered product better than other representations Evaluation Matrix

42. B.KMay 7, 2001 Research Conclusion and Contribution For the first time, a resource independent approach to process specification and planning has been developed Successfully demonstrated how one can incorporate RIOS to product data to conduct a RFQ activity of machining processes Developed integration architecture including: – RIOS data – Manufacturing resource model (schema) – Process knowledge architecture – RSPP module Process plan graph linearization Process knowledge procedure

43. B.KMay 7, 2001 Research Conclusion and Contribution Software components and integration architecture have been developed and formalized for reuse RIOS has been validated for machining activity through analysis of representational and functional requirements as well as benchmarking with other process representations NIST is interested in pursuing this program because RIOS data is becoming critical for enterprise level integration

44. B.KMay 7, 2001 Questions? Thank you Any questions?

45. B.KMay 7, 2001 RIOS_Transaction schema(2)

46. B.KMay 7, 2001 Possible Extension Web-based knowledge sharing to maintain evolving specification Expert system module Agent-based integration Cost estimation scheme Automation associated with the RIOS – Computer-assisted RIOS generation – Semantic and consistency checking Process intersection algorithm

47. B.KMay 7, 2001 PLG1 (Exhaustive)

48. B.KMay 7, 2001 PLG1 (Concise)

49. B.KMay 7, 2001 PLG2 Exhaustive Concise

50. B.KMay 7, 2001 PLG3 and PLG4 PLG3 PLG4

51. B.KMay 7, 2001 Surface IDs

52. B.KMay 7, 2001 MR Schema (1)

53. B.KMay 7, 2001 MR Schema (2)

54. B.KMay 7, 2001 MR Schema (3)

55. B.KMay 7, 2001 Collaboration Diagram of CIM LAB RSPP

56. B.KMay 7, 2001 Cost Equation (PLG)

57. B.KMay 7, 2001 Cost Equation (OLG)

58. B.KMay 7, 2001 Total Cost of Batch Order

59. B.KMay 7, 2001 Delivery Time

60. B.KMay 7, 2001 OR Connection Linearization