1. Model-Based SE Using SysML Part 2: Integrating Manufacturing Design and Simulation Leon McGinnis Georgia Institute of Technology Product & Systems Lifecycle Management Center www.pslm.gatech.edu NDIA Systems Engineering Division, M&S Committee April 22, 2009  Washington, DC

2. 2 GIT Product & Systems Lifecycle Management Center Leveraging Related Efforts SysML-related projects: –Deere, Lockheed, Boeing, NASA, NIST, TRW Automotive,... Other efforts based at GIT: –Vendor collaboration (tool licenses, support,...) –Keck Virtual Factory Lab –SysML course development For Professional Masters in SE program, continuing ed. short course,... –ASDL in AE –Tennenbaum Institute for Enterprise Transformation Consortia & other GIT involvements: –OMG (SysML,...) –PDES Inc. (MBE, APs 210, 233,...) www.pslm.gatech.edu

3. 3 Excavator Modeling & Simulation Testbed Tool Categories View

4. 4 Model-Centric Framework Produce, Merge, Enrich, Consume Tool A 1 Federated System Model Meta-Building Blocks: Information models & meta-models International standards Industry specs Corporate standards Local customizations Modeling technologies: Express, UML, SysML, COBs, OWL, XML, … Tool B j Producer Tools (Primary Authoring) Enricher Tools (Secondary Authoring) Tool C k Consumer Tools (e.g., Solvers) Tool A n... http://eislab.gatech.edu/pubs/journals/2004-jcise-peak/ (where “collective product model”  “federated system model”)

5. 5 Excavator Modeling & Simulation Testbed Interoperability Patterns View (MSI Panorama per MIM 0.1)

6. 6 My focus today: What does it mean “to integrate manufacturing with design?” What does it mean “to integrate manufacturing system design with manufacturing system simulation?” How can we make these two things happen?

7. 7 Integrating Manufacturing and Design ? ? ?

8. 8 ? ? ?

9. 9 Product Models in CAD

10. 10 Product Model (E-BOM vs M-BOM) E-BOM M-BOM

11. 11 Manufacturing Context

12. 12 Design to Manufacturing Integration EBOM to MBOM Transformation Or “EBOM to WBS” More than “interoperability” or “converting a file format”; “how” based on “what” –Sourcing (=> logistics, cost, schedule …) –Resource organization/assignment (=> mfg cost) –Inventory/WIP positioning (=> cycle time …)

13. 13 R&D Strategy Conform factory design to product design –Functional design –Detailed design Recognize process planning as the “design to manufacturing” bridge Manufacturing as part of a federated “enterprise” model

14. Factory Design Capabilities

15. 15 Design Data: EBOM + MCAD

16. 16 Functional Design for Manufacturing Process—SysML Use Cases

17. 17 Factory Functional Design

18. 18 Function Detailed Design

19. 19 Resource Model & Layout Model NameTooltypexy OperationType Cutting SpeedLoadingTime UnloadingTime Bending_Machine1 BendingMachin e2000500Single 10050 Laser_Cutter1LaserCutter1000 Cut Shape4300200 Welding_Machine1WeldingMachine30001500Assembly 100 Tool Instance Data in Excel Bill of Resource in SysML Factory Layout in FactoryCAD (AutoCAD)

20. 20 SysML Ref. Model  FactoryCAD Library SysML Reference Model Shape Drawing FactoryCAD Library

21. 21 Layout Using F-CAD Library from SysML FactoryCAD Library Select/ Place Layout Drawing

22. 22 Capturing Layout Information Database Extract SDX Layout Drawing Xpath Parser Study DB

23. 23 Observations Factory design is driven by: –What –How much –When –Where So how do we integrate those issues? Use SysML Activity Diagrams to capture how we intend to use manufacturing resources to create the product

24. 24 Process Planning Model

25. 25 Detailed Process Planning

26. 26 Operation Allocation 26 >

27. 27 Manufacturing Process Model

28. 28 Activity Diagram to MBOM Transformation Automated Transformation

29. 29 BOM Transformation using Moflon Activity Metamodel BDD Metamodel BOM Transformation rule Magic Draw JMI Source model JMI Meta-model level based on MOF (Modeling) Transformation Rule JMI Target model JMI Data Repository Integrator based on JMI level (Execution) Magic Draw Link information MD Adapter XMI Adapter Application independent Correspondence + SD described by MOF XMI Adapter MD Adapter

30. 30 Manufacturing Model Interdependencies

31. 31 Summary

32. 32 Federated Model Interfaces Tools Layout Process Plan M-BOM Library Instance Simulation E+ FactoryCAD Library Excel MD BDD : Factory Organization FactoryCAD drawing MD Activity Diagram MD BDD Access Tables eM-Plant MD BDD: E-BOM Excel: Vendor Tool info C# eM-Plant script Manual Moflon

33. 33 Conclusion SysML and formal models enable a formal interoperability between product design models and factory design and process planning models. Not clear yet how to make the connection the other way…future R&D

34. Simulation Capabilities

35. 35 Fundamental Problem in Factory Simulation Analysis Requirements Create and Run Model Results Factory simulation is not directly accessible by factory engineers.

36. 36 Observations Factory engineers must “author” requirements Simulationists must determine a process for converting “requirements” into “simulation code” We can automate what simulationists do if it conforms to a repeatable (learnable) pattern.

37. 37 Proposed Factory Simulation Framework On-Line User COTS Authoring Tools Descriptive Model Libraries Formal Descriptive Model Instance COTS Solver Analytic Model Libraries Model Translator Formal Analytic Model Instance Results

38. 38 Proposed Factory Simulation Framework Off-Line Modeler Descriptive Model Libraries Analytic Model Libraries Model Translator User

39. 39 Proposed Factory Simulation Framework

40. 40 Factory Model Concept Block State1 State2 action1 action2 action3 State1 State2 System Behavior System Structure

41. 41 Factory Structure NameTooltypexy OperationType Cutting SpeedLoadingTime UnloadingTime Bending_Machine1BendingMachine2000500Single 10050 Laser_Cutter1LaserCutter1000 Cut Shape4300200 Welding_Machine1WeldingMachine30001500Assembly 100 Tool Instance Data in Excel Bill of Resource in SysML Factory Layout in FactoryCAD (AutoCAD)

42. 42 Idle Dispatching Control system [When notified] Dispatch event Entity-Job Complete Lot Control System Notify Dispatch Behavior Modeling

43. 43 Behavior Modeling-state machine diagram

44. 44 Behavior Modeling-Sequence diagram example

45. 45 Simulation Generator--Structure + =

46. 46 Simulation Generator--Behavior + =

47. 47 Implementation Challenges NOT structure—NIST CMSD is one start toward a practical standard for structure Modeling Control! –State machine/Sequence Diagram? –Activity Diagram? –Executable UML? –What’s the fundamental conceptual model? Moore machine Mealy machine DEVS Other?

48. 48 If you want to play this game Formal languages –SysML is our bet Model transformation –MOFLON? QVT? We’re not completely sold… Implicit/Explicit paradox Domain specific languages –Profiles of SysML

49. 49 Conclusion SysML and formal models (potentially) enable an unprecedented integration of manufacturing system “description” and manufacturing system simulation (like the MCAD and ECAD domains now enjoy) Rationalization of factory control remains the fundamental challenge—how can we reconcile the complexity of real factory control with the need to create (in finite time and finite cost) useful factory simulations?

50. 50 Main Questions Addressed by Project Process: How do we include engineering analysis tools in the MBSE process? Representation: How do we represent engineering analysis models in SysML? Execution: How do we integrate engineering analysis tools & models with SysML tools & models? 50