1. IE550 2/18/2016 Design for Production in Existing Facilities (DPEF) Richard A. Wysk The Pennsylvania State University IE550 Manufacturing Systems

2. IE550 2/18/2016 Design for Production in Existing Facilities (DPEF) l Given: »a product design, »the expected production requirements for the new product, »a set of production resources and the current configuration (production lines, cells, etc.), and »the expected requirements for the products currently being produced,

3. IE550 2/18/2016 Design for Production in Existing Facilities (con’t) l Answer the following questions: »Can the new product be produced in the required quantities given the current production allocation? –if so, what are the expected production costs ? –if not, can the current production be reallocated such that all of the production requirements can be met? –if not, can the design be modified to enable production within the current resource structure? –if not, how should additional resources be acquired to meet the production requirements?

4. IE550 2/18/2016 How it’s done today: Parametric-based Feature Information l Feature information (Intra-feature specifics) »Dimensions »Size Tolerances »Surface Finishes »Geometric Tolerances

5. IE550 2/18/2016 Product, Process and Production Models l Product Engineering Library of features Feature interactions l Process Engineering Process / Feature links Inter-feature linkages Inter-process linkages l Production Engineering System Specifics Machine Specifics Fixture Specifics Tool Specifics

6. IE550 2/18/2016 Production Resource Constaints l Geometric Constraints l Machine Constraints l Jig/Fixture Constraints l Tooling Constraints l Process Constraints

7. IE550 2/18/2016 Key Process Planning Features l Plans based on Feature Precedence Graph l Generates AND/OR Graph l Collects the resource data from Databases l Is independent of Decision Table

8. IE550 2/18/2016 Example: Threaded hole (.250-20 UNF Class 3) l Process alternatives »Drill -> Tap »Drill -> Thread cut »Drill -> Thread form l Process plans »Drill ---> NxxG00G91X@locY@locZ@locM06 NxxG01Z-@sizeF50 NxxG01Z@sizeF100

9. IE550 2/18/2016 Process Planner Design Station Process Planning

10. IE550 2/18/2016 Processes l SL-20 Turning Center »Facing »Turning »Drilling »Reaming »Boring »Tapping »Threading l VF-0E Machining Center –Milling (Face/end- milling) –Drilling –Reaming –Boring –Tapping –Threading –Engraving (Ball-mill)

11. IE550 2/18/2016 AND/OR Graph Generator l Creates an AND/OR Graph Representation of a process plan l Fills out Processing Node Information »PNI is used by NC code Generator l Covers MP, MT, MH and AS/RS nodes

12. IE550 2/18/2016 Example Part Cylindrical Part Center Hole Bolt Holes Contour Thread

13. IE550 2/18/2016 Process Plans l Shop level plans MT Ml Dr Tr1 MT Tr2

14. IE550 2/18/2016 Process Plans l Workstation level plans MH VF-3 SL-20 VF-0 MH MT VF-0 Workstation #1 Workstation #2

15. IE550 2/18/2016 Process Plans (cont.) l Equipment Level Plans (Drilling) Fx Dr1 Dr2 Dr3 Dr4 Tp2 Tp3 Tp4 Tp1 Fx

16. IE550 2/18/2016 Decision Maker l Contains the hierarchical constraints »Machine »Fixture »Tool »Process »Feature l Can be updated indendent of Process Planner

17. IE550 2/18/2016 Decision Information

18. IE550 2/18/2016 IPPE Concept Design ModelProcess Model CAD System Process Planning System Production Analysis System Resource Model Instance

19. IE550 2/18/2016 Process Planner IBM Compatible Feature Information AND/OR Graph Machines Jigs/Fixtures Toolings Layout Decision Table Design Station Process Planning STEP or STEP-like PSL or PSL-like Manufacturing Resource Model

20. Resource Model Instance Resource Model Instance Resource Model Instance Resource Model Instance WWW Multi-facility Planning and Analysis Inquiries Production Orders

21. IE550 2/18/2016 Technological Hurdles l Process Planning »Given a part design, what are the processes, tools, fixtures, etc. required to manufacture the part. All feasible alternatives should be explicitly represented. l Production Planning and Analysis »Given a set of production resources and a set of production requirements with the associated process plans, how should the production be allocated among these resources in order to efficiently satisfy the requirements.

22. IE550 2/18/2016 Resource Model l A set of definitions and symbolic descriptions that are used to completely describe the individual resources in a facility as well as the possible interactions between these resources. l A resource model instance describes a specific facility and its resources.

23. IE550 2/18/2016 Production Planning & Analysis l Goal »Determining the optimal allocation of production requirements among geographically distributed manufacturing resources. l Methods »Rough capacity analysis »Detailed facility simulation »Aggregate, multi-facility simulation

24. IE550 2/18/2016 the time required for setup for an operation (load fixture, retreive tooling, etc.) the time required to load and unload a product for feature operation j (chuck, fixture, etc..) the machining/processing time for feature j tool change time/part idle time due to scheduling control L/UL t j j setup t t j m c t t i L/UL mc = E (t j setup + t j j i + t )t P A j

25. IE550 2/18/2016 Production time per piece ttt tt p set l/ul mch = + ++ The cost associated with new tooling is also a key consideration for the designer. For low and medium volume products, the cost associated with tooling and setup can dominate the total product cost. Performance Metrics

26. IE550 2/18/2016 Part p1 -> needs M1,M4 and M3 Part p2 -> needs M2 and M3 M4 M3 M2 M1 Example Layout R1 R2 R3 MT1 M1, M2, M3, M4 - Material Processors R1, R2, R3 - Material Handlers (Robots) MT1 - Material Transporter (Conveyor)

27. IE550 2/18/2016 l Concept of a manufacturing system resource model [ Wysk, R.A., Peters, B.A., and Smith, J.S., “ A Formal Process Planning Schema for Shop Floor Control ” ] »Resource Model - set of definitions and symbolic descriptions that are required to completely describe all of the individual resources in a facility as well as the necessary interactions between these resources

28. IE550 2/18/2016 Terminology l Resources (R) : Collection of assets in the facility directed towards the manufacture of the products. Includes equipment, tools, fixtures, transporters, and instruction sets l Locations (L): A precise physical location associated with a port and a part. Locations are used to link the transfer of parts between equipment types. Each location has an owner and a set of clients that can address that location l Ports (P): Ports are nodes in the graph defining the paths parts can follow through the facility (note: Graph shows the connections between the resources in the facilities l Arcs: Show which ports can be directly accessed from a particular port l Facilitator: A device than can move transporters between different ports on the MT system or move parts between a port on a MT system and a port on a MP

29. IE550 2/18/2016 Example... MP 3 MP 2 MH 1 MT 1 1 2 3 4 1 2 3 4 MH 1 Ports, Locations : 1,2,3,4 Facilitator : MH1 Arcs between : 1-2, 2-1, 1-4, 4-1, 4-3, 3-4, 2-3, 3-2 ( represent connections between the resources ) Resources: MP2, MP3 (type MP) MT1 (type MT) MH1 (type MH)

30. IE550 2/18/2016 DPEF Enabling Technologies l Currently Under Development »WWW infrastructure »Resource model –Details »Process planning tools –Representation model –Planning methods