3 “Intelligence” in Agile Mfg Systems Mechanical Systems, Sensors, ControlsAdaptive, automated, autonomous“Intelligent” robotics, adaptive process control, etc.People Systems and Decision Making“Agility” in context of unanticipated change. Reconfigurable.“Virtual” Product/Process design and validationDiagnostics and prognosticsEnterprise analyticsWhen we think about what makes assembly systems “smart” or “intelligent” – there are two aspects.One is “how can we make mechanical systems --- like tooling and equipment smarter, or more adaptive, or more intelligent”At leas as important as that is ..“what can we do to improve effectiveness/quality of PEOPLE in tasks and decision making” …
4 What is “Smart Assembly”? Virtual Factory“Intelligent/Agile Equipment”Eg: Cooperative Robots“e-Enabled”Optimized Real-timeManufacturingEg: Predictive Maintenance“Math-enabled”Virtual Product/ProcessDesign and ValidationEg. Virtual LaunchThe left side of this figure shows the “Intelligent/agile mechanical systems” perspective…The right side shows some of the elements of the human tasks and decision making …We can talk about “smart assembly” from either perspective … but also we can think about what happens as these two worlds start to come together??Is it Real?Or is it Virtual?Or is it a Hybrid?
5 What If These Worlds Merged? How could we leverage “virtual” capabilities in the plant?“Virtual Build” ReviewsLine BalancingHuman Factors/ErgoOperation and Job Element DescriptionsProcess PlanningProduct and Mfg Engineering“This is a very nice fly-through that you have shown me. When will I be able to use this on the plant floor to improve my operations?”(Paraphrased from GM Plant Manager)Virtual TrainingOperator/team leader led workplace optimization
6 What If These Worlds Merged? How could we leverage “real time data” capabilities in engineering?LayoutSpecificationsEquipment DesignPerformance“Observed State”Asset Tracking“I can’t re-use 3-D layouts because they are obsolete soon after the equipment is installed” (Paraphrased from GM Layout Engineer)
7 What If These Worlds Merged? Or, maybe even…This one is “real”Workcell SimulationThis one is “virtual”
8 Smart Assembly Space e-Mfg Virtual Agile Smart Assembly e-Manufacturing:Real-time Optimized Manufacturing(“m” & “M”)VirtualVirtual Mfg Eng. & Validation: Math Tools & ProcessesAgileSmart AssemblyFlexible Mfg System Infrastructure: Hardware Tools& Processes
9 Purpose Of WorkshopTo develop a (broad industry/academic) vision and to define the state of the art and needs in “Smart Assembly.”“Smart Assembly” refers to a next generation capability in assembly systems and technologies which integrate “virtual” and “real-time” methods in order to achieve dramatic improvements in productivity, lead-time, and agility for the design, engineering, validation, construction, installation, launch and operation of assembly processes and systems.
10 Scope (suggested…) In scope: Assembly processes and systems: putting parts/components together to make a product.Mfg Engineering and Mfg Operations activities: mfg process planning, design, engineering, validation, construction, installation, launch and operation of assembly processes and systems.Out of scope (despite importance!)Product design and modeling for assembly“Big M” manufacturing: enterprise analytics, supply chain, etc
11 Agenda – October 31:00 Welcome: Dale Hall, Director, Manufacturing Engineering Laboratory, NIST1:10 Workshop Objectives, Format and Agenda: Bob Tilove, Technical Fellow GMR&D and NIST Visiting Scientist)1:30 Plenary SessionWhat are some of the problems that you are facing that “smart assembly” might help to address? What are some examples of future scenarios enabled by smart assembly?1:30-2:00 Bryan Dods, Senior Manager, Advanced Manufacturing Research & Development; The Boeing Company2:00-2:20 Thomas Babin, Fellow of Technical Staff, Motorola2:20-2:45 Roland Menassa, Laboratory Group Manager,Agile Equipment and Processes, GM R&D CenterWhat are the tough research problems (related to the design, engineering, validation, construction, installation, launch, and operation of assembly processes and systems) that must be solved to make “smart assembly” a reality?2:45-3:15 Jack Hu, Professor of Mechanical Engineering,University of Michigan3:15 Coffee Break
12 The plenary speakers have one view … we want to hear from everyone!! Agenda – October 33:40 Plenary Session - continuedWhat are the tough implementation problems (infrastructure, standards) that must be solved to make “smart assembly” a reality?3:40-4:10 Charlie Gifford, Director Lean Production Management,GE/Fanuc Automation4:10-4:40 Mitch Vaughn, Chief Technology Officer, Production Management, UGS4:40-5:10 Bob Brown, CEO Advisor, DELMIA CorpWhat are the most promising models and opportunities for leveraging and collaboration to accelerate the development and implementation of “smart assembly”?5:10–5:40 Jim Caie, VP of Consulting, ARC Advisory Group5:40 Wrap up and collection of Break-out Session Preferences – Bob Tilove6:00 Shuttle Bus to Hotel6:30 Reception, Hilton (Courtesy of USCAR)The plenary speakers have one view … we want to hear from everyone!!
13 Agenda – October 4 8:30 Coffee 9:00 Kickoff Breakout Sessions (Richard Neal)9:15 Breakout Sessions and Working LunchSession 1: End User PerspectiveSession 2: Research Science PerspectiveSession 3: Infrastructure/Standards PerspectiveSession 4: Systems Integration and Deployment PerspectivePick up lunch between 11:30 – 12:002:00 Reports from Breakout Sessions3:40 Wrap up – Dale Hall, Bob Tilove4:00 Adjourn
14 Break-out Section Preference Form You will find a form like this in your packet. Please complete it and return it to a facilitator before you leave today!!Breakout SessionsAnd Focus QuestionsPreference1 = First Choice2 = Second Choice3 = Third Choice4= Fourth Choice(please rank all 4)End User Perspective – This group will explore what needs to be done and why from the applications view.Research Science Perspective – From the standpoint of R&D, where are the missing links? What technology voids hinder realization of smart assembly?Infrastructure and Standards Perspective – What foundational tools are required to realize smart assembly? What standards are needed to enable interoperability and cost effectiveness?Systems Integration and Deployment – This group will explore pathways to successful development of smart assembly systems and broad deployment of those systems